Emerson Copeland Scroll Digital ZPD103KC Bulletin Download

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AE4-1395 R5

Table 2 – Refrigerant Charge Limits

Model

Charge Limit

Model

Charge Limit

Pounds

ZPD34-54K5

3.6

ZRD61-81KC

4.8

ZPD61-ZPD83, ZPD91

4.8

ZRD94-125KC

7.2

ZPD90, 103, 120, 137KC

7.2

ZRDT96KC

5.4

ZPD154-182KC

8.2

ZRDU11-13MC

5.4

ZPDT12-18MC

5.4

ZRDT12-16MC

5.4

ZPDU13MC

5.4

ZRDT25MC

12.2

ZPDT21-27MC

10.9

ZPD104KCE

5.0

ZPDT31-36MC

12.2

ZPD122KCE

5.0

ZRD36-48KC

3.6

Table 1 – Copeland Scroll Digital Family Features

Model

Digital

Modulation

Valve

Discharge Gas

Temperature Protection

Discharge

Check

Valve

Internal

Pressure

Relief (IPR)

Valve

Modulation

Control

ZPD34-54K5

Required

Accessory

External Sensor Required

Yes

15 Second

Cycle

ZRD36-48KC
ZPD61-ZPD83
ZRD61-81KC

Internal Top Cap Thermistor

ZPD103, ZPD120,

ZPD137-182KC

Installed On

Compressor

External Sensor Required

Yes

ZRD94-125KC

ZPD91, ZPD104, 122KC

Required

Accessory

External Sensor Required

Part

Torque

Foot-Pounds Inch-Pounds

Modulation Valve

(ZPD103, ZPD120, ZPD137-182KC and ZRD94-125KC)

18.8-19.5

225-235

Solenoid Coil Screw

1.9-2.3

22.5-27.5

Table 3 – Torque Values

Summary of Contents for Copeland Scroll Digital ZPD103KC

Page 1: ...ntrol 7 Application Tests Oil Level Verification 7 Excessive Liquid Floodback Tests 7 Operating Envelope Tests 7 Digital Compressor Retrofit Applications 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 Assembly Line Proced...

Page 2: ...s been placed on the user s safety Safey icons are explained below and safety instructions applicable to the products in this bulletin are grouped on Page 3 These instructions should be retained throughout the lifetime of the compessor You are strongly advised to follow these safety instructions Safety Icon Explanation DANGER indicates a hazardous situation which if not avoided will result in deat...

Page 3: ...y equipment must be used Failure to follow these warnings could result in serious personal injury BURN HAZARD Do not touch the compressor until it has cooled down Ensure that materials and wiring do not touch high temperature areas of the compressor Use caution when brazing system components Personal safety equipment must be used Failure to follow these warnings could result in serious personal in...

Page 4: ...ulating its capacity from 10 to 100 A 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 or loaded state When the solenoid valve is energized the two scroll elements move apart axially or into the unloaded state During the unloaded state the compressor motor cont...

Page 5: ...ressor For vertical piping a trap every 20 feet should be sufficient to ensure proper oil return This recommendation is based upon a minimum 1500 fpm velocity or higher When the digital scroll compressor is part of a tandem a double riser should be considered to assure that the velocity remains above 1500 fpm when only the digital scroll is running Start Up and Shut Down To improve the starting ch...

Page 6: ...e Heaters A crankcase heater is required if the system charge exceeds the system charge limits listed in Table 2 For more information regarding regarding heater part numbers and installation location please refer to the equivalent non digital scroll Application Engineering bulletin listed on Page 4 Oil Type and Oil Removal Mineral oil is used in the ZRD KC compressors for R 22 applications Polyole...

Page 7: ...compressor without the need for an additional system controller For more information on the Emerson Commercial Comfort Controller please refer to AE8 1393 NOTICE For OEMs that choose their own controls package the controls must include the protection features incorporated into the Copeland Scroll Digital Compressor Controller Please consult with Application Engineering for a list of these requirem...

Page 8: ...nsitive components laboratories hospital operating and recovery rooms and equipment rooms that require constant cooling are all applications that would benefit from a modulating digital scroll Many of these are critical cooling applications and require equipment that is designed specifically for these applications Don t attempt to retrofit a non modulating HVAC unit in a critical application to on...

Page 9: ...the digital compressor into the system 1 Before removing the rubber plugs install the compressor in the unit on the mounting grommets using the appropriate lifting devices 2 Install the compressor mounting bolts 3 Connect the suction and discharge lines using standard brazing practices 4 If the compressor has an external modulation valve and tubing ZPD34 ZPD54K5 ZPD61 ZPD83KC ZPD91KC ZPD104KCE ZPD...

Page 10: ...prevent the build up of copper oxide The solenoid coil should be installed after the brazing operation so the leads are kept away from the brazing operation and the wet rag is able to fully contact the valve body Pressure Testing The pressure used on the OEM assembly line to meet the UL burst pressure requirement cannot be higher than 400 psig 27 6 bar for R 407C R 22 and 475 psig 32 8 bar for R 4...

Page 11: ...rant charge from the compressor system 3 Remove the cover from the small terminal box and remove the screw holding the coil to the valve using a Phillips screwdriver or appropriate size nut driver 4 Remove the coil from the valve and clean the area around the valve body to prevent debris and dirt from entering the system when changing the valve 5 Using manifold gauges double check to make sure the...

Page 12: ...ressures still do not move to normal values either the reversing valve if so equipped or the compressor is faulty Reconnect the compressor leads as originally configured and use normal diagnostic procedures to check operation of the reversing valve The solenoid coil should only be energized when it is installed on the solenoid valve Energizing the coil when it is not installed on the valve will re...

Page 13: ... 3s NOT PUMPING NOT PUMPING One Cycle of 15 seconds 15 seconds Figure 1 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 ...

Page 14: ...ogies Inc All rights reserved AE4 1395 R5 Figure 3 Digital Scroll Cross Sectional View ZPD103KC ZPD120KC ZPD137 182KC and ZRD94 125KC Removable External Solenoid and Coil Floating Seal Cavity Seal Cavity Vent 90 Frame Digital Scroll ...

Page 15: ...E4 1395 R5 Figure 5 Discharge Thermistors Figure 4 Compressor Capacity Graph ppt 3 23 2010 3 14 PM 1 0 10 20 30 40 50 60 70 80 90 100 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Compressor Capacity Percent of Full Load 15 Second Operating Cycle Solenoid On Time Seconds ...

Page 16: ...ZPD54K5 ZPD61 ZPD83KC ZPD91KC ZPD104KCE ZPD122KCE and ZRD36 81KC Figure 7 Tandem ZPD34 ZPD54K5 ZPD61 ZPD83KC ZPD91KC ZPD104KCE ZPD122KCE and ZRD36 81KC Arrow on valve Must point to suction Oil Equalization Line Suction Gas Equalization Manifold Discharge Manifold Assembly Suction Manifold Assembly Solenoid Valve ...

Page 17: ...sn t running Allow time to cool Put the system back into operation and retest Start Measure the voltage at the modulation coil terminals Is voltage present coinciding with the modulation cycle Troubleshoot the modulation control WARNING Disconnect and lockout the power before proceeding Remove one wire from the modulation coil Coil has continuity and isn t grounded Replace modulation coil Replace ...

Page 18: ...8KC 8 3 6 Table 1 Copeland Scroll Digital Family Features Model Digital Modulation Valve Discharge Gas Temperature Protection Discharge Check Valve Internal Pressure Relief IPR Valve Modulation Control ZPD34 54K5 Required Accessory External Sensor Required No Yes 15 Second Cycle ZRD36 48KC ZPD61 ZPD83 ZRD61 81KC Internal Top Cap Thermistor ZPD103 ZPD120 ZPD137 182KC Installed On Compressor Externa...

Page 19: ...Coil Tubing Kit 998 0090 02 ZPD34 54K5 ZPD61 ZPD83 ZPD91KC ZRD34 81KC Tubing kit is for 7 8 compressor suction All coils have 1 4 spade electrical terminals Modulation Valve Tubing Kit 998 0090 01 Modulation Valve 910 0182 00 ZPD103 ZPD120 ZPD137 182KC ZRD94 125KC All coils have 1 4 spade electrical terminals 24V Coil Holding VA Max 60 HZ 20 0 998 0060 03 120V Coil Holding VA Max 60 HZ 17 3 998 00...

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