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Applic Applic ation Enginee ation Enginee ring ring
AE4-1395
BULL ET IN
BULL ET IN
AE4-1395 August 2012
™
3 to 15 Ton Copeland Scroll Digital Compressors for Air Conditioning
TABLE OF CONTENTS
Section Page Section Page
Safety
Digital Compressor Retrofit Applications
Reasons to Retrofit ................................................. 7
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Application Engineering AE4-1395 BULL ET IN Safety Instructions Safety Instructions ™ ™ Copeland Scroll compressors are manufactured according to the latest U.S. and European Safety Copeland Scroll compressors are manufactured according to the latest U.S. and European Safety Standards. Standards. Particular emphasis has been placed on the user's safety. Safey icons are explained below Particular emphasis has been placed on the user's safety. Safey icons are explained below and safety
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Application Engineering AE4-1395 BULL ET IN Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons ELECTRICAL SHOCK HAZARD WARNING • Failure to follow these warnings could result in serious personal injury. • 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. • PRESSURIZED SYSTEM
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Application Engineering AE4-1395 BULL ET IN Introduction full capacity, or loaded state. When the solenoid valve is energized, the two scroll elements move apart axially, ™ The 3 to 15 ton Copeland Scroll Digital compressors or into the unloaded state. During the unloaded state, described in this bulletin include the follow compressor the compressor motor continues running, but since model numbers: the scrolls are separated, there is no compression. R-410A R-22 & R-407C During the loaded
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Application Engineering AE4-1395 BULL ET IN Compressor operation during the loaded state should Compressor Cycling always be inside of the envelope. The envelopes Because of the digital scroll's seamless capacity represent allowable operation of the compressor with modulation from 10% to 100%, capacity short cycling 20F° suction superheat at rated voltage. If the specified should not be a problem for single compressors. modulation ranges are exceeded, overheating of the Howeve
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Application Engineering AE4-1395 BULL ET IN bar) for R-407C & R-22 to prevent evaporator coil icing. RL32-3MAF) should be used. Copeland Ultra 22 CC, The cut in setting can be as high as 180 psig (12.5 bar) Hatcol EAL 22CC, and Mobil EAL Arctic 22 CC are for R-410A and 105 psig (7.2 bar) for R-407C & R-22 to acceptable alternatives. prevent rapid recycling in case of refrigerant loss. If additi onal oil is needed in the field for mineral oil For heat pumps, a cut out setting no low
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Application Engineering AE4-1395 BULL ET IN Modulation Control If the system contains more than 20 pounds (9 kg) of refrigerant, it is our recommendation to add one fluid Two different controls are available from Emerson to ounce of additional oil for every 5 pounds (15 ml/kg) provide digital scroll modulation control, the Copeland of refrigerant over this amount. This is a starting point ™ Scroll Digital Compressor Controller and the Emerson and oil should be added as determined
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Application Engineering AE4-1395 BULL ET IN hot-gas-bypass for capacity control are also ideal units have specific instructions developed that offer for a digital scroll retrofit. step by step guidance. Retrofit Applications To Avoid Before beginning the retrofit, the system should be operable and system operating conditions should be NOTICE logged for future reference. The compressor suction Always check with the original equipment & discharge pressures, suction superheat, subcoolin
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Application Engineering AE4-1395 BULL ET IN 7. Using the appropriate lifting devices, carefully remove latent heat. In desert and arid climates, because remove the compressor from the system. of low or no latent loads, air flow is less critical. The following steps should be followed to install the digital The controls required for variable air flow are not provided compressor into the system. by Emerson so the contractor may need to consult with controls experts in this field. 1.
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Application Engineering AE4-1395 BULL ET IN SERVICE PROCEDURES systems, carefully braze the new valve into the system, directing the torch flame away from the Modulation Troubleshooting valve body. The modulation valve and solenoid coil are engineered 10. Check for leaks using nitrogen with a properly sized for specific use with the digital scroll. Don’t attempt to regulating and relief valve. substitute replacement solenoid coils that are not of the correct part number. T
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Application Engineering AE4-1395 BULL ET IN 9. Use care when handling the replacement 5. If suction pressure does not drop and discharge valve – don’t drop the valve or impact the pressure does not rise to normal levels, reverse solenoid stem. If the valve is dropped or any two of the compressor power leads (this damaged, discard it and obtain a new valve procedure is for 3-phase compressors only) and for replacement. reapply power to make sure compressor was not wired to run in reverse dir
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Application Engineering AE4-1395 BULL ET IN 50% Loaded 80% Loaded PUMPING PUMPING 7.5 s 12s 7.5 s 3s NOT PUMPING NOT PUMPING 15 seconds One Cycle of 15 seconds Figure 1 Digital Cycle Example Figure 2 3 to 7.5 Ton Digital Scroll Cross Sectional View Note: Modulation tubing is show for reference only. Refer to Figure 8 for the correct modulation tubing configuration. 12 © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.
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Application Engineering AE4-1395 BULL ET IN 90 Frame Digital Scroll Floating Seal Cavity Seal Cavity Vent Removable External Solenoid and Coil Figure 3 8 to 15 Ton Digital Scroll Cross Sectional View 13 © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.
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Application Engineering AE4-1395 BULL ET IN ZPD34-54K5 R-22, R-407C, R-410A Operating Envelope ZPD61-91KC 160 ZRD36-81KC 150 140 130 Recommended 120 Capacity Range 10 -100% 110 Recommended Capacity Range 100 50 -100% Recommended Capacity Range 90 75 -100% 80 70 -20-10 0102030405060 Evaporating Temperature (°F) Figure 4 ZPD103-182KC R-22, R-407C, R-410A Operating Envelope ZRD94-125KC 160 150 140 130 120 Recommended Capacity 110 Range 10 -100% 100 Recommended Capacity 90 Range Recommended 50 -100
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Application Engineering AE4-1395 BULL ET IN 15 Second Operating Cycle 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 0123456789 10 11 12 13 14 15 Solenoid On-Time (Seconds) Figure 6 Compressor Capacity Graph *.ppt 3/23/2010 3:14 PM 1 Figure 7 Discharge Thermistors 15 © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A. Compressor Capacity (Percent of Full Load)
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Application Engineering AE4-1395 BULL ET IN Arrow on valve Must point to suction Figure 8 3 to 7.5 Ton Modulation Valve Piping Solenoid Valve Discharge Manifold Assembly Suction Gas Equalization Manifold Oil Equalization Suction Line Manifold Assembly Figure 9 3 To 7.5 Ton Tandem 16 © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.
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Application Engineering AE4-1395 BULL ET IN Start WARNING! Is the compressor Is the compressor Disconnect and lockout Allow time to cool running? overheated? No Yes the power before proceeding Yes No Perform troubleshooting Observe the compressor to determine why the Put the system back into Remove one wire from suction &discharge compressor isn’t operation and retest the modulation coil pressures running Are pressures changing with the Operation Measure the resistance modulation is nor
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Application Engineering AE4-1395 BULL ET IN Table 1 Copeland Scroll Digital Family Features Internal Digital Discharge Discharge Gas Temperature Pressure Modulation Model Modulation Check Protection Relief (IPR) Control Valve Valve Valve ZPD34-54K5 ZRD36-48KC External Sensor Required Required No Yes Accessory ZPD61-91KC 15 Second Cycle ZRD61-81KC Internal Top Cap Thermistor ZPD103-182KC Installed On External Sensor Required Yes No Compressor ZRD94-125KC Table 2 Refrigerant Charge
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Application Engineering AE4-1395 BULL ET IN Table 4 – Compressor Accessories Part Part Description Part Number Models Notes Category Copeland Scroll Digital 943-0024-01 All For OEM applications Compressor Controller Emerson Commercial Comfort 943-0175-00 All For retrofit applications Controller Modulation Valve & 24V Coil 998-0061-19 24V Coil Only 023-0060-18 Tubing kit is for 7/8" 110V Coil Only TBD ZPD34-54K5 compressor suction; all coils ZPD61-91KC 220V Coil Only TBD Modulation have
