Emerson Climate Technologies Variable Frequency Drives, Discus, Scroll, ZB, ZS, ZF, ZP, ZR, ZRHV72KJE, ZBHV45KJE Compressor Application Engineering Bulletin

AE21-1369 R1
November 2011
AE21-1369 R1
Use of Variable Frequency Drives (VFDs) with
Copeland Scroll® and Discus® Compressors
INDEX PAGE
• Low starting current obviates the need for assisted
start devices
1. Introduction........................................................ 1
2. Operation of a Variable Frequency Drive........... 1
3. Evaluation and Important Considerations.......... 1
4. Limits of Use with Copeland® Compressors ...... 2
5. Approved Frequency Ranges with
Standard Motors................................................. 2
6. Minimum Speed................................................. 2
7. Effect of the VFD on Performance and
Power Input ....................................................... 2
8. Control of VFD Frequency................................. 2
9. Start Contactor Positioning ............................... 2
10. Starting and Ramp Up ....................................... 2
11. Electrical Shielding and Voltage Rise................. 2
12. Vibration............................................................. 3
13. Recommended VFD Range............................... 3
14. Typical VFD Parameter Set Up for Discus
(Scroll) Compressors......................................... 3
• With gradual speed increase from standstill there
is less risk of sudden liquid or oil return to the
compressor on start up
The objective of this bulletin is to provide technical
guidelines to developers, designers or installers that
intend to use VFDs on Copeland Discus compressors in
their refrigeration systems. The operation of a VFD, the
effect on compressor application range, performance
and power, precautions and some implications on
system design are discussed.
2. Operation of a Variable Frequency Drive
A VFD works by converting the input mains alternating
current to direct current and, from this, generating
a simulated A.C. signal at varying frequencies. A
compressor driven by a squirrel cage induction motor
will run at a speed corresponding to the frequency. The
speed will be in direct proportion to the frequency.
1. Introduction
Variable frequency drives (VFDs) are used to vary the
speed of motors and in this way can be used to control
the capacity of a compressor. For refrigeration users
they can be an effective method of accurately matching
compressor capacity to a load requirement. A method of
reducing compressor output is needed in almost every
application. With the emphasis today on saving energy
by reducing head pressures, an effective capacity
control method can bring enormous benefits. Without
the means to run efficiently at low capacity, compressor
cycling by switching on/off is most commonly used. This
method introduces large fluctuations and high power
consumption due to heavily loaded heat exchangers.
Multiple compressor solutions overcome this problem
to some extent and stepping by means of cylinder
unloading is used with piston compressors.
3. Evaluation and Important Considerations
The advantages of varying compressor speed are:
The power absorbed by a compressor operating with
a VFD will always be more than for a direct connected
compressor running at the same speed. It is important
to choose a high quality VFD because the VFD absorbs
a certain amount of power and also the nature of the
electrical waveform at the motor is disjointed, resulting
in increased motor losses.
Investigations carried out by Emerson Climate
Technologies have included computer simulations,
variable speed compressor performance testing,
reliability testing, and refrigeration system field data
comparisons. Most VFDs are capable of generating
frequencies from 2.5 Hz to over 300 Hz. This is well
outside the range of any refrigeration compressor,
therefore part of the investigation has been focused on
assessing practical limits.
Limits arise due to the capability of the oil pump to
maintain lubrication at low speed and motor cooling.
Increased losses at higher speeds can result in less
efficient operation and compressor overheating (high
discharge temperatures).
• The load is more closely matched with minimal
variation in evaporating pressure and fluctuations
in load temperature are minimized
• Better system efficiency at part load
• Extended lifetime of equipment due to continuous
operation instead of cycling
© 2011 Emerson Climate Technologies
Printed in the U.S.A.
When considering a VFD, the following points should
be taken into account:
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AE21-1369 R1
6. Minimum Speed
• Loss of efficiency unless care is taken with system
design and control
The minimum allowable frequency of 25 Hz for Discus
and 45 Hz for scroll is governed by the lowest speed
at which the lubrication system can operate effectively.
• Conventional capacity control methods may not be
used with a VFD (i.e. blocked suction, or Copeland
Digital) on the same compressor
7. Effect of the VFD on Performance and Power
Input
• Vibration resonance may occur at certain speeds
and these are very difficult to predict
The capacity can be calculated as being in direct
proportion to the speed. A compressor is designed to
have optimum pumping efficiency at its nominal speed,
usually 1750 RPM for discus and 3500 RPM for scroll.
When operating at speeds other than the nominal the
efficiency will change because of the behaviour of the
valve reeds and the change in pressure drop through
the valve plate. However, as these tend to balance out,
the change in volumetric efficiency is small.
• Restrictions on operating envelope may be
necessary
• Risk of electrical disturbance to control signals
4. Limits of Use with Copeland® Compressors
With many VFDs it is very easy to alter the maximum
and minimum output frequencies and the frequency
range, so care must be taken to ensure the frequencies
are correctly adjusted to prevent damage to the
compressor.
8. Control of VFD Frequency
The signal necessary to control the VFD depends on the
type of VFD used. They are commonly controlled by an
analog 4 to 20 mA signal. This signal should respond to
changes in the system's control variable, for example
changes in suction pressure or room temperature.
Emerson strongly recommends controlling off of suction
pressure because a response to a temperature signal
may lag.
Note! In most variable frequency drives, you can also
program "skip" frequencies to avoid vibration resonance
that may occur at certain speeds.
5. Approved Frequency Ranges with Standard
Motors
See Table 1 below.
Normally the ratio of voltage/frequency (V/f) is kept
constant, and it is only when the required voltage is
above the supply voltage that the amps increase. For
example, a 380V 60Hz motor will only require 320V
at 50 Hz according to the constant V/f rule, and can
therefore be safely operated at all conditions up to 60
Hz with a suitable drive. See Figure 1 below.
9. Start Contactor Positioning
If a contactor is used to disconnect the VFD from the
motor it should be interlocked to only switch when the
VFD is off. The VFD should not be allowed to operate
with the output from the drive to the motor as an open
circuit. There should be a contactor on each side of
the drive, ie, between the drive and the supply and
between the drive and the compressor motor. They
should be interlocked to break the supply side first.
When switching on, the motor side contactor should
be made first.
Note! Output voltage from the drive can not exceed the
input voltage to the drive.
Table 1 – Approved Operating Range
for Copeland® Compressors
Speed
Range
3D, 4D, & 6D
25 - 60 Hz
Refrigeration Scroll
(ZB,ZS,ZF)
45 - 60 Hz
Air Conditioning
Scroll (ZP,ZR)
45 - 70 Hz
Notes
Contact your
Emerson Climate
Technologies
representative for
extended operating
ranges.
Voltage
Model Family
Note: Application Engineering Bulletin AE4-1343
should be referenced when applying the ZRHV72KJE
and ZBHV45KJE variable speed horizontal Copeland
Scroll compressors.
© 2011 Emerson Climate Technologies
Printed in the U.S.A.
500
450
400
350
300
250
200
150
100
50
0
ine
0V L
ge
a
Volt
46
ltage
ine Vo
230V L
20
25
30
35
40
45
Frequency
Figure 1
2
50
55
60
65
AE21-1369 R1
below the minimal speed as called out in Table 1 could
lead to vibration problems during start up. Spring
mounts should not be used as they have a natural
frequency below 65 Hz. As a rule of thumb, the system
should be designed or the VFD control should be
configured (skip frequencies programmed), such that
there is no operation at resonant frequencies between
20 and 70Hz.
When using a VFD bypass, care should be taken to
ensure there can be no voltage feedback to the VFD.
Therefore when the bypass contactor is closed and the
bypass is in operation, the contactors on either side of
the VFD must be open. See Figure 2 for an example
of an approved optional VFD wiring bypass.
10. Starting and Ramp Up
A VFD is capable of delivering a soft start, but at the
same time care must be taken to ensure that stalling
does not occur. The VFD must be able to deliver
sufficient power at the lower frequencies to ensure
that the compressor accelerates to nominal speed
in approximately 3 seconds or less. Only general
guidance can be given here, because the exact torque
requirements will depend on system pressures at the
time of start up. Longer ramp up times could result in
inadequate lubrication.
13. Recommended VFD Range
Emerson Climate Technologies recommends the
use of the Control Techniques® brand of VFDs with
Copeland Discus® compressors. Control Techniques
VFDs have been tested with the compressors and
include vector control algorithms for optimum torque
generation, EMC filters for electrical noise reduction,
and all of the necessary VFD features required for
successful compressor operation. VFD selection tables
are available on request.
11. Electrical Shielding and Voltage Rise
14. Typical VFD Parameter Set Up for Discus
(Scroll) Compressors
Wiring of the electrical enclosure and the installation
must be carefully conducted in accordance with EMC
recommendations. High quality, high reliable pressure
sensors must be used and it is necessary to follow
EMC measures to ensure that the VFD does not
disturb the signals from pressure transducers. Suction
and high pressure sensors signals must be noise-free
to the controller input. For best results select a VFD
with a built-in EMC filter or add the manufacturer's
recommended optional filter if it is not a standard
component.
The following is a list of some control parameters for
configuring a Control Techniques® Commander SK
VFD.
Par01 = 25 Hz Minimum Frequency (45 Hz for scroll)
Par02 = 60Hz Maximum frequency (70 HZ for air conditioning scroll products)
Par03 = 5 sec Acceleration ramp
Par04 = 10 sec Deceleration ramp
Because the waveform generated by the VFD is built up
from pulses, there is a danger that the rate of voltage
rise on an individual pulse can damage the motor
windings. In order to minimize the risk of motor problems
it is suggested that the VFD be operated at its lowest
switching frequency and that the distance between the
VFD and the compressor be as short as possible.
Par06 = Motor rated current (A)
Par07 = 1750 Motor Rated Speed (3500 for scroll)
Par08 = 460 Motor rated voltage
Par37 = 3kHz Switching frequency
Par39 = 60 Motor rated frequency
12. Vibration
Par41 = Ur_I Vector control mode
A compressor running at fixed speed imposes
vibrations on its associated framework at a set group of
frequencies. The framework can of course be designed
such that its natural frequencies differ from the imposed
frequencies.
Note that other parameters will need to be adjusted
to match the control method and frequency set point
input type used.
A compressor driven at variable speed will impose
different frequencies at each speed, so the framework
design to eliminate vibration throughout the speed range
is more complex.
The framework structure should be stiff enough such
that its resonant frequencies are above the maximum
frequency, ie, 60 Hz. Designing with natural frequencies
© 2011 Emerson Climate Technologies
Printed in the U.S.A.
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Figure 2
Example of Optional VFD Bypass Wiring Diagram
AE21-1369 R1
© 2011 Emerson Climate Technologies
Printed in the U.S.A.
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