Emerson Copeland Scroll ZS KAE Series User guide

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© 2015 Emerson Climate Technologies, Inc.
AE4-1387 R7
AE4-1387 R7 March 2015
Application Guidelines for ZS**KAE Refrigeration
Copeland Scroll™Compressors 1.3-4.5 HP
Safety
Safety Instructions................................................2
Safety Icon Explanation .......................................2
Instructions Pertaining to Risk of Electrical
Shock, Fire, or Injury to Persons..........................3
Safety Statements................................................3
Introduction.............................................................4
Nomenclature.......................................................4
Operating Envelope .............................................4
Application Considerations
Accumulators .......................................................4
Superheat Requirements .....................................4
Crankcase Heaters ..............................................4
Discharge Line Thermostat ..................................4
Pressure Controls ................................................5
Pump Down Recommendations...........................5
IPR Valve ............................................................5
Internal Temperature Protection ..........................5
Motor Protection...................................................5
Oil Types ..............................................................5
Oil Charges ..........................................................5
Compressor Tubing and Mounting .......................5
Starting Characteristics ........................................5
Fusite ...................................................................6
Shell Temperature ................................................6
Connection Fittings ..............................................6
Three-Phase Rotation Direction...........................6
Brief Power Interruptions......................................6
Deep Vacuum Operation......................................6
ZS**KAE Compressors in Copeland™
Condensing Units...................................................7
Features ...............................................................7
Condensing Unit Mounting...................................7
Bump Start Protection ..........................................7
Brief Power Interruptions......................................7
Headmaster Refrigerant Selection Instructions....7
Rack Applications.................................................7
Assembly Line Procedures
Unbrazing System Components ..........................7
High Potential (Hipot) Testing...............................7
Service Procedures
Copeland Scroll™ Functional Check .....................8
New Installation....................................................9
Field Service ........................................................9
Tables & Figures
Compressor Models and Approved Refrigerants/
Lubricants........................................................10
Charge Limitations .............................................10
Crankcase Heater ..............................................10
Conduit Ready Heater Terminal Box Kits...........10
Discharge Thermostat Line Kits .........................10
Pressure Control Settings .................................. 11
Recommended Oil Charges by Model Family.... 11
Voltage Ranges (Typical) ................................... 11
ZS*KAE Application Envelope for R-404A/
R-507 (Extended Medium Temp) ....................12
ZS*KAE Application Envelope for R-22
(Medium/High Temp).......................................12
ZS*KAE Application Envelope for R-134A
(Medium /High Temp)......................................13
ZS*KAE Application Envelope for R-407A/407C/
R-448A/R-449A (Extended Medium Temp)....13
1.3 - 4.5 HP Refrigeration Scroll 53 Frame
Condensing Unit Mounting..............................14
1.3 - 4.5 HP Refrigeration Scroll 63 Frame
Condensing Unit Mounting..............................14
Typical Suction Tubing .......................................15
Motor Terminal (Fusite) Connections for Single
Phase and Three Phase Scrolls......................15
Scroll Wiring Schematic .....................................16
TABLE OF CONTENTS
Section Page Section Page

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© 2015 Emerson Climate Technologies, Inc.
AE4-1387 R7
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. Safey 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 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. Safey 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 compessor. 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 or serious injury.
WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION, used with the safety alert symbol, indicates a hazardous
situation which, if not avoided, could result in minor or moderate injury.
NOTICE is used to address practices not related to personal injury.
CAUTION, without the safety alert symbol, is used to address practices
not related to personal injury.
DANGER
WARNING
CAUTION
NOTICE
CAUTION

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© 2015 Emerson Climate Technologies, Inc.
AE4-1387 R7
ELECTRICAL SHOCK HAZARD
• 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.
•
• Failure to follow these warnings could result in serious personal injury.
PRESSURIZED SYSTEM HAZARD
• 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
• 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
• 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.
•
install, commission and maintain this equipment.
•
• All valid standards and codes for installing, servicing, and maintaining electrical and
refrigeration equipment must be observed.
Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons
WARNING
WARNING
WARNING
CAUTION

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© 2015 Emerson Climate Technologies, Inc.
AE4-1387 R7
INTRODUCTION
The ZS**KAE Copeland Scroll™compressor represents
the latest generation of compliant scroll technology for
the refrigeration industry.
Nomenclature
The refrigeration scroll model numbers include
the nominal capacity at standard 60HZ ARI rating
conditions for medium temperature (20/120ºF). For
additional information on this product, please refer
to the Online Product Information accessible from
the Emerson Climate Technologies web site at www.
emersonclimate.com.
Z = Scroll
S = Extended Medium Temperature Application
09K = nominal Capacity (x 1,000 Btu/hr)
A = Compressor Generation
E = POE Oil
Operating Envelope
The ZS**KAE refrigeration scroll compressor models can
be used with a variety of refrigerants depending on the
model selected and the lubricant used. (See Table 1.)
The ZS**KAE models are intended for extended
medium and high temperature refrigeration type duty.
The approved operating envelopes for these models
are such that they are ideally suited for applications
such as ice machines, bulk milk and frozen carbonated
beverage/frozen uncarbonated beverage. The models
and operating envelopes are depicted in Figures 1A,
1B and 1C.
APPLICATION CONSIDERATIONS
Accumulators
Due to the scrolls’ inherent ability to handle liquid
refrigerant in flooded start and defrost cycle
operation conditions, accumulators may not be
required. An accumulator is required on single
compressor systems when the charge limitations
exceed those values listed in Table 2. On systems
with defrost schemes or transient operations that
allow prolonged uncontrolled liquid return to the
compressor, an accumulator is required unless a
suction header of sufficient volume to prevent liquid
migration to the compressor is used.
Excessive liquid ood back or repeated ooded starts
will dilute the oil in the compressor causing inadequate
lubrication and bearing wear. Proper system design will
minimize liquid ood back, thereby ensuring maximum
compressor life.
Superheat Requirements
In order to assure that liquid refrigerant does not return
to the compressor during the running cycle, attention
must be given to maintaining proper superheat at the
compressor suction inlet. Emerson recommends a
minimum of 20°F (11°C) superheat, measured on the
suction line 6 inches (152mm) from the suction valve,
to prevent liquid refrigerant oodback.
Another method to determine if liquid refrigerant is
returning to the compressor is to accurately measure
the temperature difference between the compressor
oil crankcase and the suction line. During continuous
operation we recommend that this difference be a
minimum of 50°F (27°C). This “crankcase differential
temperature” requirement supersedes the minimum
suction superheat requirement in the last paragraph.
To measure oil temperature through the compressor
shell, place a thermocouple on the bottom center (not
the side) of the compressor shell and insulate from the
ambient.
During rapid system changes, such as defrost or ice
harvest cycles, this temperature difference may drop
rapidly for a short period of time. When the crankcase
temperature difference falls below the recommended
50°F (27°C), our recommendation is the duration should
not exceed a maximum (continuous) time period of two
minutes and should not go lower than a 25°F (14°C)
difference.
Contact your Emerson Climate Technologies
representative regarding any exceptions to the above
requirements.
Crankcase Heaters
Crankcase heaters are required on all ZS**KAE scroll
compressors where the system charge exceeds charge
limit.
The listed crankcase heaters are intended for use
only when there is limited access (See Table 3). The
heaters are not equipped for use with electrical conduit.
Where applicable, electrical safety codes require lead
protection, a crankcase heater terminal box should be
used. Recommended crankcase heater terminal box
and cover kit numbers are listed in Table 3A. If there

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© 2015 Emerson Climate Technologies, Inc.
AE4-1387 R7
are any questions concerning their application, contact
your Emerson Climate Technologies representative.
Discharge Line Thermostat
Figures 1A, 1B and 1C show the operating maps
based on refrigerant for the ZS**KAE scroll. Operation
beyond these limits can cause high compression ratios
or excessive internal compressor temperatures. This
will result in overheating the scroll members, causing
excessive wear resulting in premature compressor
failure.
If the system is designed where operation within these
guidelines cannot be guaranteed, then the discharge
line thermostat is required in the compressor control
circuit.
The thermostats have a cut out setting that will insure
discharge line temperatures below the 275°F maximum
limit. It should be installed approximately 6 inches from
the discharge tube outlet. If a service valve is installed
at the discharge tube, the thermostat should be located
5 inches from the valve braze.
Kits have been set up to include the thermostat, retainer,
and installation instructions. These thermostats must
be used with ½” O.D. discharge lines to ensure proper
thermal transfer and temperature control. They work
with either 120 or 240-volt control circuits and are
available with or without an alarm circuit capability.
See Table 4 for a list of discharge line thermostat kit
numbers.
Pressure Controls
Both high and low-pressure controls are required on all
models. See Table 5 for set points.
Pump Down Recommendations
All the ZS**KAE scrolls have an internal spring loaded
low-leak discharge check valve suitable for pump down
application. This valve prevents system pressures from
equalizing and pump down can be achieved. However,
during laboratory testing, we have observed a potential
short cycling condition on the ZS09KAE through
ZS33KAE models. This phenomenon can be attributed
to several factors:
1. Location of low-pressure control sensor. If it is
located right at the suction inlet of the compressor,
it will be more sensitive to pressure spikes.
2. Actual low-pressure setting. Refer to our
recommended setting in Table 5. If the differential
pressure setting is too close, this will increase the
possibility of short cycling.
3. Type of Low-pressure control can have an effect
on cycling. The encapsulated non-adjustable type
is more susceptible to causing excessive cycling
due to tolerances.
4. If short cycling cannot be avoided, using a 3-minute
time delay will limit the cycling of the compressor
to an acceptable level.
IPR Valve
Refrigeration scroll compressors (1.3 - 4.5 hp) ZS09-
33KAE have internal pressure relief valves, which open
at a discharge to suction differential pressure of 375
to 450 psi. This action will trip the motor protector and
remove the motor from the line.
Internal Temperature Protection
Refrigeration scroll compressors (1.3 - 4.5 hp)
ZS09-33KAE incorporate a thermo disc which is a
temperature-sensitive snap disc device located at the
mufer plate port. It is designed to open and route hot
discharge gas back to the motor protector thus removing
the compressor from the line.
Motor Protection
Conventional inherent internal line break motor
protection is provided.
Oil Types
Polyol ester lubricants must be provided if the scroll
compressor is to be used with HFC refrigerants. See
Form 93-11 for a complete list of all Emerson approved
lubricants.
CAUTION
POE must be handled carefully and the proper
protective equipment (gloves, eye protection,
etc.) must be used when handling POE lubricant.
POE must not come into contact with any surface
or material that might be harmed by POE, includ-
ing without limitation, certain polymers (e.g. PVC/
CPVC and polycarbonate).
Oil Charges
The recommended oil charges for these compressors
are shown in Table 6.

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© 2015 Emerson Climate Technologies, Inc.
AE4-1387 R7
Compressor Tubing and Mounting
Compressor mounting must be selected based on
application. Consideration must be given to sound
reduction and tubing reliability. Some tubing geometry
or “shock loops” may be required to reduce vibration
transferred from the compressor to external tubing.
Starting Characteristics
Single-phase scroll compressors are designed with
permanent split capacitor (PSC) type motors and
therefore will start without the need of start assist
devices in most applications. However, if low voltage
conditions exist at start up, protector trips can result.
Therefore, start assist devices (start capacitors and
relays) are available to maximize starting characteristics
under abnormal conditions. See Table 8 for voltage
ranges.
Fusite
Fusite pin molded orientation for single-phase and
three- phase refrigeration scroll compressors are shown
in Figure 4.
Shell Temperature
System component failure may cause the top shell
and discharge line to briey reach temperatures above
300°F. Wiring or other materials, which could be
damaged by these temperatures, should not come in
contact with the shell.
Connection Fittings
Scroll compressors are provided only with sweat
connections. (Consult your Emerson Climate
Technologies representative for details).
See section on New Installation for suggestions on
how to properly braze these ttings.
Three-Phase Rotation Direction
Scroll compressors are directional dependent: i.e., they
will compress in one rotational direction only. On single-
phase compressors, this is not an issue since they will
only start and run in the proper direction (except as
described in the Labeled Brief Power Interruptions).
Three-phase scrolls, however, will rotate in either
direction depending on the power of the phasing. So
there is a 50/50 chance of connected power being
“backwards.” Contractors should be warned of this.
Appropriate instructions or notices should be provided
by the Original Equipment Manufacturer.
Verication of proper rotation can be made by observing
that the suction pressure drops and the discharge
pressure rises when the compressor is energized.
Additionally, if operated in reverse the compressor is
noisier and its current draw is substantially reduced
compared to tabulated values.
Although operation of scroll in reverse direction for brief
periods of time is not harmful, continued operation could
result in failure.
All three-phase compressors are wired identically
internally. Once the correct phasing is determined for
a specic system or installation, connecting properly
phased power leads to the same fusite terminals will
maintain the proper rotation.
Brief Power Interruptions
Brief power interruptions (less than ½ second) may
result in powered reverse rotation of single-phase
refrigeration scroll compressors. High-pressure
discharge gas expands backward through the scrolls
at power interruption causing the scroll to orbit in
the reverse direction. If power is reapplied while this
reversal is occurring, the compressor may continue to
run noisily in the reverse direction for several minutes
until the compressor internal protector trips. This has no
negative effect on durability. When the protector resets,
the compressor will start and run normally.
Emerson strongly encourages the use of a timer
which can sense brief power interruptions and lock the
compressor out of operation for two minutes. A typical
timer circuit is shown in Figure 5.
No time delay is required on three phase models to
prevent reverse rotation due to power interruptions.
Deep Vacuum Operation
WARNING
Do not run a refrigeration scroll compressor in
a deep vacuum. Failure to heed this advice can
result in permanent damage to the compressor.
A low-pressure control is required for protection against
deep vacuum operation. See the section on pressure
controls for the proper set points. (See Table 5)
Scroll compressors (as with any refrigeration
compressor) should never be used to evacuate
refrigeration or air conditioning systems. See AE24-

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compressor operating envelope.
The Headmaster Control Valve has a dual pressure
setting feature which allows a choice between two
xed settings; The DS element has an internal
spring which is set to maintain the lower setting.
The element is then charged with air to obtain the
higher setting (180 psig) and the capillary tube is
pinched and fused. If the capillary tube is left intact,
the valve will maintain a 180 psig setting. If the
capillary tube is clipped and fused again, the valve
will maintain a 100 psig setting.
It is important to fuse the capillary tube tip after
clipping to prevent moisture from entering the
element.
Tubing Considerations – Proper tube design must be
taken into consideration when designing the tubing
connecting the scroll to the remaining system. The
tubing should provide enough “exibility” to allow normal
starting and stopping of the compressor without exerting
excessive stress on the tube joints. In addition, it is
desirable to design tubing with a natural frequency away
from the normal running frequency of the compressor.
Failure to do this can result in tube resonance and
unacceptable tubing life. Figure 3 shows examples of
acceptable tubing congurations.
CAUTION
These examples are intended only as guidelines to
depict the need for exibility in tube designs. In order to
properly determine if a design is appropriate for a given
application, samples should be tested and evaluated for
stress under various conditions of use including voltage,
frequency, and load uctuations, and shipping vibration.
The guidelines above may be helpful; however, testing
should be performed for each system designed.
Rack Applications
ZS**KAE Compressors are not approved for rack or
parallel applications because the compressors do not
have sight glasses and cannot be equipped with oil
equalization devices.
ASSEMBLY LINE PROCEDURES
Unbrazing System Components
CAUTION
If the refrigerant charge is removed from a scroll unit
by bleeding the high side only, it is sometimes possible
for the scrolls to seal, preventing pressure equalization
1105 for proper system evacuation procedures.
ZS**KAE COMPRESSORS IN COPELAND™
CONDENSING UNITS
The new FFAP Copeland condensing units will offer the
latest technology utilizing the efcient ZS**KAE scroll
product along with incorporating the Emerson Electronic
Unit Controller (EUC) on all models.
In Table 7 are the approved refrigerants along with the
minimum operating temperature ranges based on the
refrigerants applied.
Performance data along with the applicable
nomenclature information can be found on the www.
emersonclimate website.
Features
All condensing units come equipped from the factory
with the Electronic Unit Controller. The controller has
a minimum low pressure cutout setting of 0 psig. See
Table 5 for the recommended pressure control settings
based on refrigerant.
Condensing Unit Mounting
For 1.3 - 4.5 H.P. refrigeration scroll condensing unit
applications, soft mounts are recommended. See
Figures 2A and 2B.
Bump Start Protection
The bump start function has been enabled in the EUC
so whenever power is applied or re-applied to the unit
the system will energize the compressor for 2 seconds
on and 5 seconds off. This will occur for 3 cycles, and
then continuous power will be supplied to the system
for normal operation.
Brief Power Interruptions
As part of the EUC control, a two minute time delay has
been programmed into the controller on all condensing
units which will sense a brief power interruption and
lock the compressor / unit out of operation for two
minutes.
Headmaster Refrigerant Selection Instructions
Incorporated into the SINGLE FAN FFAP condensing
unit is a dual pressure setting headmaster which will
allow for the unit to operate in low ambient conditions
with the approved refrigerants outlined in Table 1.
Please follow the instructions provided below after
the refrigerant selection is made, failure to do so will
cause the system to operate outside of its approved

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© 2015 Emerson Climate Technologies, Inc.
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through the compressor. This may leave the low side
shell and suction line tubing pressurized. If a brazing
torch is then applied to the low side, the pressurized
refrigerant oil mixture could ignite as it escapes and
contacts the brazing ame. It is important to check both
the high and low sides with manifold gauges before
unbrazing. In the case of an assembly line repair,
remove the refrigerant from both the high and low sides.
Instructions should be provided in appropriate product
literatures and assembly areas.
High Potential (Hipot) Testing
Many of the Copeland brand compressors are
congured with the motor below the compressor. As a
result, when liquid refrigerant is within the compressor
shell the motor can be immersed in liquid refrigerant to
a greater extent than with compressors with the motor
mounted above the compressor. When Copeland brand
compressors are Hipot tested and liquid refrigerant is
in the shell, they can show higher levels of leakage
current than compressors with the motor on top because
of the higher electrical conductivity of liquid refrigerant
than refrigerant vapor and oil. This phenomenon
can occur with any compressor when the motor is
immersed in refrigerant. The level of current leakage
does not present any safety issue. To lower the current
leakage reading, the system should be operated for a
brief period of time to redistribute the refrigerant to a
more normal conguration and the system Hipot tested
again. See bulletin AE4-1294 for Megohm testing
recommendations. Under no circumstances should
the Hipot or Megohm test be performed while the
compressor is under a vacuum.
SERVICE PROCEDURES
Copeland Scroll Functional Check
Refrigeration scroll compressors do not have internal
suction valves. It is not necessary to perform functional
compressor tests to check how low the compressor will
pull suction pressure. This type of test may damage a
scroll compressor. The following diagnostic procedure
should be used to evaluate whether a Copeland Scroll
compressor is functioning properly.
1. Verify proper unit voltage.
2. Normal motor winding continuity and short to
ground checks will determine if the inherent
overload motor protector has opened or if an
internal short to ground has developed. If the
protector has opened, the compressor must cool
sufciently to reset.
3. With service gauges connected to suction
and discharge pressure ttings, turn on the
compressor. If suction pressure falls below
normal levels, the system is either low on charge
or there is a ow blockage.
4a. Single-Phase Compressors
If the suction pressure does not drop and the
discharge pressure does not rise to normal levels
the compressor is faulty.
4b. Three-Phase Compressors
If the suction pressure does not drop and the
discharge pressure does not rise, reverse any two
of the compressor power leads and reapply power
to make sure the compressor was not wired to
run in the reverse direction.
The compressor current draw must be compared to
published compressor performance curves at the
compressor operating conditions (pressures and
voltages). Signicant deviations (±15%) from published
values may indicate a faulty compressor.
NOTICE
Note that the ZS09-19KAE-(TFD, TFE, TF7, TF5) three
phase motors use a modied "Scott-T" connection
and don't have equal resistance on all three windings.
Two windings will have equal resistances and the third
winding will be lower than the other two. See Figure
A. Carefully compare measured motor resistance
values to the two different published resistance values
for a given compressor model before replacing the
compressor as being defective. Due to the nature of
the Scott-T construction there is an inherent current
imbalance in the motors that is much larger than what
is seen in a standard 3-phase motor. Effectively you
will have two terminals drawing similar currents while
the third will draw a higher current. The current draw
on the Scott –T motors as shown in the performance
data and in the operating envelope (available online at
www.emersonclimate.com under the Online Product
Information link) comes from the 2 main windings. The
larger ZS21-33KAE compressors have conventional
three-phase motors with equal resistances in each
winding.

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Figure A
Scott-Tee Three Phase
A PHASE B PHASE
A
M1 T1 M2
B
A2
A1 C PHASE
C
New Installation
• The copper-coated steel suction, discharge, and
injection tubes on scroll compressors can be
brazed in approximately the same manner as
any copper tube.
• Recommended brazing material – Any Silfos
material is recommended, preferably with a
minimum of 5% silver. However, 0% silver is
acceptable.
• Use of a dry nitrogen purge to eliminate
possibility of carbon buildup on internal tube
surfaces is recommended.
• Be sure process tube tting I.D. and process
tube O.D. are clean prior to assembly.
• Apply heat in Area 1. As tube approaches
brazing temperature, move torch ame to Area
2. (See Scroll Tube Brazing gure below.)
• Heat Area 2 until braze temperature is attained,
moving torch up and down and rotating around
tube as necessary to heat tube evenly. Add
braze material to the joint while moving torch
around circumference.
• After braze material ows around joint, move
torch to heat Area 3. This will draw the braze
material down into the joint. The time spent
heating Area 3 should be minimal.
• As with any brazed joint, overheating may be
detrimental to the nal result.
Field Service
To disconnect:
• Recover refrigerant from both the high and low
side of the system. Cut tubing near compressor.
To reconnect:
• Recommended brazing materials – Silfos with
minimum 5% silver or silver braze material with
ux.
• Reinsert tubing tting.
• Heat tube uniformly in Area 1, moving slowly to
Area 2. When joint reaches brazing temperature,
apply brazing material. (See gure below)
• Heat joint uniformly around the circumference to
ow braze material completely around the joint.
• Slowly move torch in Area 3 to draw braze
material into the joint.
Do not overheat joint.
Scroll Tube Brazing

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Model HP Refrigerant Lubricant
ZS09KAE 1.3 R-22/R-404A/R-507/R-134a/R-407A/R-407C/R-448A/R-449A POE
ZS11KAE 1.5 R-22/R-404A/R-507/R-134a/R-407A/R-407C/R-448A/R-449A POE
ZS13KAE 1.9 R-22/R-404A/R-507/R-134a/R-407A/R-407C/R-448A/R-449A POE
ZS15KAE 2.1 R-22/R-404A/R-507/R-134a/R-407A/R-407C/R-448A/R-449A POE
ZS19KAE 2.5 R-22/R-404A/R-507/R-134a/R-407A/R-407C/R-448A/R-449A POE
ZS21KAE 3.2 R-22/R-404A/R-507/R-134a/R-407A/R-407C/R-448A/R-449A POE
ZS26KAE 3.5 R-22/R-404A/R-507/R-134a/R-407A/R-407C/R-448A/R-449A POE
ZS29KAE 4 R-22/R-404A/R-507/R-134a/R-407A/R-407C/R-448A/R-449A POE
ZS33KAE 4.5 R-22/R-404A/R-507/R-134a/R-407A/R-407C/R-448A/R-449A POE
Table 1
Compressor Models and Approved Refrigerants/Lubricants
See Emerson Climate Technologies Form 93-11 for a complete list of all Emerson approved
lubricants.
Model Family Charge Limits
ZS09, 11, 13, 15, 19KAE 8lbs
ZS21, 26, 29, 33KAE 10lbs
Table 2 – Charge Limitations
Model Part No. Volts Watts Length (in.)
ZS09, 11, 13, 15, 19KAE
018-0094-00 240 40 21
018-0094-01 120 40 21
018-0094-03 480 40 21
ZS21, 26, 29, 33KAE
018-0095-04 240 70 48
018-0095-05 480 70 48
018-0095-06 575 70 48
018-0095-07 120 70 48
Table 3 – Crankcase Heater
Model Number Kit Number
ZS09-19KAE 998-0358-00
ZS21-33KAE 998-7026-00
Table 3A –
Conduit Ready Heater Terminal Box Kits
Table 4
Discharge Thermostat Line Kits
Kit Number Conduit Lead
Connector
Alarm
Contact
998-0540-00 NO NO
998-0548-00 NO YES
998-7022-02 YES NO

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© 2015 Emerson Climate Technologies, Inc.
AE4-1387 R7
Model
Type
Pressure
Control
R-404A/
R-507 R-134a R-22 R-407A/ R-448A/R-449A R-407C
ZS*KAE
Low 8 PSIG min. 4 PSIG min. 17 PSIG min. 6 PSIG min. 1in Hg min.
High 450 PSIG
max.
340 PSIG
max.
425 PSIG
max. 428 PSIG max. 425 PSIG max.
Table 5 – Pressure Control Settings
Table 6 – Recommended Oil Charges by Model Family
Model Family Initial Recharge Frame Size
ZS09-19KAE 25 19 53
ZS21-33KAE 42 34 63
Refrigerant
Extended
Medium Temp
(-30 F to 25 F)
Medium Temp
(0 F to 25 F)
High Temp
(25 F to 45 F)
R-22 X X
R-407C X X
R-404A X X
R-134a X X
R-407A X
Table 7 – FFAP Condensing Unit Operating Envelopes
Voltage 60 Hertz Rating 50 Hertz Rating
Code Rating Min. Max. Rating Min. Max.
C 208/230-3 187 253 200-3 180 220
D 460-3 414 506 380/420-3 342 462
E 575-3 518 633 500-3 450 550
V 208/230-1 197 253 200-1 180 220
V* 208/230-1 187 253 200-1 180 220
5 200/230-3 180 253 200/220-3 180 242
7 380-3 342 418 X X X
J 265-1 239 292 220/240-1 198 264
R X X X 220/240-3 180 264
Table 8 – Voltage Ranges (Typical)
The typical voltage range is (+/-) 10 % from rated voltage with the exemption of the 208/230 dual rated **V
models which are -5% +10% (197 min to 253 max voltage)from nominal as shown in the above table. The
following ZS**KAE models are now approved to operate within the full (+/-)10% range with a minimal voltage of
187 and a maximum voltage of 253 (ZS09,11,13,15,19, 21, 26KAE-PFV). The following models are not qualied
to the full (+/-) 10% at this time, ZS29KAE-PFV and ZS33KAE-PFV.
*

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© 2015 Emerson Climate Technologies, Inc.
AE4-1387 R7
-34-29 -24-19 -14-9-41 6
-18
-8
2
12
22
32
42
52
62
0
20
40
60
80
100
120
140
160
-30-20 -100 10 20 30 40 50
Evaporating Temp, °C
Condensing Temp, °C Condensing Temp, °F
Evaporating Temp, °F
Maximum Return Gas =65°F
Maximum
Return
Gas = 40°F
Figure 1A – ZS*KAE Application Envelope for R-404A/R-507 (Extended Medium Temp)
-1
4
10
16
21
27
32
38
43
49
54
60
66
71
-23 -18 -12 -7 -1 4 10 16
30
40
50
60
70
80
90
100
110
120
130
140
150
160
-10 0 10 20 30 40 50 60
SH=20°F
Condensing Temp,°C
Evaporating Temp,°C
Condensing Temp,°F
Evaporating Temp, °F
Figure 1B – ZS*KAE Application Envelope for R-22 (Medium/High Temp)

13
© 2015 Emerson Climate Technologies, Inc.
AE4-1387 R7
Figure 1C – ZS*KAE Application Envelope for R-134A (Medium/High Temp)
16
21
27
32
38
43
49
54
60
66
71
77
-29 -23 -18 -12 -7 -1 4 10 16
60
70
80
90
100
110
120
130
140
150
160
170
-20 -10 0 10 20 30 40 50 60
Minimum 20°F
Superheat
Required
Condensing Temp, °C
Evaporating Temp, °C
Evaporating Temp, °F
Condensing Temp, °F
RG=65°F
Figure 1D - ZS*KAE Application Envelope for R-407A/407C/R-448A/R-449A (Extended Medium Temp)
-34-29 -24-19 -14-9-41 6
-18
-8
2
12
22
32
42
52
62
0
20
40
60
80
100
120
140
160
-30-20 -100 10 20 30 40 50
Evaporating Temp, °C
Condensing Temp, °C Condensing Temp, °F
Evaporating Temp, °F
R-407C Only
20°F Superheat Limit

14
© 2015 Emerson Climate Technologies, Inc.
AE4-1387 R7
Figure 2A
ZS09KAE to ZS19KAE Refrigeration Scroll 53 Frame Condensing Unit Mounting
027-0262-00
30-35 Durometer
Kit 527-0044-15
028-0188-15 Sleeve
028-0188-15 Sleeve
028-0188-15
Sleeve
Gap
Figure 2B
ZS21KAE to ZS33KAE Refrigeration Scroll 63 Frame Condensing Unit Mounting
027-0186-00
35-45 Durometer
Kit 527-0116-00
028-0188-15 Sleeve
028-0188-15 Sleeve
028-0188-16
Sleeve
Gap

15
© 2015 Emerson Climate Technologies, Inc.
AE4-1387 R7
NOTES:
1. The above tubing congurations are guidelines to minimize tube stress.
2. Follow similar guidelines for discharge tubing and oil return tubing as needed.
3. If a run of over 20” is required, intermediate clamps may be necessary.
4. Do not hang weights on tubing (e.g. lter drier on suction tubing) except after clamps or close
to the header.
5. Tube runs of less than 8” are not recommended.
6. This dimension should be made as short as possible (e.g. 2” or less) but still insuring a proper
braze joint.
7. The above tubing recommendations are based on “no elbow joints”. The use of continuous
tubing is preferred.
Figure 4
Motor Terminal (Fusite) Connections for
Single Phase and Three Phase Scrolls
Figure 3
Typical Suction Tubing

16
© 2015 Emerson Climate Technologies, Inc.
AE4-1387 R7
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 afliates (collectively "Emerson"), as applicable, reserve the right to modify the design or specications 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.
Figure 5
Scroll Wiring Schematic
Typical Solid State Timer
Discharge Line
Thermostat
Compressor
Contactor
Coil
Other Protective
Devices (if used)
System Operating
Thermostat
Fuse
(Optional)
Condenser Fan
Contactor Coil
(if used)
Time Delay Relay Specifications
Timer Opens: 1 Electrical Cycle
(.016 Seconds with 60 HZ Operation)
After Power is Removed
Timer Closes: 2 Minutes (+/- 20%) Later,
Whether Power is Restored or Not
CSR = Current Sensing Relay
Contact
230/240 VAC
C2
C1