Emerson Copeland Scroll ZPD103, Bulletin

Page 1: ... 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 Procedures 3 To 7 5 Ton Modulation Valve Brazing Procedure 9 Press...

Page 2: ...ticular emphasis has 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 ...

Page 3: ...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 Personal safety equipment must be used Failure to follow these warnings could result in ...

Page 4: ...lenoid 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 continues running but since the scrolls are separated there is no compression During the loaded state the compressor delivers 100 capacity an...

Page 5: ...own To improve the starting characteristics of the digital scroll compressor the the Emerson controllers delay loading the compressor for 0 1 seconds Likewise to eliminate the reverse rotation sound at shut down the compressor is unloaded 0 5 seconds before shut down Compressor Cycling Because of the digital scroll s seamless capacity modulation from 10 to 100 capacity short cycling should not be ...

Page 6: ...m is acceptable If additional oil is needed in the field for POE applications Copeland Ultra 32 3MAF Lubrizol Emkarate RL32 3MAF Parker Emkarate RL32 3MAF Virginia LE32 3MAF or Nu Calgon 4314 66 Emkarate RL32 3MAF should be used Copeland Ultra 22 CC Hatcol EAL 22CC and Mobil EAL Arctic 22 CC are acceptable alternatives If additional oil is needed in the field for mineral oil applications Sonneborn...

Page 7: ...a few minutes either more oil is required in the system or an oil recovery cycle is needed For more information on what an oil recovery cycle is please consult with Application Engineering If the system contains more than 20 pounds 9 kg of refrigerant it is our recommendation to add one fluid ounce of additional oil for every 5 pounds 15 ml kg of refrigerant over this amount This is a starting poi...

Page 8: ...cations NOTICE Always check with the OEM of the equipment being considered for the digital scroll retrofit before the retrofit is undertaken The OEM may have specific instructions developed that offer step by step guidance Before beginning the retrofit the system should be operable and system operating conditions should be logged for future reference The compressor suction discharge pressures suct...

Page 9: ...ritime climates is important to maintain coil temperatures low enough to remove latent heat In desert and arid climates because of low or no latent loads air flow is less critical The controls required for variable air flow are not provided by Emerson so the contractor may need to consult with controls experts in this field Condenser Air Flow Modulating the condenser air flow is not critical to th...

Page 10: ...top cap 7 Carefully unbraze and remove the tubing stubs from the suction T and top cap tubing swage Carefully unbrazing and removing these stubs will allow the tubing suction T fitting to be reused 8 After these fittings have cooled clean the fittings and prepare to braze the new valve in place Wrap a wet rag around the valve body to keep from overheating the valve 9 Using standard brazing practic...

Page 11: ...uction and discharge pressure fittings turn on the compressor If suction pressure falls below normal levels the system is either low on charge or there is a flow blockage in the system 5 If suction pressure does not drop and discharge pressure does not rise to normal levels reverse any two of the compressor power leads this procedure is for 3 phase compressors only and reapply power to make sure c...

Page 12: ...Loaded 80 Loaded PUMPING PUMPING 7 5 s 7 5 s 12s 3s NOT PUMPING NOT PUMPING One Cycle of 15 seconds 15 seconds Figure 1 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 ...

Page 13: ...gies Inc Printed in the U S A AE4 1395 Application Engineering B U L L E T I N Figure 3 8 to 15 Ton Digital Scroll Cross Sectional View Removable External Solenoid and Coil Floating Seal Cavity Seal Cavity Vent 90 Frame Digital Scroll ...

Page 14: ...07C R 410A Operating Envelope ZPD34 54K5 ZPD61 91KC ZRD36 81KC Recommended Capacity Range 75 100 Recommended Capacity Range 50 100 Recommended Capacity Range 10 100 40 50 60 70 80 90 100 110 120 130 140 150 160 20 10 0 10 20 30 40 50 60 Condensing Temperature F Evaporating Temperature F R 22 R 407C R 410A Operating Envelope ZPD103 182KC ZRD94 125KC Recommended Capacity Range 75 100 Recommended Cap...

Page 15: ...n Engineering B U L L E T I N Figure 7 Discharge Thermistors Figure 6 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: ...plication Engineering B U L L E T I N Figure 8 3 to 7 5 Ton Modulation Valve Piping Figure 9 3 To 7 5 Ton Tandem Arrow on valve Must point to suction Oil Equalization Line Suction Gas Equalization Manifold Discharge Manifold Assembly Suction Manifold Assembly Solenoid Valve ...

Page 17: ...hy the compressor isn 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 modul...

Page 18: ...DT12 16MC 12 5 4 ZRDT25MC 27 12 2 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 91KC ZRD61 81KC Internal Top Cap Thermistor ZPD103 182KC Installed On Compresso...

Page 19: ...4 54K5 ZPD61 91KC ZRD34 81KC Tubing kit is for 7 8 compressor suction all coils have 1 4 spade electrical terminals 24V Coil Only 023 0060 18 110V Coil Only TBD 220V Coil Only TBD Modulation Valve 24V Coil Tubing Kit 998 0090 02 Modulation Valve Tubing Kit 998 0090 01 Modulation Valve 910 0109 00 ZPD103 182KC ZRD94 125KC All coils have 1 4 spade electrical terminals 24V Coil 998 0060 03 120V Coil ...