NO: 9-16 DATE: 2/11/16 TO: EMERSON CLIMATE TECHNOLOGIES WHOLESALERS -EXECUTIVES -PRODUCT MANAGERS -EMERSON TM TECHNICAL SPECIALISTS -BRANCH PERSONNEL SUBJECT: Procedure for Changing CS Compressor to Copeland ZS Scroll Compressor for Select Condensing Units. This Change out is NOT recommended for Ice Machine Applications. Emerson is recommending as possible replacements of CS27/33 welded compressor models with ZSKA Scroll models for Condensing Units. Instructions for compressor change out are listed below. Copeland replacement Scroll compressor models for units with CS33 & CS27 Hermetic reciprocating compressor Original Copeland Compressor Model (Hermetic) CS27K6E-PFV Replacement Copeland Compressor Model * ZS29KAE-PFV Unit/Compressor Voltages 230/1/60 * ZS compressor requires 88-106/330 Volt start capacitor (Optional) 60/MFD/440 Volt run capacitor CS27K6E-TF5 ZS29KAE-TF5 230/3/60 CS27K6E-TFD ZS29KAE-TFD 460/3/60 CS33K6E-PFV ** ZS33KAE-PFV 230/1/60 ** ZS compressor requires 88-106/330 Volt start capacitor (Optional) 80/MFD/440 Volt run capacitor CS33K6E-TF5 ZS33KAE-TF5 230/3/60 CS33K6E-TFD ZS33KAE-TFD 460/3/60 1
Capacity (Btu/hr) EER Scroll v. Recip Performance Comparison 20 F Evap 70000 20 60000 50000 40000 30000 Scroll - ZS33K Capacity Recip - CS33K Capacity 20/120 Rating Point Recip EER Scroll EER 21% Delta 18 16 14 12 10 8 20000 6 10000 4 2 0 140 130 120 110 105 100 95 90 80 70 Condensing Temperature ( F) Parts required in addition to compressor to make the conversion: 0 Crankcase heater part# 918-0043-00/07 (supplied by Copeland wholesaler) Voltage dependent. Molded power plug part# 529-0060-24 (supplied by Copeland wholesaler). Compressor mounting kit part# 527-0116-00 (Supplied by Copeland wholesaler). One 3 pole, 40 amp contactor with appropriate coil voltage to match system. o Note: Only 2 poles will be utilized on a single phase compressor units. 7/8 and 1/2 tubing along with various fittings such as elbows and couplings. A minimum of 6% silver alloy should be used. Liquid line drier. For single phase low voltage or brownout concerns. o A Potential relay and start capacitor may be applied to the scroll compressor (See figure 1). o Part numbers are: ZS Model Start Capacitor Run Capacitor Relay ZS33KAE-PFV 914-0036-03 914-0037-38 040-0166-37 ZS29KAE-PFV 914-0036-03 914-0037-22 940-0001-79 2
The mounting footprint on these Hermetic and Scroll compressors are identical. The refrigeration piping is substantially different and will vary by individual unit depending on installed options. Because of this, there will be additional cut & fit field piping required during installation of the ZS compressor. Connection points are very different. Be sure to evaluate Scroll compressor orientation before installation. CS Welded Hermetic Compressor Height 14.60 ZS Scroll Compressor Height 16.54 3
Conversion process for CS Welded Hermetic compressor to ZS Scroll compressor: *All work to be complete by a qualified HVAC/HVAR technician following refrigeration best practices and safe guidelines 1. Disconnect power from the condensing unit. 2. Remove condensing unit s panels for full access to the compressor and open the electrical panel. 3. Connect gauge set hoses to both high and low side valves ports and open. 4. Connect gauge set hose to reclaimer then reclaim system refrigerant until gauge pressures all read 0 PSI. 5. While reclaiming refrigerant, start disconnecting the wiring from the compressor, the compressor contactor, and all electrical between contactor and compressor. 6. Un-braze the discharge line and suction lines from the existing CS compressor. 7. Remove the rubber mounting grommets. 8. Remove the CS compressor and place to the side. 9. Install the new mounting feet onto the new ZS compressor and place on the base in a manner that the suction line is in close proximity to the suction connection on the ZS compressor. 10. Utilizing the 7/8 and 1/2 piping and components along with tubing benders, etc. braze in the suction and discharge lines. The pressure switch connection points may need to be moved and new Schrader valves installed. 11. With hoses still connected to suction and discharge valves, connect your vacuum pump and begin the evacuation process. Evacuate to 500 microns. 12. While evacuating, install the new compressor contactor, wiring, capacitors, and relay. For single phase units follow the wiring diagrams shown at the end of this document (Figure 1 for Brownout, Figure 3 for Standard Scroll), (230 and 460 three phase diagrams are the same). 13. The crankcase heater is a belly band style with only two leads. Connect heater leads back to L1 and L2 on the line side of the compressor contactor. 4
14. When 500 microns has been achieved, turn off pump and close valves. Let it stand for at least 30 minutes to make sure vacuum is maintained. A leak can be suspected due to rise in gauge pressure. At that point, pressurize system with dry nitrogen and a small amount of refrigerant and perform a leak test before proceeding to next steps. 15. Break the vacuum with as much of the original equipment recommended refrigerant charge as possible by charging liquid into the receiver valve. It is sometimes possible to get it all in but if not, finish the charging when running through the low side of the system. 16. The RLA of the ZS is slightly higher than that of the CS on most models which will impact the MCA/MOPD per the table below. This chart covers both the ZS29 AND ZS33 scroll compressors. Unit Electrical Specifications with Replacement ZS Scroll Compressor Original Reciprocating Compressor New Scroll Compressor RLA Original (CS) New (ZS) CS27K6E-PFV ZS29KAE-PFV 21.5 23.4 CA27K6E-TF5 ZS29KAE-TF5 13.7 18.4 CS27K6E-TFD ZS29KAE-TFD 7.6 8.4 CS33K6E-PFV ZS33KAE-PFV 27.6 23 CS33K6E-TF5 ZS33KAE-TF5 16.8 20 CS33K6E-TFD ZS33KAE-TFD 8.8 9 *Using this chart you will need to confirm that the existing wire and breaker sizes supplying power to the condensing unit are correct to comply with all state & local codes. 5
17. Contractor must determine MCA and MOPD Values 18. When all electrical is confirmed to be correct, turn on power. With pressure in the system the low pressure switch should be closed and the compressor contactor should engage. Remember that three phase Scroll compressors can run backwards, so confirm that suction and discharge pressures do not equalize! If pressures equalize, remove power from unit, reverse two of the electrical leads to the compressor at the contactor then restart system normally. 19. After charging is complete, check for a 20 F superheat at the compressor. It will be normal to have high superheat, high suction/discharge pressures and high amperage draws on initial startup of a warm box but when the box is within 5 F of desired temperature, 20 F superheat should be achieved. If not, adjust the expansion valve. Check for restrictions across filter driers, solenoids, piping, dirty coils, or any other abnormalities. 20. Remove refrigeration gages and securely re-install all service valve port caps. 21. Re-install all of the condensing unit panels and front screen. 22. Clean up all debris. For further details on the application of Copeland Scroll compressors please refer to, MB2012CC-31. Additional product performance and electrical information can be accessed online at EmersonClimate.com. Log in or register for Online Product Information. For additional questions, please contact your Emerson Climate Technologies Sales Manager or Application Engineer. 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. 6
Single Phase Compressor with Start Capacitor and Potential Relay Standard Scroll Single Phase Compressor without start capacitor 7