Air Compressor User Manual

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Printed in the U.S.A.

AE4-1395

Application Engineering

BULLETIN

3 to 15 Ton Copeland Scroll Digital

™

Compressors for Air Conditioning

AE4-1395

August 2012

Application Engineering

BULLETIN

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

Nomenclature ....................................................... 4

Digital Compressor Operation .............................. 4

How It Works ....................................................... 4

Application Considerations

Operating Envelope .............................................. 4

Solenoid Valve and Coil ........................................ 5

Pressure Fluctuations ........................................... 5

Piping .................................................................... 5

Start Up and Shut Down ....................................... 5

Compressor Cycling .............................................. 5

Sound Characteristics ........................................... 5

Internal Pressure Relief (IPR) Valve ...................... 5

High Pressure Control ........................................... 5

Low Pressure Control ............................................ 5

Scroll Temperature Protection ............................... 6

Crankcase Heaters ............................................... 6

Oil Type and Oil Removal ..................................... 6

Power Factor ......................................................... 6

Tandem Applications ............................................. 6

Modulation Control ................................................ 7

Application Tests

 OilLevelVerication .............................................. 7

Excessive Liquid Floodback Tests ......................... 7

Operating Envelope Tests ..................................... 7

Digital Compressor Retrot Applications

 ReasonstoRetrot ................................................. 7

 RetrotApplicationsToAvoid .................................. 8

Performance Modeling ............................................ 8

 SystemModications .............................................. 8

Compressor Selection & Change-Out ................... 8

Refrigerant Flow Control ....................................... 9

Evaporator Air Flow ............................................... 9

Condenser Air Flow ............................................... 9

Modulation Control ................................................ 9

Assembly Line Procedures

3 To 7.5 Ton Modulation Valve Brazing Procedure ...9

Pressure Testing ......................................................9

Service Procedures

Modulation Troubleshooting ...................................10

3 to 7.5 Ton Modulation Valve Replacement

Procedure ...............................................................10

8 To 15 Ton Modulation Valve Replacement

Procedure ...............................................................10

Scroll Compressor Functional Check ..................... 11

Figures & Tables

Digital Cycle Example ............................................12

3 to 7.5 Ton Digital Scroll Cross Sectional View .....12

8 to 15 Ton Digital Scroll Cross Sectional View ......13

3-7.5 Ton Operating Envelope ................................14

8-15 Ton Operating Envelope .................................14

Compressor Capacity Graph ..................................15

Discharge Thermistors ...........................................15

3 to 7.5 Ton Modulation Valve Piping .....................16

3 To 7.5 Ton Tandem ..............................................16

Modulation Troubleshooting ...................................17

Copeland Scroll Digital Family Features ................18

Refrigerant Charge Limits ......................................18

Torque Values .........................................................18

Compressor Accessories .......................................19

TABLE OF CONTENTS

Section Page Section Page

Summary of content (19 pages)

PAGE 1
Application Engineering Application Engineering B L LL E L T EI BU U AE4-1395 N T I AE4-1395 N August 2012 3 to 15 Ton Copeland Scroll Digital™ Compressors for Air Conditioning TABLE OF CONTENTS Section Page Section Safety Safety Instructions.................................................. 2 Safety Icon Explanation......................................... 2 Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons............ 3 Safety Statements.............................
PAGE 2
Application Engineering B U L L E T I N AE4-1395 Safety Instructions Safety Instructions ™ 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. Particularhas emphasis has been placed onsafety. the user's safety.
PAGE 3
Application Engineering B U L L E T I N Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons WARNING ELECTRICAL SHOCK HAZARD • 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.
PAGE 4
Application Engineering B U L L E Introduction The 3 to 15 ton Copeland Scroll Digital compressors described in this bulletin include the follow compressor model numbers: R-22 & R-407C ZPD34 to ZPD54K5 ZRD36 to ZRD81KC ZPD61 to ZPD91KC ZRD94 to ZRD125KC ZPD103 to ZPD182KC ZPD and ZRD digital scroll compressors are variable capacity compressors that can modulate down to 10% of full load.
PAGE 5
Application Engineering B U L L E Compressor operation during the loaded state should always be inside of the envelope. The envelopes represent allowable operation of the compressor with 20F° suction superheat at rated voltage. If the specified modulation ranges are exceeded, overheating of the compressor and tripping of the overload can occur because of inadequate motor cooling.
PAGE 6
Application Engineering B U L L E bar) for R-407C & R-22 to prevent evaporator coil icing. The cut in setting can be as high as 180 psig (12.5 bar) for R-410A and 105 psig (7.2 bar) for R-407C & R-22 to prevent rapid recycling in case of refrigerant loss. I N AE4-1395 RL32-3MAF) should be used. Copeland Ultra 22 CC, Hatcol EAL 22CC, and Mobil EAL Arctic 22 CC are acceptable alternatives.
PAGE 7
Application Engineering B U L L E Modulation Control I N AE4-1395 If the system contains more than 20 pounds (9 kg) of refrigerant, it is our recommendation to add one fluid ounce of additional oil for every 5 pounds (15 ml/kg) of refrigerant over this amount. This is a starting point and oil should be added as determined through system testing or as required by the end use application in the field.
PAGE 8
Application Engineering B U L L E T I N AE4-1395 hot-gas-bypass for capacity control are also ideal units for a digital scroll retrofit. have specific instructions developed that offer step by step guidance. Retrofit Applications To Avoid Before beginning the retrofit, the system should be operable and system operating conditions should be logged for future reference.
PAGE 9
Application Engineering B U L L E T I N AE4-1395 7. Using the appropriate lifting devices, carefully remove the compressor from the system. remove latent heat. In desert and arid climates, because of low or no latent loads, air flow is less critical. The following steps should be followed to install the digital compressor into the system. The controls required for variable air flow are not provided by Emerson so the contractor may need to consult with controls experts in this field. 1.
PAGE 10
Application Engineering B U L L E SERVICE PROCEDURES I N AE4-1395 systems, carefully braze the new valve into the system, directing the torch flame away from the valve body. Modulation Troubleshooting The modulation valve and solenoid coil are engineered for specific use with the digital scroll. Don’t attempt to substitute replacement solenoid coils that are not of the correct part number. The 3 to 7.
PAGE 11
Application Engineering B U L L E 9. Use care when handling the replacement valve – don’t drop the valve or impact the solenoid stem. If the valve is dropped or damaged, discard it and obtain a new valve for replacement. I N AE4-1395 5.
PAGE 12
Application Engineering B U L L E T 50% Loaded I N AE4-1395 80% Loaded PUMPING PUMPING 7.5 s 7.5 s 12s NOT PUMPING 3s 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. © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.
PAGE 13
Application Engineering B U L L E T I N 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 © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.
PAGE 14
Application Engineering B U L L E T I N R-22, R-407C, R-410A Operating Envelope 160 AE4-1395 ZPD34-54K5 ZPD61-91KC ZRD36-81KC 150 Condensing Temperature (°F) 140 130 Recommended Capacity Range 10 -100% 120 Recommended Capacity Range 50 -100% 110 100 Recommended Capacity Range 75 -100% 90 80 70 -20 -10 0 10 20 30 Evaporating Temperature (°F) 40 50 60 Figure 4 R-22, R-407C, R-410A Operating Envelope 160 ZPD103-182KC ZRD94-125KC 150 140 Condensing Temperature (°F) 130 120
PAGE 15
Application Engineering B U L L E T I N AE4-1395 15 Second Operating Cycle Compressor Capacity (Percent of Full Load) 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 0 1 2 3 4 5 6 7 8 9 Solenoid On-Time (Seconds) Figure 6 Compressor Capacity Graph *.ppt 3/23/2010 3:14 PM 1 Figure 7 Discharge Thermistors © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.
PAGE 16
Application Engineering B U L L E T I N AE4-1395 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 Line Suction Manifold Assembly Figure 9 3 To 7.5 Ton Tandem © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.
PAGE 17
Application Engineering B U L L E T I N AE4-1395 Start Is the compressor running? No Yes Yes Allow time to cool WARNING! Disconnect and lockout the power before proceeding Put the system back into operation and retest Remove one wire from the modulation coil No Perform troubleshooting to determine why the compressor isn’t running Observe the compressor suction & discharge pressures Are pressures changing with the modulation cycle? Is the compressor overheated? Yes Operation is normal
PAGE 18
Application Engineering B U L L E T I N AE4-1395 Table 1 Copeland Scroll Digital Family Features Model Digital Modulation Valve Discharge Gas Temperature Protection Discharge Check Valve Internal Pressure Relief (IPR) Valve No Yes Yes No Modulation Control ZPD34-54K5 ZRD36-48KC ZPD61-91KC Required Accessory ZRD61-81KC External Sensor Required Internal Top Cap Thermistor ZPD103-182KC Installed On Compressor ZRD94-125KC External Sensor Required Table 2 Refrigerant Charge Limits
PAGE 19
Application Engineering B U L L E T I N AE4-1395 Table 4 – Compressor Accessories Part Category Modulation Part Description Part Number Models Copeland Scroll Digital Compressor Controller 943-0024-01 All For OEM applications Emerson Commercial Comfort Controller 943-0175-00 All For retrofit applications Modulation Valve & 24V Coil 998-0061-19 24V Coil Only 023-0060-18 110V Coil Only TBD 220V Coil Only TBD Modulation Valve, 24V Coil, Tubing Kit 998-0090-02 Modulation Valve &