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Copeland Digital Scroll ZPD103KCE, Manuallines

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Copeland Digital Scroll ZPD103KCE Manuallines Download Page 6

 

C6.2.15/0815/E 

 

3 

2 

Product description 

2.1  Common information about Copeland Scroll Digital

™ compressors 

The  Scroll  compressor  has  been  under  development  at  Emerson  Climate  Technologies  since 
1979.  It  is  the  most  efficient  and  durable  compressor  Emerson  Climate  Technologies  has  ever 
developed for air conditioning and refrigeration. 

These  application  guidelines  deal  with  the  following  Copeland  Scroll  Digital

™ 

compressors: 

R407C 

R410A 

Compressor 

HP 

kW

(*)

 

Motor 

 

Compressor 

HP 

kW

(*)

 

Motor 

ZRD42KCE 

3.6 

9 

PFJ/TFD 

 

ZPD34KSE 

2.8 

8 

PFZ/TFM 

ZRD48KCE 

4 

10.2 

PFZ/TFD 

 

ZPD42KSE 

3.5 

9 

PFZ/TFM 

ZRD61KCE 

5 

12.5 

TFD 

 

ZPD54KSE 

4.6 

11.8 

PFZ/TFM 

ZRD72KCE 

6 

14.8 

TFD 

 

ZPD61KCE 

5 

13.3 

PFZ/TFD 

ZRD81KCE 

6.5 

16.7 

TFD 

 

ZPD72KCE 

6 

15.4 

TFD 

ZRD94KCE 

8 

19.8 

TFD 

 

ZPD83KCE 

7 

17.7 

TFD 

ZRD125KCE 

10 

26 

TFD 

 

ZPD91KCE 

7.5 

19.3 

TFD 

 

 

 

 

 

ZPD103KCE 

9 

22.4 

TFD 

 

 

 

 

 

ZPD104KCE 

9 

22.4 

TFD 

 

 

 

 

 

ZPD120KCE 

10 

26 

TFD 

 

 

 

 

 

ZPD122KCE 

10 

26 

TFD 

 

 

 

 

 

ZPD137KCE 

12 

29.3 

TFD 

 

 

 

 

 

ZPD154KCE 

13 

32.9 

TFD 

 

 

 

 

 

ZPD182KCE 

15 

39.1 

TFD 

(*)

 According to EN 12900 

 
Copeland  Scroll  Digital  compressors  have  one  Scroll  compression  set  driven  by  a  single-  or 
three-phase induction motor. The scroll set is mounted at the upper end of the rotor shaft of the 
motor. The rotor shaft axis is in the vertical plane. 

2.2  Nomenclature

 

The model designation contains the following technical information about the compressor: 

 

 

S

afet

y 

in

struct

ion

s

 

P

ro

d

u

ct 

d

es

cr

ipt

ion

 

Inst

all

atio

n

 

E

lec

tr

ica

l 

c

o

n

n

ec

tion

 

S

tar

ting

 up

 & 

o

p

er

atio

n

 

Ma

int

enan

c

e & 

repai

r 

Dismant

ling

 & 

d

ispo

sa

l 

 

 

Summary of Contents for Digital Scroll ZPD103KCE

Page 1: ...Digital Scroll Compressors for Air Conditioning ZRD42K to ZRD125K ZPD34K to ZPD182K TM Application Guidelines ...

Page 2: ...Compressor handling 9 3 1 1 Transport and storage 9 3 1 2 Positioning and securing 9 3 1 3 Installation location 9 3 1 4 Mounting parts 9 3 2 Solenoid valves 10 3 3 Solenoid valve installation 11 3 3 1 General recommendations 11 3 3 2 Tubing recommendations 12 3 4 Tandem compressors 12 3 5 Discharge check valve 14 3 6 Brazing procedure 14 3 7 Shut off valves and adaptors 15 3 8 Oil separator 16 3 ...

Page 3: ... 24 5 5 Initial start up 25 5 6 Rotation direction 25 5 7 Pressure fluctuations 25 5 8 Starting sound 25 5 9 Deep vacuum operation 26 5 10 Shell temperature 26 5 11 Minimum run time 26 5 12 Sound characteristics 26 5 13 Shut off sound 26 5 14 Frequency 26 5 15 Oil level control 27 5 16 Digital system control 27 5 17 Power factor 27 6 Maintenance repair 28 6 1 Exchanging the refrigerant 28 6 2 Rota...

Page 4: ...ailable at www emersonclimate eu These instructions should be retained throughout the lifetime of the compressor You are strongly advised to follow these safety instructions 1 1 Icon explanation WARNING This icon indicates instructions to avoid personal injury and material damage CAUTION This icon indicates instructions to avoid property damage and possible personal injury High voltage This icon i...

Page 5: ... other materials in the area of the compressor do not get in touch with it Lock and mark accessible sections CAUTION Overheating Bearing damage Do not operate compressors without refrigerant charge or without being connected to the system CAUTION Contact with POE Material damage POE lubricant must be handled carefully and the proper protective equipment gloves eye protection etc must be used at al...

Page 6: ...ZRD72KCE 6 14 8 TFD ZPD61KCE 5 13 3 PFZ TFD ZRD81KCE 6 5 16 7 TFD ZPD72KCE 6 15 4 TFD ZRD94KCE 8 19 8 TFD ZPD83KCE 7 17 7 TFD ZRD125KCE 10 26 TFD ZPD91KCE 7 5 19 3 TFD ZPD103KCE 9 22 4 TFD ZPD104KCE 9 22 4 TFD ZPD120KCE 10 26 TFD ZPD122KCE 10 26 TFD ZPD137KCE 12 29 3 TFD ZPD154KCE 13 32 9 TFD ZPD182KCE 15 39 1 TFD According to EN 12900 Copeland Scroll Digital compressors have one Scroll compressio...

Page 7: ...nts R407C R410A Copeland brand products standard oil Emkarate RL 32 3MAF Servicing oil Emkarate RL 32 3MAF Mobil EAL Arctic 22 CC Mobil EAL Arctic 22 CC Table 1 Qualified refrigerants and oils 2 3 2 Application limits CAUTION Inadequate lubrication Compressor breakdown The superheat at the compressor suction inlet must always be sufficient to ensure that no refrigerant droplets enter the compresso...

Page 8: ...0 15 10 5 0 5 10 15 Condensing Temperature o C Evaporating Temperature oC R410A 25 30 35 40 45 50 55 60 65 70 25 20 15 10 5 0 5 10 15 Condensing Temperature o C Evaporating Temperature oC R410A 20 25 30 35 40 45 50 55 60 65 70 35 30 25 20 15 10 5 0 5 10 15 20 25 Condensing Temperature o C Evaporating Temperature oC R410A Safety instructions Product description Installation Electrical connection St...

Page 9: ...with an external solenoid valve This normally closed de energized solenoid valve is a key component for achieving modulation When the solenoid valve is in its normally closed position the compressor operates at full capacity When the solenoid valve is energized the two scroll elements move apart axially During the unloaded state the compressor motor continues running but since the scrolls are sepa...

Page 10: ...ls ZRD42K to ZRD81K and ZPD34K to ZPD91K Figure 5 Example of a cycle Figure 6 Solenoid opening time depending on the load in a 15 second cycle Scrolls separated by approximately 1 mm Safety instructions Product description Installation Electrical connection Starting up operation Maintenance repair Dismantling disposal ...

Page 11: ...fferent but functionally both approaches to modulation achieve the same results and are to be controlled in exactly the same way Figure 9 Modulation method in larger model ranges 25 30 35 40 45 50 55 60 65 70 25 20 15 10 5 0 5 10 15 Condensing Temperature o C Evaporating Temperature oC R410A Solenoid valve opens 10 100 recommended application range 50 100 recommended application range 75 100 recom...

Page 12: ...g should be removed first before pulling the suction connection plug to allow the dry air pressure inside the compressor to escape Pulling the plugs in this sequence prevents oil mist from coating the suction tube making brazing difficult The copper coated steel suction tube should be cleaned before brazing No object eg a swaging tool should be inserted deeper than 51 mm into the suction tube or i...

Page 13: ...supplied by Emerson Climate Technologies must be used Care must be taken during the brazing process that no solid parts can enter the control piston compartment or the solenoid valve tubing To prevent solid parts from entering the control valve seat the solenoid valve kit contains a filter screen which has to be placed into the horizontal tube of the valve before brazing the tube connections as sh...

Page 14: ...tal mounting is not permitted The valve operation is directional See Figures 18 19 below for inlet and outlet locations Do not restrict the line size coming from or leaving the solenoid Use 3 8 soft drawn copper Figure 16 Control valve without coil Figure 17 Control valve pipe connection Safety instructions Product description Installation Electrical connection Starting up operation Maintenance re...

Page 15: ... qualified Tandem design units are available upon request from Emerson Climate Technologies It needs to have an OEM system control device providing the signals for common operation modulation as well as for single compressor operation In general the architecture of such a system controller runs the digital compressor continuously and cycles only the standard compressor if the capacity demand drops...

Page 16: ...s only Figure 20 Oil equalization line design Figure 21 Top view of the piping design Figure 22 Tandem configuration with ZRD125K and ZPD103K to ZPD182K Digital Standard Safety instructions Product description Installation Electrical connection Starting up operation Maintenance repair Dismantling disposal ...

Page 17: ...ORTANT Blockage Compressor breakdown Maintain a flow of oxygen free nitrogen through the system at very low pressure during brazing Nitrogen displaces the air and prevents the formation of copper oxides in the system If allowed to form the copper oxide material can later be swept through the system and block screens such as those protecting capillary tubes thermal expansion valves and accumulator ...

Page 18: ...per brazing procedures may have to be changed from those commonly used 3 7 Shut off valves and adaptors CAUTION Leaking system System breakdown It is strongly recommended to periodically re torque all pipe and fixing connections to the original setting after the system has been put into operation Figure 24 Adaptors and shut off valves Braze connections can be converted to Rotalock by means of adap...

Page 19: ...g loads no matter what the system charge is can dilute the oil As a result bearings are inadequately lubricated and wear may occur To determine if the accumulator can be removed dedicated tests must be carried out to ensure that excessive liquid does not flood back to the compressor during defrost or varying loads The defrost test must be done at an outdoor ambient temperature of around 0 C in a h...

Page 20: ...erify acceptability of sound performance If adequate attenuation is not achieved use a muffler with a larger cross sectional area to inlet area ratio A ratio of 20 1 to 30 1 is recommended A hollow shell muffler will work quite well Locate the muffler at minimum 15 to maximum 45cm from the compressor for the most effective operation The farther the muffler is placed from the compressor within thes...

Page 21: ...event vibration transmission into any lines attached to the unit In a split system the most important goal is to ensure minimal vibration in all directions at the service valve to avoid transmitting vibrations to the structure to which the lines are fastened A second difference of the Copeland Scroll is that under some conditions the normal rotational starting motion of the compressor can transmit...

Page 22: ...cording to IEC 60034 5 Cable glands have an influence on the protection class of the terminal box It is strongly recommended to use appropriate cable glands in order to reach the rated protection class We advise installers service providers to pay attention to this aspect every time they install or replace a Copeland Scroll compressor and to use cable glands according to EN 50262 or any other rele...

Page 23: ...motor protection is provided 4 2 4 Protection devices Independently from the internal or external motor protection fuses must be installed before the compressor Selection of fuses has to be carried out according to VDE 0635 DIN 57635 IEC 269 1 or EN 60 269 1 4 2 5 Crankcase heaters IMPORTANT Oil dilution Bearing malfunction Turn the crankcase heater on 12 hours before starting the compressor A cra...

Page 24: ...motor protector to cause a trip During developmental blocked fan testing it is sometimes noted that the valve opens but the compressor does not shut off while the discharge pressure continues to climb This condition is normally caused by floodback and may be corrected by using a more restrictive expansion device or reducing the refrigerant charge Compressors ZRD94K ZRD125K and ZPD120K to ZPD182K d...

Page 25: ...tal scroll compressors an internal discharge temperature protector is included in the compressor standard delivery Otherwise an external discharge temperature protector must be installed Models ZRD42K to ZRD48K ZRD94K ZRD125K and ZPD34K to ZPD182K do not have internal temperature protection and therefore require an external thermostat or a discharge temperature sensor NTC thermistor mounted as clo...

Page 26: ... the compressor housing is under vacuum Emerson Climate Technologies subjects all Scroll compressors to a high voltage test after final assembly Each motor phase winding is tested according to EN 0530 or VDE 0530 part 1 at a differential voltage of 1000V plus twice the nominal voltage Since high voltage tests lead to premature ageing of the winding insulation further additional tests of that natur...

Page 27: ...ssible obtain drawings wiring diagrams etc It is ideal to use a check list but always check the following Visual check of the electrics wiring fuses etc Visual check of the plant for leaks loose fittings such as TXV bulbs etc Compressor oil level Calibration of HP LP switches and any pressure actuated valves Check setting and operation of all safety features and protection devices All valves in th...

Page 28: ...on of proper rotation direction There is no negative impact on durability caused by operating three phase Copeland Scroll compressors in the reversed direction for a short period of time under one hour but oil may be lost Oil loss can be prevented during reverse rotation if the tubing is routed at least 15 cm above the compressor After several minutes of operation in reverse the compressor s prote...

Page 29: ...ight tube available from Emerson Climate Technologies and install it in a system with the longest connecting lines that are approved for the system The minimum on time becomes the time required for oil lost during compressor start up to return to the compressor sump and restore a minimal oil level that will ensure oil pick up through the crankshaft Cycling the compressor for a shorter period than ...

Page 30: ...rs operate in the safe zone 5 16 Digital system control Due to the pulsing characteristic of Copeland Scroll Digital compressors superheat control needs to be performed by qualified solutions in order to ensure the stability reliability and good performance of the system Currently qualified solutions are ALCO Gated Logic Control o Superheat driver EC3 D72 EC3 D73 o Electronic expansion valve EX4 E...

Page 31: ...ay be plugged with debris or may become plugged shortly after a compressor failure This will result in starvation of oil to the replacement compressor and a second failure When a single compressor or tandem is exchanged in the field it is possible that a major portion of the oil may still be in the system While this may not affect the reliability of the replacement compressor the extra oil will ad...

Page 32: ... in ppm by weight at 25 C and 50 relative humidity h hours If the moisture content of the oil in a refrigeration system reaches unacceptably high levels corrosion and copper plating may occur The system should be evacuated down to 0 3 mbar or lower If there is uncertainty as to the moisture content in the system an oil sample should be taken and tested for moisture Sight glass moisture indicators ...

Page 33: ...ctions should be provided in appropriate product literature and assembly line repair areas If compressor removal is required the compressor should be cut out of system rather than unbrazed 7 Dismantling disposal Removing oil and refrigerant Do not disperse in the environment Use the correct equipment and method of removal Dispose of oil and refrigerant properly Dispose of compressor properly DISCL...

Page 34: ...WAY FINLAND Pascalstr 65 DE 52076 Aachen Tel 49 2408 929 0 Fax 49 2408 929 525 nordic sales emerson com FRANCE GREECE MAGHREB 8 Allée du Moulin Berger FR 69134 Ecully Cédex Technoparc CS 90220 Tel 33 4 78 66 85 70 Fax 33 4 78 66 85 71 mediterranean sales emerson com EASTERN EUROPE TURKEY Pascalstr 65 DE 52076 Aachen Tel 49 2408 929 0 Fax 49 2408 929 525 easterneurope sales emerson com ROMANIA Tel ...

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