Related Manuals for Copeland Digital Scroll ZRD42KCE
Summary of Contents for Copeland Digital Scroll ZRD42KCE
- Page 1 Application Guidelines Digital Scroll Compressors for Air Conditioning ZRD42K* to ZRD125K*, ZPD34K* to ZPD182K*...
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Page 2: Table Of Contents
1.1 Icon explanation ......................... 1 1.2 Safety statements ......................1 1.3 General instructions ......................2 Product description ..................3 2.1 Common information about Copeland Scroll Digital™ compressors......... 3 2.2 Nomenclature ........................3 2.3 Application range ....................... 4 2.3.1 Qualified refrigerants and oils ................4 2.3.2... - Page 3 4.2.4 Protection devices ....................20 4.2.5 Crankcase heaters ....................20 4.3 Pressure safety controls ....................21 4.3.1 IPR valve (Internal Pressure Relief valve) ............21 4.3.2 High-pressure control ................... 21 4.3.3 Low-pressure control .................... 21 4.4 Discharge temperature protection ................... 22 4.5 Low ambient cut-out ......................
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Page 4: About These Guidelines
About these guidelines The purpose of these application guidelines is to provide guidance in the application of Copeland Scroll™ compressors in users’ systems. They are intended to answer the questions raised while designing, assembling and operating a system with these products. -
Page 5: General Instructions
General instructions WARNING System breakdown! Personal injuries! Never install a system in the field and leave it unattended when it has no charge, a holding charge, or with the service valves closed without electrically locking out the system. System breakdown! Personal injuries! Only approved refrigerants and refrigeration oils must be used. -
Page 6: Product Description
39.1 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. -
Page 7: Application Range
It is essential that the glide of refrigerant blends (primarily R407C) is carefully considered when adjusting pressure and superheat controls. Oil recharge values can be taken from Copeland Scroll compressors brochures or Copeland™ brand products Select software at www.emersonclimate.eu. Qualified refrigerants... - Page 8 ZPD34K*E to ZPD54K*E ZPD61K*E to ZPD91K*E R410A R410A Evaporating Temperature ( Evaporating Temperature ( 10K Suction superheat ZPD103K*E to ZPD137K*E ZPD154K*E & ZPD182K*E R410A R410A -35 -30 -25 -20 -15 -10 -5 10 15 20 25 Evaporating Temperature ( Evaporating Temperature ( 10K Suction superheat Figure 2: Application envelopes with R410A (Dew point) C6.2.15/0815/E...
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Page 9: Dimensions
Figure 3: Compressor dimensions Operation, design & performance The Copeland Scroll Digital compressor is capable of modulating its capacity from 10% to 100%. The compressor is supplied along 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. - Page 10 Scrolls separated by approximately 1 mm Full capacity No capacity Solenoid de-energized Solenoid energized Figure 4: Modulation of Scroll models 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 C6.2.15/0815/E...
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Page 11: Mechanical Differences In The Digital Compressor Ranges
ZPD34K*E to ZPD91K*E ZPD103K*E to ZPD182K*E ZRD42K*E to ZRD81K*E ZRD94K*E & ZRD125K*E R410A R410A Evaporating Temperature ( Evaporating Temperature ( 10-100% recommended application range 50-100% recommended application range 75-100% recommended application range Figure 7: Recommended capacity modulation ranges according to the operating conditions Mechanical differences in the Digital compressor ranges Figure 8: Single Digital Scrolls in the ZRD and ZPD ranges The internal mechanics of the smaller and the larger models are different but functionally both... -
Page 12: Installation
Installation WARNING High pressure! Injury to skin and eyes possible! Be careful when opening connections on a pressurized item. Compressor handling 3.1.1 Transport and storage WARNING Risk of collapse! Personal injuries! Move compressors only with appropriate mechanical or handling equipment according to weight. Keep in the upright position. -
Page 13: Solenoid Valves
Sleeve Rubber spacer Figure 11: Rubber mounting parts for single models Hard mounts + washer + bolts Fixation Figure 12: Rigid mounting parts for Tandem models Figure 13: Rubber mounting parts rail-to-ground for Tandem models Solenoid valves IMPORTANT The external solenoid valve is a critical component for proper operation of this compressor. -
Page 14: Solenoid Valve Installation
Figure 14: Position of the external solenoid valve Figure 15: Recommended piping Solenoid valve installation 3.3.1 General recommendations Solenoid must be mounted vertically, within ± 15° of vertical. Horizontal mounting is not permitted. The valve operation is directional. See Figures 18 & 19 below for inlet and outlet locations. -
Page 15: Tubing Recommendations
Figures 18 & 19. Tandem compressors Copeland Scroll Digital compressors ZRD48K* to ZRD81K* and ZPD54K* to ZPD91K* can be used in a Tandem arrangement (code 422 in nomenclature), if the single compressor cannot cover the required capacities and/or there are higher fluctuations in capacity demand. The fittings for gas equalization and oil equalization must be connected between the two compressors (see Figure 20). - Page 16 Figure 19: No slanted alignment of the oil equalization line! Use models from 09J… onwards only! Figure 20: Oil equalization line design Figure 21: Top view of the piping design Digital Standard Figure 22: Tandem configuration with ZRD125K* and ZPD103K* to ZPD182K* C6.2.15/0815/E...
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Page 17: Discharge Check Valve
Table 2: Tandem configurations with standard models and Digital Scroll compressors Discharge check valve There is no discharge check valve at the discharge port of Copeland Scroll Digital compressors ZRD42K* to ZRD81K* and ZPD34K* to ZPD91K* since the high-side pressure is needed to support the operation of the un-loader mechanism. -
Page 18: Shut-Off Valves And Adaptors
Heat area 2 until braze temperature is attained, moving the torch up and down and rotating around the tube as necessary to heat the tube evenly. Add braze material to the joint while moving the torch around the joint to flow braze material around the circumference. ... -
Page 19: Oil Separator
Oil separator During any operating cycle of Copeland Scroll Digital compressors, there is a loaded state during which the compressor operates at full capacity. The velocity of gas during this loaded state is sufficient to return oil back to the compressor. Laboratory tests have established that there is no... -
Page 20: Screens
3.12 Reversing valves Since Copeland Digital Scroll compressors have a very high volumetric efficiency their displacements are lower than those of equivalent capacity reciprocating compressors. As a result, Emerson Climate Technologies recommends that the capacity rating on reversing valves be no more than 1.5 to 2 times the nominal capacity of the compressor in order to ensure proper... -
Page 21: Suction Line Noise And Vibration
A second difference of the Copeland Scroll is that under some conditions the normal rotational starting motion of the compressor can transmit an "impact" noise along the suction line. This may be particularly pronounced in three-phase models due to their inherently higher starting torque. -
Page 22: Electrical Connection
Copeland Scroll compressor and to use cable glands according to EN 50262 or any other relevant standard of application in their country/region. Examples of correct electrical installations are shown in Figures 31 &... -
Page 23: Motor Winding
The motor insulation material is class "B" (TF*) for the compressor models covered in these guidelines. This is according to VDE 0530, IEC 34-18-1 or DIN 57530. 4.2.3 Motor protection For all Copeland Scroll Digital compressors, conventional inherent internal line break motor protection is provided. 4.2.4 Protection devices Independently from the internal or external motor protection, fuses must be installed before the compressor. -
Page 24: Pressure Safety Controls
excessive start up clearing noise. The addition of a crankcase heater will reduce noise and dimming light complaints since the compressor will no longer have to clear out liquid during start. A crankcase heater is required for three-phase compressors when the system charge exceeds the compressor charge limit listed in Table 4 below. -
Page 25: Discharge Temperature Protection
(such as operation outside the approved application limits, improper control operation or loss of refrigerant injection charge). This could cause compressor damage. Discharge gas temperature protection is required for any application with Copeland brand compressors in order to guarantee positive compressor protection. This protection must not be used as an operating envelope controller but as a safety device. -
Page 26: Low Ambient Cut-Out
Low ambient cut-out A low ambient cut-out is not required to limit air-to-air heat pump operation. Air-to-water heat pumps must be reviewed since this configuration could possibly run outside of the approved operating envelope causing overheating or excessive pressure ratio operation. High-potential testing WARNING Conductor cables! Electrical shock! Shut off power supply before high-... -
Page 27: Starting Up & Operation
Starting up & operation WARNING Diesel effect! Compressor destruction! The mixture of air and oil at high temperature can lead to an explosion. Avoid operating with air. IMPORTANT Oil dilution! Bearing malfunction! Turn the crankcase heater on 12 hours before starting the compressor. Strength pressure test The compressor has been strength-tested in the factory. -
Page 28: Initial Start-Up
During the very brief start-up, a clicking sound is audible, resulting from initial contacting of the spirals and is normal. Due to the design of the Copeland Scroll compressors, the internal compression components always start unloaded even if system pressures are not balanced. In addition, since internal compressor pressures are always balanced at start-up, low-voltage starting characteristics are excellent for Copeland Scroll compressors. -
Page 29: Deep Vacuum Operation
5.12 Sound characteristics For the Copeland Scroll Digital compressor the sound spectrum of the loaded state and that of the unloaded state are quite different. The unloaded sound power is normally 2 dB(A) higher than the loaded sound power. -
Page 30: Oil Level Control
10%. Oil dilution means the amount of refrigerant in a certain volume of oil. Please refer to the oil dilution chart in Figure 25 to ensure that the Copeland Scroll Digital compressors operate in the safe zone. -
Page 31: Maintenance & Repair
Maintenance & repair Exchanging the refrigerant Qualified refrigerants and oils are given in section 2.4.1. It is not necessary to replace the refrigerant with new unless contamination due to an error such as topping up the system with an incorrect refrigerant is suspected. To verify correct refrigerant composition, a sample can be taken for chemical analysis. -
Page 32: Lubrication And Oil Removal
Lubrication and oil removal WARNING Chemical reaction! Compressor destruction! Do not mix up ester oils with mineral oil and/or alkyl benzene when used with chlorine-free (HFC) refrigerants. The compressor is supplied with an initial oil charge. The standard oil charge for use with refrigerants R407C and R410A is a polyolester (POE) lubricant Emkarate RL 32 3MAF. -
Page 33: Unbrazing System Components
Unbrazing system components WARNING Explosive flame! Burning! Oil-refrigerant mixtures are highly flammable. Remove all refrigerant before opening the system. Avoid working with an unshielded flame in a refrigerant charged system. Before opening up a system it is important to remove all refrigerant from both the high and low sides of the system. - Page 34 The Emerson logo is a trademark and service mark of Emerson Electric Co. Emerson Climate Technologies Inc. is a subsidiary of Emerson Electric Co. Copeland is a registered trademark and Copeland Scroll is a trademark of Emerson Climate Technologies Inc.. All other trademarks are property of their respective owners.
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