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AE4-1395
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
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
© 2012 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
Application Engineering
Application Engineering
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Compressors for Air Conditioning
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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
Pressure Testing ......................................................9
Modulation Troubleshooting ...................................10
Procedure ...............................................................10
Procedure ...............................................................10
Scroll Compressor Functional Check ..................... 11
Figures & Tables
Digital Cycle Example ............................................12
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
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AE4-1395
August 2012
Page
Table of Contents
Troubleshooting
Related Manuals for Emerson AE4-1395
Summary of Contents for Emerson AE4-1395
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Page 1: Table Of Contents
Excessive Liquid Floodback Tests ......7 Modulation Troubleshooting ........17 Operating Envelope Tests ........7 Copeland Scroll Digital Family Features ....18 Refrigerant Charge Limits ........18 Torque Values ............18 Compressor Accessories ........19 © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A. -
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. © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A. -
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. © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A. -
Page 4: Introduction
The operating envelope of the digital scroll compressors achieving modulation. When the solenoid valve is in its for all loading conditions is shown in Figures 4 and 5. normally closed position, the compressor operates at © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A. -
Page 5: Solenoid Valve And Coil
The external solenoid valve and coil specified by timer to prevent short cycling. Emerson must be used since this is a critical component for the proper functioning of this compressor. The Sound Characteristics... -
Page 6: Scroll Temperature Protection
POE must be handled carefully and the proper Most digital scrolls do not have internal discharge protective equipment (gloves, eye protection, etc.) gas temperature protection. In order for the Emerson must be used when handling POE lubricant. POE controllers to operate properly an NTC sensor must be... -
Page 7: Modulation Control
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... -
Page 8: Retrofit Applications To Avoid
NOTICE difference in the suction and discharge tubing locations, as well as the height of the compressor. Emerson Climate Technologies, Inc. is not responsible or liable for incorrect energy use The following steps should be followed to remove the predictions. -
Page 9: Refrigerant Flow Control
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. Before removing the rubber plugs, install the compressor in the unit on the mounting grommets Condenser Air Flow using the appropriate lifting devices. -
Page 10: Service Procedures Modulation Troubleshooting
Controller please refer to AE8-1328. For more the compressor. To replace the modulation valve, follow information on troubleshooting the Emerson Commercial these recommended steps: Comfort Controller please refer to AE8-1393. -
Page 11: Scroll Compressor Functional Check
Such a test may damage a Section H of the Emerson Electrical Handbook, scroll compressor. The following diagnostic procedure Form No. 6400. -
Page 12: Digital Cycle Example
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: To 15 Ton Digital Scroll Cross Sectional View
Application Engineering AE4-1395 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: 3-7.5 Ton Operating Envelope
Evaporating Temperature (°F) Figure 4 ZPD103-182KC R-22, R-407C, R-410A Operating Envelope ZRD94-125KC Recommended Capacity Range 10 -100% Recommended Capacity Range 50 -100% Recommended Capacity Range 75 -100% Evaporating Temperature (°F) Figure 5 © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A. -
Page 15: Compressor Capacity Graph
Application Engineering AE4-1395 15 Second Operating Cycle 100% 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: To 7.5 Ton Modulation Valve Piping
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 © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A. -
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 10 Modulation Troubleshooting © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A. -
Page 18: Copeland Scroll Digital Family Features
10.9 ZPDT31-36MC 12.2 ZRD36-48KC ZRD61-81KC ZRD94-125KC ZRDU11-13MC ZRDT12-16MC ZRDT25MC 12.2 Table 3 Torque Values Torque Part Foot-Pounds Inch-Pounds Modulation Valve 18.8-19.5 225-235 (ZPD103-182KC & ZRD94-125KC) Solenoid Coil Screw 1.9-2.3 22.5-27.5 © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A. -
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.