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AE4-1395 R5
3 to 15 Ton Copeland Scroll Digital
Section
Safety
Safety Instructions .................................................. 2
Safety Icon Explanation ......................................... 2
Electrical Shock, Fire, or Injury to Persons ............ 3
Safety Statements .................................................. 3
Introduction .............................................................. 4
Nomenclature ........................................................ 4
Digital Compressor Operation ............................... 4
How It Works ........................................................ 4
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
Oil Level Verification ............................................... 7
Excessive Liquid Floodback Tests .......................... 7
Operating Envelope Tests ...................................... 7
© 2015 Emerson Climate Technologies, Inc. All rights reserved.
Compressors for Air Conditioning
™
TABLE OF CONTENTS
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Section
Reasons to Retrofit ................................................ 7
Retrofit Applications To Avoid ................................. 8
Performance Modeling ........................................... 8
System Modifications ............................................. 8
Compressor Selection & Change-Out .................. 8
Refrigerant Flow Control ...................................... 9
Evaporator Air Flow .............................................. 9
Condenser Air Flow .............................................. 9
Modulation Control ............................................... 9
Modulation Valve Brazing Procedure ...................... 9
Pressure Testing ..................................................... 9
Modulation Troubleshooting ................................. 10
Procedure ............................................................. 10
Scroll Compressor Functional Check ................... 12
Figures & Tables
Digital Cycle Example .......................................... 13
Digital Scroll Cross Sectional View ...................... 13
Digital Scroll Cross Sectional View ...................... 14
Compressor Capacity Graph ................................ 15
Discharge Thermistors ......................................... 15
Modulation Valve Piping ....................................... 16
Tandem ................................................................ 16
Modulation Troubleshooting ................................. 17
Copeland Scroll Digital Family Features .............. 18
Refrigerant Charge Limits .................................... 18
Torque Values ....................................................... 18
Compressor Accessories ..................................... 19
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AE4-1395 R5
April 2016
Page
Table of Contents
Troubleshooting
Related Manuals for Emerson Copeland Scroll Digital ZPD34
Summary of Contents for Emerson Copeland Scroll Digital ZPD34
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Page 1: Table Of Contents
Copeland Scroll Digital Family Features ....18 Application Tests Refrigerant Charge Limits ........18 Oil Level Verification ..........7 Torque Values ............18 Excessive Liquid Floodback Tests ......7 Compressor Accessories ........19 Operating Envelope Tests ........7 © 2015 Emerson Climate Technologies, Inc. All rights reserved. -
Page 2: Safety Instructions
NOTICE NOTICE is used to address practices not related to personal injury. CAUTION, without the safety alert symbol, is used to address practices CAUTION not related to personal injury. © 2015 Emerson Climate Technologies, Inc. All rights reserved. -
Page 3: Instructions Pertaining To Risk Of Electrical Shock, Fire, Or Injury To Persons
• 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. © 2015 Emerson Climate Technologies, Inc. All rights reserved. -
Page 4: Introduction
Please refer to the Online Product Information low side of the compressor during the unloaded state. at EmersonClimate.com for more information on During the loaded state the solenoid valve is de- performance at part load. © 2015 Emerson Climate Technologies, Inc. All rights reserved. -
Page 5: Application Considerations
The external solenoid valve and coil specified by However, if the digital compressor is in tandem with a Emerson must be used since this is a critical component non modulated scroll, short cycling of the non modulated for the proper functioning of this compressor. The... -
Page 6: Scroll Temperature Protection
The refrigerant charge limit for tandem compressors is equivalent non-digital scroll Application Engineering bulletin listed on Page 4. © 2015 Emerson Climate Technologies, Inc. All rights reserved. -
Page 7: Modulation Control
Commercial Comfort Controller, please refer to AE8-1393. Excessive Liquid Flood Back Tests It is expected that the design will not flood during operation at all of the varying loaded and modulation © 2015 Emerson Climate Technologies, Inc. All rights reserved. -
Page 8: Digital Compressor Retrofit Applications
Applications such as clean rooms for manufacturing prior to any system modifications. sensitive components, laboratories, hospital operating and recovery rooms, and equipment rooms that require © 2015 Emerson Climate Technologies, Inc. All rights reserved. -
Page 9: Compressor Selection & Change-Out
Reducing air flow in humid or maritime climates is 1. Before removing the rubber plugs, install the important to maintain coil temperatures low enough to © 2015 Emerson Climate Technologies, Inc. All rights reserved. -
Page 10: Modulation Control
UL burst pressure requirement cannot be higher The controls required for variable air flow are not provided than 400 psig (27.6 bar) for R-407C & R-22 and 475 by Emerson so the contractor may need to consult with psig (32.8 bar) for R-410A. Higher pressure may result controls experts in this field. - Page 11 Depending from entering the system when changing the valve. on the equipment being serviced, additional steps may be required. Refer to OEM instructions for more information. © 2015 Emerson Climate Technologies, Inc. All rights reserved.
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Page 12: Scroll Compressor Functional Check
6. To test if the compressor is pumping properly, the compressor current draw must be compared to published compressor performance curves © 2015 Emerson Climate Technologies, Inc. All rights reserved. -
Page 13: Digital Cycle Example
Figure 2 Digital Scroll Cross Sectional View ZPD34-ZPD54K5, ZPD61-ZPD83KC, ZPD91KC, ZPD104KCE, ZPD122KCE, and ZRD36-81KC Note: Modulation tubing is show for reference only. Refer to Figure 6 for the correct modulation tubing configuration. © 2015 Emerson Climate Technologies, Inc. All rights reserved. -
Page 14: Digital Scroll Cross Sectional View
AE4-1395 R5 90 Frame Digital Scroll Floating Seal Cavity Seal Cavity Vent Removable External Solenoid and Coil Figure 3 Digital Scroll Cross Sectional View ZPD103KC, ZPD120KC, ZPD137-182KC and ZRD94-125KC © 2015 Emerson Climate Technologies, Inc. All rights reserved. -
Page 15: Compressor Capacity Graph
AE4-1395 R5 15 Second Operating Cycle 100% Solenoid On-Time (Seconds) Figure 4 Compressor Capacity Graph *.ppt 3/23/2010 3:14 PM 1 Figure 5 Discharge Thermistors © 2015 Emerson Climate Technologies, Inc. All rights reserved. -
Page 16: Modulation Valve Piping
ZPD34-ZPD54K5, ZPD61-ZPD83KC, ZPD91KC, ZPD104KCE, ZPD122KCE, and ZRD36-81KC Solenoid Valve Discharge Manifold Assembly Suction Gas Equalization Manifold Oil Equalization Suction Line Manifold Assembly Figure 7 Tandem ZPD34-ZPD54K5, ZPD61-ZPD83KC, ZPD91KC, ZPD104KCE, ZPD122KCE, and ZRD36-81KC © 2015 Emerson Climate Technologies, Inc. All rights reserved. -
Page 17: Modulation Troubleshooting
Replace modulation Is voltage present, Troubleshoot the valve, follow valve Put the system back into coinciding with the modulation control replacement operation and retest modulation cycle? instructions Figure 8 Modulation Troubleshooting © 2015 Emerson Climate Technologies, Inc. All rights reserved. -
Page 18: Copeland Scroll Digital Family Features
12.2 ZPDT21-27MC 10.9 ZPD104KCE ZPDT31-36MC 12.2 ZPD122KCE ZRD36-48KC Table 3 – Torque Values Torque Part Foot-Pounds Inch-Pounds Modulation Valve 18.8-19.5 225-235 (ZPD103, ZPD120, ZPD137-182KC and ZRD94-125KC) Solenoid Coil Screw 1.9-2.3 22.5-27.5 © 2015 Emerson Climate Technologies, Inc. All rights reserved. -
Page 19: Compressor Accessories
Emerson Climate Technologies, Inc. does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any Emerson Climate Technologies, Inc. product remains solely with the purchaser and end-user.