Emerson COPELAND ZO18AG Instruction Manual

Copeland™Scroll Compressors
for R744 Refrigeration Applications
ZO18AG to ZO46AG, ZOV18AG to ZOV38AG
Application Guidelines

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About these guidelines ...............................................................................................1
1Safety instructions...........................................................................................1
1.1 Icon explanation............................................................................................................... 1
1.2 Safety statements ............................................................................................................ 1
1.3 General instructions......................................................................................................... 2
2Product description .........................................................................................3
2.1 Compressor range ........................................................................................................... 3
2.2 Matched pairs of compressor and drive........................................................................... 3
2.3 Variable speed advantages ............................................................................................. 4
2.4 Nomenclature................................................................................................................... 5
2.5 BOM Variations................................................................................................................ 5
2.6 Application considerations............................................................................................... 5
2.6.1 Qualified refrigerant and oil.................................................................................. 5
2.6.2 Application limits................................................................................................... 6
2.6.3 PED category, maximum allowable pressures PS and internal free volume....... 8
2.6.4 Admissible temperature and relative humidity ranges ......................................... 8
2.6.5 Design features .................................................................................................... 9
2.7 Dimensions .................................................................................................................... 10
3Installation......................................................................................................11
3.1 Compressor and drive handling..................................................................................... 11
3.1.1 Transport and storage........................................................................................ 11
3.1.2 Positioning and securing.................................................................................... 11
3.1.3 Installation location............................................................................................. 11
3.2 Compressor mounting parts .......................................................................................... 12
3.3 Shut-off valves and adaptors......................................................................................... 12
3.4 Pressure safety controls ................................................................................................ 13
3.4.1 Pressure relief valves......................................................................................... 13
3.4.2 High-pressure protection.................................................................................... 13
3.4.3 Low-pressure protection..................................................................................... 13
3.5 Crankcase heater........................................................................................................... 13
3.6 Discharge gas temperature protection........................................................................... 14
3.6.1 Excessive discharge gas temperatures ............................................................. 15
3.6.2 Discharge temperature sensor NTC .................................................................. 15
3.7 Filter screens ................................................................................................................. 16
3.8 Mufflers .......................................................................................................................... 16
3.9 Sound and vibrations..................................................................................................... 16
3.10 Active oil management................................................................................................... 17
3.11 Suction line accumulator................................................................................................ 17
4Electrical connection.....................................................................................18
4.1 General recommendations............................................................................................. 18

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4.2 Electrical wiring.............................................................................................................. 18
4.3 Terminal box .................................................................................................................. 19
4.4 Electro-magnetic compatibility (EMC) filter.................................................................... 20
4.5 Line reactors .................................................................................................................. 20
4.6 Motor insulation.............................................................................................................. 20
4.7 Motor protection............................................................................................................. 20
4.8 Off-cycle power consumption ........................................................................................ 20
4.9 High-potential testing ..................................................................................................... 20
5Start-up & operation.......................................................................................21
5.1 Strength-pressure test ................................................................................................... 21
5.1.1 Compressor strength-pressure test.................................................................... 21
5.1.2 System strength-pressure test ........................................................................... 21
5.2 Compressor tightness test............................................................................................. 21
5.3 System evacuation......................................................................................................... 22
5.4 Preliminary checks –Pre-starting.................................................................................. 22
5.5 Charging procedure....................................................................................................... 22
5.6 Run-in time..................................................................................................................... 23
5.7 Initial start-up ................................................................................................................. 23
5.8 Rotation direction........................................................................................................... 23
5.9 Start-and-stop routine.................................................................................................... 23
5.10 Starting sound................................................................................................................ 23
5.11 Deep vacuum operation................................................................................................. 24
5.12 Shell temperature........................................................................................................... 24
5.13 Pumpdown cycle............................................................................................................ 24
5.14 Minimum run time .......................................................................................................... 24
5.15 Shut-off sound................................................................................................................ 24
5.16 Oil level .......................................................................................................................... 24
6Maintenance & repair.....................................................................................25
6.1 Qualification of workers.................................................................................................. 25
6.2 Disassembling system components .............................................................................. 25
6.3 Provisions of legislation & leak check requirements...................................................... 25
6.4 Exchanging the refrigerant............................................................................................. 25
6.5 Replacing a compressor................................................................................................ 26
6.5.1 Compressor replacement................................................................................... 26
6.5.2 Start-up of a new or replacement compressor................................................... 26
6.6 Lubrication and oil removal............................................................................................ 26
6.7 Oil additives ................................................................................................................... 27
7Troubleshooting.............................................................................................28
8Dismantling & disposal..................................................................................31
9References......................................................................................................31

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Appendix1: Tightening torques................................................................................32
DISCLAIMER ..............................................................................................................32

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About these guidelines
The purpose of these guidelines is to provide guidance in the application of Copeland™scroll
compressors and Emerson control drives in users’systems operating with CO2(R744). 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 and drives. The performance and reliability of the products may
be impacted if they are not used according to these guidelines or are misused.
These application guidelines cover stationary applications only. For mobile applications, please
contact the Application Engineering department at Emerson as other considerations may apply.
1 Safety instructions
Copeland scroll fixed- and variable-speed compressors and Emerson motor control drives are
manufactured according to the latest relevant European and US safety standards. Particular
emphasis has been placed on the user’s safety.
The ZO(V)*AG compressors and drives are intended for installation in systems in accordance with
the European Machinery Directive MD 2006/42/EC, the Pressure Equipment Directive
PED 2014/68/EU, the Low Voltage Directive LVD 2014/35/EU and the Electromagnetic Compatibility
Directive EMC 2014/30/EU. They may be put to service only if they have been installed in systems
according to instructions and conform to the corresponding provisions of legislation.
The Material Safety Datasheet (MSDS) for R744 shall be considered when working with this type of
refrigerant - please check this document provided by the gas supplier.
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. The system has
to be labelled according to the applicable standards and legislation.
▪Only qualified and authorized RACHP (refrigeration, air conditioning and heat pump)
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.

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1.3 General instructions
WARNING
Pressurized system! Serious personal injuries and/or system
breakdown! Accidental system start before complete set-up must be avoided.
Never leave the system unattended without locking it out electrically when it is
on vacuum and has no refrigerant charge, when it has a holding charge of
nitrogen, or when the compressor service valves are closed.
The system contains refrigerant and oil under pressure. The mixture of air and
oil at high temperature can lead to an explosion (Diesel effect). Avoid operating
with air.
System breakdown! Personal injuries! Only CO2and approved refrigeration
oils must be used. Remove refrigerant from both high- and low-pressure sides
with a suitable recovery unit before removing the compressor.
WARNING
CO2refrigerant! Danger of suffocation! Never release significant volumes
of CO2or the entire contents of the system into closed rooms. In case of closed
room, if possible, keep the room well ventilated and/or install a CO2detection
device. CO2is odourless and colourless, so it cannot be perceived directly in
case of emission.
WARNING
Leaking CO2refrigerant! Danger of dry ice formation! In case of system
leakage, the decreasing pressure in the system might cross the triple point of
carbon dioxide. Dry ice formation can block pipes & components. Unexpected
high pressure inside the system might occur.
WARNING
Earth leakage current! Danger of electric shock! This product can cause
both AC and DC earth leakage current. To protect against both kinds of leakage
current it is recommended to use an AC/DC sensitive RCD on the power supply
side.
WARNING
High voltage! Danger of electric shock and/or system breakdown!
Disconnect and lock out power before servicing. Allow drive components to
electrically discharge before servicing. Respect the time according to drive
manual before servicing the drive. Use compressor with grounded system only.
Refer to original equipment wiring diagrams. Electrical connections must be
made by qualified electrical personnel.
WARNING
High surface temperature! Burning! Do not touch the compressor or piping
until they have cooled down. Ensure that other materials in the area of the
compressor do not come into contact with it. Mark and secure accessible
sections.
WARNING
Dry ice formation! Frostbite! Whenever a pressure drop with carbon dioxide
occurs, there is a risk of dry ice formation. There is a high risk of frostbite when
touching dry ice!
CAUTION
Overheating! Bearing damage! Do not operate compressor without
refrigerant charge or without it being connected to the system.
CAUTION
Contact with PAG! Material damage! PAG lubricant must be handled
carefully and the proper protective equipment (gloves, eye protection, etc.)
must be used at all times. PAG 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.

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2 Product description
2.1 Compressor range
These application guidelines cover Copeland™scroll fixed- and variable-speed compressor
models ZO(V)*AG using CO2(R744). These compressors have a speed range of 1500 to 6000
revolutions per minute, corresponding to 25 to 100 revolutions per seconds (1/s). They are intended
for use in refrigeration applications. They feature a three-phase brushless permanent magnet (BPM)
motor which is controlled by an Emerson EVM/EVH motor control drive, referred to as the "EVM/EVH
drive" or "drive" throughout these guidelines.
Figure 1: ZO(V)*AG compressor and EVM/EVH drive
NOTE: For more information on the motor control drive please refer to the EVM/EVH User
Manual.
Compressor
Cooling capacity* (kW) with R744
Motor
1500
rpm
3000
rpm
4500
rpm
6000
rpm
ZO18AG
-
5.95
-
-
TFD
ZO25AG
-
8.25
-
-
TFD
ZO38AG
-
12.45
-
-
TFD
ZO46AG
-
15.15
-
-
TFD
ZOV18AG
2.90
6.29
9.54
12.45
9X9
ZOV25AG
4.06
8.65
13.20
17.45
4X9
ZOV38AG
6.27
13.15
20.10
27.00
4X9
* Evaporating temperature: -35 °C; condensing temperature: -5 °C; suction gas superheat: 10 K;
liquid sub-cooling: 0 K
Table 1: ZO(V)*AG compressor capacity for LT applications
2.2 Matched pairs of compressor and drive
The ZOV*AG compressors with motor code "X" are offered as matched pairs with the EVM/EVH
drive, designed in accordance with EN 60335-1.
The matched pairs have been designed for maximum efficiency and reliability. The drive will power
the compressor, control the compressor running speed and communicate with the master controller
in Modbus RTU protocol. The drive requires cooling and is typically installed in the unit near the
compressor. To optimize drive efficiency and to limit electromagnetic interferences, external chokes
must be connected to the three-phase drive.
The ZOV*AG compressors are sold as unprotected compressors. They are dedicated for use with a
third-party drive. The motor protection is under the responsibility of the system manufacturer/installer.
A third-party control system must include discharge temperature protection, current overload
protection, and a soft start-and-stop routine. Contact the Application Engineering department at
Emerson for compressor motor specifications and speed adjustment requirements.
It is important to ensure correct wiring at both the compressor and drive connections prior to

4 AGL_Ref_ST_ZO_E_Rev00
starting the compressor to avoid miswiring or a powered reverse situation. Both situations could
potentially cause compressor damage.
The matched pairs of compressor and drive released by Emerson are listed in Table 2 hereunder:
Compressor
Drive
IP
rating
Max. working
temperature
Drive power supply
ZOV18AG-9X9
EVM-344012-E20EFN
IP2X
40 °C
3~ / 400 V / 50 Hz
ZOV18AG-9X9
EVM-344016-E20EFN
IP2X
50 °C
3~ / 400 V / 50 Hz
ZOV18AG-9X9
EVH-344016-R21BEN
IP54
50 °C
3~ / 400 V / 50 Hz
ZOV18AG-9X9
EVH-344012-R21BEN
IP54
40 °C
3~ / 400 V / 50 Hz
ZOV25AG-4X9
EVM-344012-E20EFN
IP2X
40 °C
3~ / 400 V / 50 Hz
ZOV25AG-4X9
EVM-344016-E20EFN
IP2X
50 °C
3~ / 400 V / 50 Hz
ZOV25AG-4X9
EVH-344016-R21BEN
IP54
50 °C
3~ / 400 V / 50 Hz
ZOV25AG-4X9
EVH-344012-R21BEN
IP54
40 °C
3~ / 400 V / 50 Hz
ZOV38AG-4X9
EVM-344016-E20EFN
IP2X
40 °C
3~ / 400 V / 50 Hz
ZOV38AG-4X9
EVM-344023-E20EFN
IP2X
50 °C
3~ / 400 V / 50 Hz
ZOV38AG-4X9
EVH-344023-R21BEN
IP54
50 °C
3~ / 400 V / 50 Hz
ZOV38AG-4X9
EVH-344016-R21BEN
IP54
40 °C
3~ / 400 V / 50 Hz
Table 2: Matched pairs EVM/EVH drive with ZOV*AG compressors
Compressor
Drive
Cooling capacity* (kW)
1500
rpm
3000
rpm
4500
rpm
6000
rpm
ZOV18AG-9X9
EVM-344012-E20EFN
2.90
6.29
9.54
12.45
ZOV18AG-9X9
EVM-344016-E20EFN
2.90
6.29
9.54
12.45
ZOV18AG-9X9
EVH-344016-R21BEN
2.90
6.29
9.54
12.45
ZOV18AG-9X9
EVH-344012-R21BEN
2.90
6.29
9.54
12.45
ZOV25AG-4X9
EVM-344012-E20EFN
4.06
8.65
13.20
17.45
ZOV25AG-4X9
EVM-344016-E20EFN
4.06
8.65
13.20
17.45
ZOV25AG-4X9
EVH-344016-R21BEN
4.06
8.65
13.20
17.45
ZOV25AG-4X9
EVH-344012-R21BEN
4.06
8.65
13.20
17.45
ZOV38AG-4X9
EVM-344016-E20EFN
6.27
13.15
20.10
27.00
ZOV38AG-4X9
EVM-344023-E20EFN
6.27
13.15
20.10
27.00
ZOV38AG-4X9
EVH-344023-R21BEN
6.27
13.15
20.10
27.00
ZOV38AG-4X9
EVH-344016-R21BEN
6.27
13.15
20.10
27.00
* Evaporating temperature: -35 °C; condensing temperature: -5 °C; suction gas superheat: 10 K; liquid sub-
cooling: 0 K
Table 3: Cooling capacity in kW for selected matched pairs
NOTE: Operate Emerson matched pairs of inverter and compressor only. Other combinations
could cause problems, such as starting issues, low capacity operation or other unusual
errors.
NOTE: For the latest list of matched pairs EVM/EVH with ZOV*AG please refer to the EVM/EVH
User Manual or contact the Application Engineering department at Emerson.
2.3 Variable speed advantages
The variable speed scroll is a key component in the variable capacity system. A variable capacity
system will use less electrical energy by minimizing On/Off cyclical losses, maximizing heat
exchanger efficiency by operating at part load during a majority of the total operating hours, and by
operating with reduced airflow rates and fan power.
The variable speed scroll and drive are suitable for a variety of "best-in-class" applications. Both may
be used in other types of applications provided that the envelope and other operating restrictions are
met. The primary benefit of this product is to substantially reduce electrical energy consumption and
associated expenses.

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Additionally, a variable speed scroll offers the capability of controlling temperatures to ranges
exceeding simple On/Off control, improving overall system conditions. The onboard electronics
embedded in the drive greatly reduce the possibility of operation outside the designed parameters
which in turn increases overall system reliability.
2.4 Nomenclature
The model designation contains the following technical information:
Figure 2: Compressor nomenclature
Figure 3: Drive nomenclature
2.5 BOM Variations
The BOM (bill of material) number at the end of the compressor designation indicates the different
compressor layouts and details. ZO(V)*AG compressors are available in the following BOM version:
BOM
Suction and discharge
connections
T-Box
Mounting
parts
Sight
glass
Schraeder
valve
592
Rotalock
IP54 / IP2X
Without
Yes
Yes
Table 4: BOM designation
Please refer to the Emerson price list for more details.
2.6 Application considerations
2.6.1 Qualified refrigerant and oil
Qualified refrigerant
R744 (CO2)
Copeland standard oil
Zerol RFL68-EP (PAG)
Servicing oil
Zerol RFL68-EP (PAG)
Oil factory charge
(in litres)
ZO*AG
ZOV*AG
0.9
0.8
Table 5: Qualified refrigerant and oil
ZO(V)*AG compressors are delivered with a factory charge of PAG (polyalkylene glycol) oil.
The compressors should not operate with the oil level below ¼ of the oil sight glass.
Oil recharge values can be taken from Copeland Select software available at
www.climate.emerson.com/en-gb.

6 AGL_Ref_ST_ZO_E_Rev00
NOTE: Use only lubricants that are qualified for the product. The use of non-approved
lubricants can damage the product and will result in loss of warranty!
The recommended quality for carbon dioxide purity class is 4.0 [(≥ 99.99 %) H2O ≤ 10 ppm,
O2 ≤ 10 ppm, N2≤ 50 ppm] or higher.
The characterization of R744 (CO2) according to EN 378-1 is safety class A1, not flammable,
ODP = 0 and GWP = 1. High concentrations of CO2are dangerous. This refrigerant is odourless and
colourless. Therefore the use of CO2detectors is required.
CO2is heavier than air. As a result, local concentrations (especially at floor level or in deeper slots,
ie, CO2pockets) can be higher than average values in the machine room. The ventilation system
must take this into account.
2.6.2 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 20 K is required.
ZOV*AG compressors operating envelopes depend on the running speed. The envelope limitations
are mainly related to lubrication and drive power limitation. ZO*AG compressors are fixed speed and
therefore the application limits do not depend on the running speed.
For application envelopes and technical data, please refer to Copeland Select software available at
www.climate.emerson.com/en-gb.
Figure 4: Envelope of the ZO*AG compressors
Figure 5: Envelope of the ZOV*AG compressors
NOTE: For matched pairs with smaller drives, please check the application envelopes in
Copeland Select software at www.climate.emerson.com/en-gb.

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Please note the following considerations about operating envelopes:
▪Before compressor start with the matched pair of ZOV*AG and the EVM/EVH drive, the pressure
difference in the system has to be below 25 bar. If the pressure difference is reduced by opening
the expansion valve, care must be taken to avoid liquid floodback to the compressor –also see
section 3.11 "Suction line accumulator".
▪An oil return test for the system must be performed. If required, the system design should be
improved to ensure sufficient oil return from the system to the compressor –also see section
5.16 "Oil level".
▪At start-up the system should be able to bring the compressor to a point inside the envelope as
fast as possible and to keep the compressor running there. Running outside the envelope is not
allowed.
▪Running/oscillating the compressor in and out of the envelope borders is not allowed and should
be avoided.
▪Running the compressor below the envelope at low condensing temperatures is possible for no
longer than 30 minutes but the user must be aware that unloading noise from the compressor can
occur. In this area the speed limits according to the evaporating temperatures in the envelope
should be respected.
▪The qualified application envelopes will change with the compressor speed. At all operating
conditions the minimum and maximum speed limits according to Figure 5 have to be respected.
With changing operating conditions the speed limits have to be determined by linear interpolation
between the limits given in Figure 5 –also see speed limits animation in Select software available
at www.climate.emerson.com/en-gb.
▪Fast speed changes can cause instable control, eg, on the superheat control. Per Emerson
experience speed changes should be not higher than approximately 200 rpm/s depending on the
system reaction.
▪The user should adequately take care of controlling the envelope.
▪To stop the compressor, see Figure 6 "Controlled shutdown".
Figure 6: Controlled shutdown and ramp-up
NOTE: Emerson iProRACK controller series 5 offers all required features to operate the
ZO(V)*AG scroll compressors in the low temperature stage of a booster system.
NOTE: Before first start, each drive has to be configured according to the compressor model.
NOTE: The EVM/EVH drive overload protection aims at protecting the drive and the
compressor. It cannot be used in the system as an operating envelope limitation. For more
details on the overload protection refer to the EVM/EVH User Manual.
NOTE: Paralleling of variable-speed ZOV*AG compressors with fixed-speed ZO*AG models is
possible.

8 AGL_Ref_ST_ZO_E_Rev00
2.6.3 PED category, maximum allowable pressures PS and internal free volume
The ZO(V)*AG compressor models covered in these guidelines are PED Class 1, according to the
Pressure Equipment Directive PED 2014/68/EU.
The pressure PS is the maximum allowable pressure at the low- and high-pressure sides of the
compressor. The maximum pressure values PS for the individual compressor type are printed on the
nameplate of the compressor. Safety is established in compliance with the relevant standards
applicable to the given product.
Compressor
PS
High-pressure
side
PS
Low-pressure
side
TS max
LP side
Internal free
volume
LP side
Internal free
volume
HP side
PED
Class
ZO*AG
60 bar(g)
45 bar(g)
50 °C
2.8 l
0.34 l
1
ZOV*AG
60 bar(g)
45 bar(g)
50 °C
3.3 l
0.34 l
1
Table 6: Maximum allowable pressures PS, TS, internal free volume and PED category
2.6.4 Admissible temperature and relative humidity ranges
ZO(V)*AG compressors must comply with the ambient temperature and humidity ranges specified in
Table 7 below, both for storage and in operation.
Compressor
model
Min / max relative
humidity
Min / max ambient
temperatures in storage or
at standstill
Min / max ambient
temperatures in
operation
ZO*AG
30 % / 95 %
No condensing
-50 C° / 50 °C
-50 C° / 50 °C
ZOV*AG
30 % / 95 %
No condensing
-50 C° / 50 °C
-50 C° / 50 °C
Table 7: Acceptable ambient temperature and humidity ranges for ZO(V)*AG compressors
NOTE: Please refer to the EVM/EVH User Manual for the ambient temperature and humidity
ranges.

AGL_Ref_ST_ZO_E_Rev00 9
2.6.5 Design features
The variable-speed scroll ZOV*AG has a number of design features that improve efficiency and
reliability. An HVE valve is part of ZOV*AG models for higher performance at high pressure ratio.
This valve prevents reverse rotation during shutdown; however, some shutdown sound may occur.
All ZOV*AG compressors are equipped with a positive displacement oil pump to ensure an adequate
supply of oil to the bearing system throughout the operating speed range of 1500 to 6000 rpm.
The motor in the variable-speed scroll is a three-phase, brushless permanent magnet (BPM) design
coupled with a rotor embedded with high energy magnets. The input voltage is a series of +DC pulses,
spaced in time to create an alternating current frequency.
ZO(V)*AG compressors use a shutdown valve located in the discharge fitting. This check valve is
not a low-leak-back check valve and will leak when pressure differential across the check valve is
low.
Figure 7: ZO*AG compressor cross sectional view
Figure 8: ZOV*AG compressor cross sectional view

10 AGL_Ref_ST_ZO_E_Rev00
2.7 Dimensions
Figure 9: External dimensions of the ZO*AG
Compressor
A
B
C
D
E
F
ZO18AG to
ZO46AG
415.8 mm
390.2 mm
209.9 mm
67.4 mm
83.2 mm
285.8 mm
Table 8: Dimensions of the ZO*AG
Figure 10: External dimensions of the ZOV*AG
Compressor
A
B
C
D
E
F
ZOV18AG to
ZOV38AG
385.8 mm
360.1 mm
179.9 mm
67.4 mm
83.2 mm
255.8 mm
Table 9: Dimensions of the ZOV*AG

AGL_Ref_ST_ZO_E_Rev00 11
3 Installation
WARNING
High pressure! Injury to skin and eyes possible! Be careful when opening
connections on a pressurized item.
3.1 Compressor and drive handling
WARNING
Static electricity! Personal injuries! Personnel handling the drives in a
manufacturing plant environment should guard against static electricity by
using the appropriate equipment, eg, antistatic wrist straps and mats.
3.1.1 Transport and storage
WARNING
Risk of collapse! Personal injuries! Move compressors only with
appropriate mechanical or handling equipment according to weight. Keep in
the upright position. Respect stacking loads according to Figure 11. Check
the tilting stability and if needed take action to ensure the stability of the
stacked loads. Keep the packaging dry at all times.
Respect the maximum number of identical packages which may be stacked on one
another, where "n" is the limiting number:
▪Transport: n = 1
▪Storage: n = 2
Figure 11: Maximum stacking loads for transport and storage
The compressor tilt angle should not exceed 30° during transport and handling. This will prevent oil
from exiting through the suction stub. A tilt angle of maximum 45° is allowed for a very short time.
Tilting the compressor more than 45° might affect its lubrication at start-up.
NOTE: The compressor is pre-charged with dry air to avoid any moisture contamination.
3.1.2 Positioning and securing
IMPORTANT
Handling damage! Compressor malfunction! Only use the lifting eyes
whenever the compressor requires positioning. Using discharge or suction
connections for lifting may cause damage or leaks.
The compressor should be kept vertical during handling.
The discharge connection plug should be removed first before pulling the suction connection plug to
allow the dry air pressure inside the compressor to escape. Pulling the plugs in this sequence
prevents oil mist from coating the suction tube making brazing difficult. The copper-coated steel
suction tube should be cleaned before brazing.
The compressor plugs must be removed as late as possible before brazing so that the air humidity
does not affect the oil characteristics.
No object, eg, a swaging tool should be inserted deeper than 45 mm into the suction tube as it might
damage the suction screen and motor. Also, no object should be inserted deeper than 30 mm into
the discharge tube to avoid damage to the check valve.
3.1.3 Installation location
Ensure the compressor and drive are installed on a solid level base. For single compressor
applications, the compressor tilt angle during operation should not exceed 15° to allow adequate
lubrication. For multiple compressor parallel configurations, the compressors must be positioned
completely vertically on a totally horizontal surface or rail.

12 AGL_Ref_ST_ZO_E_Rev00
3.2 Compressor mounting parts
The compressors are designed to be mounted on vibration absorber grommets. The grommets
dampen the start-up surge of the compressor and minimise sound and vibration transmission to the
compressor base during operation. The metal sleeve inside is a guide designed to hold the grommet
in place. It is not designed as a load-bearing member, and application of excessive torque to the
bolts can crush the sleeve. Its inner diameter is approximately 8.5 mm to fit, eg, an M8 screw. The
mounting torque should be 13 ± 1 Nm. It is critically important that the grommet is not compressed.
See Emerson spare parts software for reference.
Standard mounting parts for ZO*AG –Soft mountings
Standard mounting parts for ZOV*AG –Soft mountings
Figure 12: Rubber mounting parts with sleeves
3.3 Shut-off valves and adaptors
CAUTION
Leaking system! System breakdown! It is recommended to periodically re-
torque all pipe and fixing connections to the original settings after the system
has been put into operation.
Torque settings of system valves and adaptors with Rotalock connections might decrease
significantly after some time in operation. Recurring temperature changes, vibration and other
influencing parameters can lead to expansion and contraction of the metal material and a relaxation
of the gaskets. It is recommended to periodically retorque the Rotalock connections to the original
settings.
However, pipe plugs with sealant applied at the factory are not to be retorqued, as this would break
the seal and create a leak path in the cured sealant.
Figure 13: Shut-off valves and connection adapters
Rotalock shut-off valves are available for the suction as well as discharge sides.
Please refer to Appendix 1 for proper tightening torques.
NOTE: More information about adaptors and shut-off valves can be found in the Emerson
spare parts software, available at www.climate.emerson.com/en-gb/tools-resources.

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3.4 Pressure safety controls
3.4.1 Pressure relief valves
CAUTION
High pressure! System leak! In the event that a pressure relief valve
activates repeatedly, check and replace it in order to avoid a permanent leak.
Always check system for CO2loss after activation of the pressure relief valve.
Pressure relief valves shall be placed on both the suction and discharge sides of the compressor.
The pressure relief valve does not replace pressure switches or additional safety valves in the
system.
▪High-pressure side (HP): 60 bar
▪Low-pressure side (LP): 45 bar
Usually after a blow-off, pressure relief valves are no longer perfectly tight. It is therefore
recommended to control (replace) the pressure relief valves after any blow-off.
3.4.2 High-pressure protection
Applicable regulations and standards, for example EN 378-2, shall be followed to apply appropriate
control and ensure that the pressure never exceeds the maximum limit.
High-pressure protection is required to stop the compressor operating outside the allowable pressure
limits. The high-pressure control must be installed correctly, which means that no service valve is
allowed between the compressor and the pressure protection.
The high-pressure cut-out setting shall be determined according to the applicable standard, the type
of system, the refrigerant and the maximum allowable pressure PS.
The high-pressure limiter has to be connected to the drive. For electrical specification please check
the drive user manual. Normally the high-pressure limiter must be closed. If the limiter is open, the
drive will not operate.
NOTE: For detailed specifications and instructions to connect the high-pressure limiter to the
drive, please refer to the EVM/EVH User Manual.
3.4.3 Low-pressure protection
CAUTION
Operation outside the application envelope! Compressor breakdown! A
low-pressure protection shall be fitted in the suction line to stop the
compressor when it operates outside the envelope limits.
Applicable regulations and standards shall be followed to apply appropriate control and ensure that
the pressure is always above the required minimum limit.
Low-pressure protection is required to stop the compressor operating outside the allowable envelope
limits. The low-pressure control must be installed correctly into the suction line, which means that no
service valve is allowed between the compressor and the pressure protection.
The minimum cut-out setting shall be determined according to the refrigerant and the allowed
operation envelope –see Select software at www.climate.emerson.com/en-gb.
3.5 Crankcase heater
CAUTION
Overheating and burnout! Compressor damage! Never apply power to the
crankcase heater in free air, before the crankcase heater is installed on the
compressor or when it is not in complete contact with the compressor shell.
IMPORTANT
Oil dilution! Bearing malfunction! Turn the crankcase heater on 12 hours
before starting the compressor.
A crankcase heater is used to prevent refrigerant from migrating into the shell during standstill
periods.
The initial start-up in the field is a very critical period for any compressor because all load-bearing
surfaces are new and require a short break-in period to carry high loads under adverse conditions.
The crankcase heater must be turned on a minimum of 12 hours prior to starting the

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compressor. This will prevent oil dilution and bearing stress on initial start-up. The crankcase
heater must remain energized during compressor off cycles.
Compressor model
Crankcase heater
Position
Height (mm)
ZO18AG to ZO46AG
15
ZOV18AG to ZOV38AG
15
Table 10: Crankcase heater position
NOTE: Please refer to the Spare Parts list available at www.climate.emerson.com/en-gb/tools-
resources to select the correct crankcase heater model.
Caution: Crankcase heaters must be properly grounded!
For installation, the manufacturer/installer shall follow the recommendations mentioned below.
Assembly instructions
▪Choose the appropriate model according to compressor size and required wattage.
▪Check the compressor application guidelines for crankcase heater connection and operation.
▪Position the crankcase heater between the lower cover and the lower bearing weld projection
(Fig. 14).
▪Fit the heater horizontally around the crankcase, ensuring that it is in close contact with the
compressor housing along the entire length.
▪Avoid having the heating portion of the heater in contact with any weld projection (Fig. 15 & 16).
▪Avoid having the assembly heater inclined (Fig. 17).
▪Close the lock and tighten the screw, torque: 2-3 Nm.
▪The excess clamp bracket may be trimmed. Sharp edges must not come into contact with wires.
▪The presence of the heater shall be made evident by the posting of caution signs or markings at
appropriate locations.
Figure 14 Figure 15 Figure 16 Figure 17
Electrical connection
▪Connect the crankcase heater according to the compressor application guidelines.
▪The crankcase heater must be connected only to its rated voltage.
▪The metal braid of the heater must be connected to a suitable earthing terminal.
▪Check the resistance according to the technical data.
▪Perform an insulation test before start-up.
▪Electrical security and safety measures are to be provided on site.
3.6 Discharge gas temperature protection
CAUTION
Inadequate lubrication! Scroll set damage! All ZO(V)*AG compressors
must be equipped with a discharge gas temperature protection.
A good system control shall prevent the system from operating outside the published operating
envelope and acceptable superheat range, whatever the climatic conditions and the capacity
demand. However, under some extreme operating conditions such as loss of charge or improper
control operation, the internal discharge gas temperature reached can cause compressor damage.

AGL_Ref_ST_ZO_E_Rev00 15
In order to ensure positive compressor protection, discharge gas temperature protection is required
for any application with Copeland compressors.
The maximum discharge gas temperature is 135 °C for ZO(V)*AG compressors.
Discharge gas temperature protection is the "fall-back" for failure of the system control. It is essential
that proper control of both the evaporating and condensing pressures and the superheat is
maintained and has the ability to cope with all likely conditions and high loads. Reliance on protectors
will cause inadequate system performance and short cycling.
NOTE: The maximum discharge gas temperatures indicated in this chapter are valid for safe
operation within the approved application envelope. The discharge line thermostat has the
function of a compressor protection device; it is not designed to control the operating
envelope. For compressor envelope control, an additional control device or regulation must
be used.
3.6.1 Excessive discharge gas temperatures
A few of the possible consequences of excessive discharge gas temperatures are listed below:
▪Since the oil circulates in the system with the refrigerant, it is subjected to high discharge gas
temperatures. If the discharge gas temperature becomes too high, the so-called "cooking" effect
will occur (heating of oil under exclusion of air). Carbon deposits can form at points of high
temperature, for example on the valves, oil channels, oil filters, etc. The oil lubricity will be reduced
and a progressive wear process will occur which will prematurely damage the compressor.
▪The stability of the refrigerant can also be affected, particularly if traces of contaminant are
present.
The problems listed under the first 2 points frequently occur simultaneously, particularly since the
chemical reaction speed approximately doubles with every 10 °C temperature rise. This directly leads
to chemical reactions of the oil with the refrigerant and the compounds extracted from sealants and
insulation material. As a consequence, contaminants of various types, among them acids, will form
inside the system.
3.6.2 Discharge temperature sensor NTC
Variable- and fixed-speed compressors need an external discharge line temperature sensor. The
correct reading of this sensor is fundamental for discharge line temperature control. The sensor must
ensure accuracy and adequate dynamic behaviour.
Mounting recommendations
▪The temperature sensor should be installed along the straight or bended pipe at a distance of
120 mm from the compressor outlet.
▪The sensor must be installed in a copper sleeve to improve response time and to reduce setoff.
The copper sleeve must be brazed on the surface of the discharge pipe.
▪Use thermal compound to improve the heat transfer from the sleeve to the sensor. The thermal
compound must be approved for maximum system operating temperatures.
▪The discharge pipe including the sensor must be insulated to reduce the impact of ambient
temperature.
▪Protect the sensor from being moved or removed from its position by transport, vibration or any
other incident.
Figure 18: Sensor installation
NOTE: For complete mounting recommendations please refer to Assembly Instructions.
C30.11 "NTC Mounting Recommendations".
NOTE: When using an Emerson qualified drive, please refer to the drive user manual to see
how to connect it.