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AE4-1402 R4

April 2016

ZPV063 Copeland Scroll

™

Variable Speed Compressors

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

Product Description ................................................4

Compressor Data ...................................................4

Power Supply .........................................................4

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

Agency Approvals ..................................................4

OEM Lab Testing

Drive & Variable Speed Scroll Set-Up ....................4

Modeling System Performance ..............................4

Compressor Design Features

.................................4

Compressor Motor .................................................4

Oil Pump ................................................................5

Application Considerations

Compressor Temperature Protection .....................5

Variable Speed Drive Options

Third Party Drive ................................................5

Emerson

™

EVC1 Drive Features

Oil Boost.......................................................5

Motor Protection ...........................................5

Reverse Rotation Protection ........................5

Missing Phase Protection.............................5

Short Cycle Protection .................................5

Resonance Avoidance Feature ....................5

Discharge Temperature Protection ...............5

Emerson EVC1 Operating Envelope............6

Emerson EVC1 Starting and

Stopping Routine..........................................6

Emerson EVC1 Drive and Variable Speed

Scroll Set-Up ..........................................................6

Refrigerant .............................................................6

Operating Envelope ...............................................6

High Pressure Control ............................................6

Low Pressure Control .............................................6

Discharge Temperature Protection .........................7

Motor Overload Protection .....................................7

Oil Type ..................................................................7

Maximum Tilt Angle ................................................7

Contaminant Control ..............................................7

Refrigerant Piping ..................................................8

Discharge Check Valve ..........................................8

Suction and Discharge Tube Design ......................8

Compressor Mounting ............................................9

Discharge Mufflers

.................................................9

Airborne Sound Control ..........................................9

Expansion Devices .................................................9

Reversing Valves ...................................................9

Accumulators ........................................................10

Off-Cycle Migration Control ...................................10

Manifolded Compressors ......................................10

Manifolded Applications ........................................10

Application Tests

General Application Tests ......................................11

Assembly Line Procedures

Installing the Compressor .....................................11

Assembly Line Brazing Procedure ........................12

Pressure Testing ...................................................12

Assembly Line System Charging Procedure .........12

High Potential Testing ...........................................12

Final Run Test .......................................................12

Unbrazing System Components ...........................13

Service Procedures

Electrical Troubleshooting .....................................13

Troubleshooting Motor Temperature Trip ..............13

Compressor Replacement After a Motor Burn ......13

Start-Up of a New or Replacement Compressor ...13

Figures & Tables

Compressor Nomenclature ...................................14

Operating Envelopes .............................................15

Oil Dilution Chart ...................................................16

Scroll Suction Tube Brazing ..................................17

How a Scroll Works ...............................................18

Discharge Thermistors ..........................................19

ZPV063 Cross Sectional View ..............................19

Electrical Nomenclature For Multiples ..................20

Compressor Accessories & Service Parts .............21

Compressor Motor Specifications

.........................22

Emerson Compressor & Drive Selection ...............22

Compressor Refrigerant Charge Limits Table .......23

Speed Adjustment Requirements ..........................23

TABLE OF CONTENTS

Section Page Section Page

Содержание Copeland Scroll ZPV063

Страница 1: ...or Overload Protection 7 Oil Type 7 Maximum Tilt Angle 7 Contaminant Control 7 Refrigerant Piping 8 Discharge Check Valve 8 Suction and Discharge Tube Design 8 Compressor Mounting 9 Discharge Mufflers 9 Airborne Sound Control 9 Expansion Devices 9 Reversing Valves 9 Accumulators 10 Off Cycle Migration Control 10 Manifolded Compressors 10 Manifolded Applications 10 Application Tests General Applica...

Страница 2: ...e 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 death or serious injury WARNING indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION used with the safety alert symbol indicates a hazardous situation which if not avoided could re...

Страница 3: ...ectrically locking out the system Use only approved refrigerants and refrigeration oils Personal safety 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 Perso...

Страница 4: ...ying conductors RLA MCC 1 4 Max Operating Current The maximum input current to the drive at nominal voltage when the compressor is running inside any one of the operating envelopes at the speed range designated for that envelope Please refer to Table 1 for more technical data for the compressor Power Supply The compressor and drive are an integral and optimized combination The drive will convert t...

Страница 5: ...1 drive includes an oil boost cycle when the compressor operates between 1000 and 1800 RPM The oil boost cycle starts once the compressor operates for two hours between 1000 and 1800 RPM During the oil boost cycle the drive forces the compressor to run for five minutes at 3600 RPM After operating for five minutes at 3600 RPM the drive allows the compressor to operate between 1000 and 1800 RPM Figu...

Страница 6: ...t in oil pump out if the system has long interconnecting piping Customers that choose to operate in these higher evaporating temperature areas should use a compressor sample with a sight tube during system development testing to ensure that an adequate level of oil is maintained in the compressor sump Sight tubed compressors for monitoring the oil level are available by contacting Application Engi...

Страница 7: ...r protective equipment gloves eye protection etc must be used when handling POE lubricant POE must not come into contact with any surface or material that might be harmed by POE and spills should be cleaned up quickly with paper towels soap and water Maximum Tilt Angle Applications such as transportation air conditioning or mobile radar applications may require the compressor to operate at some an...

Страница 8: ...of the sight glass The compressor oil level should be checked with the compressor off to avoid the sump turbulence when the compressor is running These compressors are available to the OEM with a production sight glass that can be used to determine the oil level in the compressor in the end use application These compressors are also available to the OEM with an oil Schrader fitting on the side of ...

Страница 9: ... not have the ability to control the refrigerant flow across a wide range of operating pressures and flow rates required by the variable capacity system To better control superheat an electronic expansion valve EXV is recommended Electronic expansion valves have the ability to more precisely control superheat at lower settings over a wider operating range than a TXV They also have the capability t...

Страница 10: ...d to at least 100 Watts when the compressor is off To use fewer than 100 Watts or to comply with future DOE requirements for off cycle power consumption off cycle migration testing must be performed A 70 watt crankcase heater may be used instead of the motor windings to provide heat to the base CAUTION Stator heat for off cycle migration must not be energized when the system is in a vacuum or if t...

Страница 11: ...w system designs should be evaluated throughout the entire expected operating range of the unit to ensure the system will perform reliably throughout the life of the product Test data taken throughout the operating range of the unit should be closely scrutinized to help identify gross errors in system design that may produce conditions that could lead to compressor failure General Application Test...

Страница 12: ...rmally low suction pressures during charging NOTICE Do not operate the compressor without enough system charge to maintain at least 55 psig 3 8 bar suction pressure Do not operate the compressor with the low pressure cut out disabled Do no operate with a restricted suction or liquid line Depending on the discharge pressure allowing pressure to drop below 55 psig 3 8 bar for more than a few seconds...

Страница 13: ...damage to the drive Measuring the current in the three individual wires feeding the compressor will provide no useful information to the service technician other than to show that each winding of the compressor is drawing current The more appropriate measurement is the current input to the drive Current input to the drive can be compared to the published values of MCC and RLA Compressor Replacemen...

Страница 14: ...ndem Cubic Centimeters Per Revolution 3 numeric characters Optional E POE Oil P POE R410A 1st Generation VS Only K1 Nominal Capacity Capacity at Rating Condition Multiplier 2 3 numeric characters K 1 000 M 10 000 C SCFM VARIABLE SPEED COMPRESSOR NOMENCLATURE Application Range Code Application Refgn Substance Compressed P AC HP R 410A B H Heat Pump Optimized R410A Figure 1 Compressor Nomenclature E...

Страница 15: ...75 80 85 90 Tcond F Tevap F ZPV063 Operating Envelope 20 F 11 C SH 15 F 8 C SC 95 F 35 C Ambient Solid Line Boundaries OEM tes ng is required to monitor the DLT in the dashed line boundaries 2600 6000 RPM 2200 6000 RPM 1800 7200 RPM Tcond C Tevap C DLT 275 F 1000 7200 RPM An Oil Boost Cycle Is Required For Speeds 1000RPM 1800RPM Cycle Parameters 1000RPM 1800RPM For 2 Hours Ramp To 3600RPM For 5 Mi...

Страница 16: ...ise superheat A cold sump may result in high refrigerant migration after shut down Figure 4 Oil Dilution Chart 30 25 20 15 10 5 0 5 10 24 14 4 6 16 26 36 10 0 10 20 30 40 50 60 70 80 90 100 110 20 10 0 10 20 30 40 50 Evaporating Temperature C Compressor Sump Temperature C Compressor Sump Temperature F Evaporating Temperature F 200 F 93 3 C Max Oil Temp Acceptable Unacceptable Too Much Refrigerant ...

Страница 17: ... Add braze material to the joint while moving torch around joint to flow braze material around circumference After braze material flows around joint move torch to heat Area 3 This will draw the braze material down into the joint The time spent heating Area 3 should be minimal As with any brazed joint overheating may be detrimental to the final result Field Service WARNING Remove refrigerant charge...

Страница 18: ...18 2016 Emerson Climate Technologies Inc AE4 1402 R4 Figure 6 ...

Страница 19: ...arge Thermistors Fluid Brake Sight Glass Floating Seal 7 8 22 3mm Discharge Fitting 1 1 8 28 7mm Fixed Scroll BPM Motor Orbiting Scroll Counterweight Cup for Oil Circulation Positive Displacement Oil Pump Suction Fitting Management Figure 8 ZPV063 Cross Sectional View ...

Страница 20: ...E 1 E 9 X X X First Character Second Character Third Character Follows VS Motor Type VS Fixed Tandem Follows Fixed Electrical Code E E E E F Z E W Y X E B X F C X W G Examples 2E9 TFD 2ZD 3X9 TF7 3C7 4E9 TE5 4E5 5X9 TEE 5BE Figure 9 Electrical Nomenclature For Multiples ...

Страница 21: ...scharge Line Thermistor 085 0261 00 ZPV063 Fits 7 8 Tube Discharge Line Thermistor Molex Connector 085 0211 00 ZPV063 Fits 7 8 Tube Thermistor Clip 032 0688 04 ZPV063 7 8 Clip Suction Discharge Discharge Rotalock O Ring Seal 020 0028 02 ZPV063 Suction Rotalock O Ring Seal 020 0028 03 Discharge Rotalock Service Valve 7 8 998 0510 90 Suction Rotalock Service Valve 1 1 8 998 0510 99 Discharge Rotaloc...

Страница 22: ... 1 Motor Poles 6 Motor Input Frequency Hertz 50 360 Recommended Switching Frequency Hertz 6 000 Table 2 Compressor Motor Specifications Drive Model EVC1150B K1 114 EVC1150B L1 114 EVC1150B J1 114 Compressor Model ZPV0631E 4E9 ZPV0631E 4E9 ZPV0631E 5E9 Drive Voltage Input 380 480 500 575 200 240 Drive Nominal Power 15 KW 15 KW 15 KW Drive Max Continuous Output Current 31 Amps 27 Amps 58 Amps NOTE C...

Страница 23: ...s kg ZPV063 15 7 18 8 18 8 Charge allowance for system Speed Range RPM Default RPM Acceleration RPM Sec Deceleration RPM Sec Notes Range Default Range Default Start 3600 7200 3600 400 1000 1 0 NA NA 1 Run 1000 7200 200 RPM S Stop 1000 7200 3600 or Envelope Minimum NA NA 50 500 2 0 2 3 4 Notes 1 Once the compressor reaches 3600 RPM hold for two minutes prior to accelerating or decelerating 2 If env...

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