Copeland ZPV063 variable speed compressor Application guideline

AE4-1402
February 2015
AE4-1402 R1
ZPV063 Copeland Scroll™ Variable Speed Compressors
TABLE OF CONTENTS
Section
Page
Safety
Page
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
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
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
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
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
Compressor Accessories & Service Parts.............20
Compressor Motor Specifications .........................21
Emerson Compressor & Drive Selection...............21
Compressor Refrigerant Charge Limits Table .......22
Speed Adjustment Requirements..........................22
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
© 2015 Emerson Climate Technologies, Inc.
Section
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Safety Instructions
Copeland Scroll™ variable speed compressors are manufactured according to the latest U.S. and European
Safety Standards. Particular 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
DANGER indicates a hazardous situation which, if not avoided, will result
in death or serious injury.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION
CAUTION, used with the safety alert symbol, indicates a hazardous
situation which, if not avoided, could result in minor or moderate injury.
NOTICE
CAUTION
NOTICE is used to address practices not related to personal injury.
CAUTION, without the safety alert symbol, is used to address practices
not related to personal injury.
© 2015 Emerson Climate Technologies, Inc.
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Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons
ELECTRICAL SHOCK HAZARD
• Disconnect and lock out power before servicing.
• Allow drive components to electrically discharge before servicing. Refer
to the drive specifications for amount of time required before servicing.
• Use compressor with grounded system only.
• Refer to original equipment wiring diagrams.
• Electrical connections must be made by qualified electrical personnel.
• Failure to follow these warnings could result in serious personal injury.
PRESSURIZED SYSTEM HAZARD
• System contains refrigerant and oil under pressure.
• Remove rerfrigerant from both the high and low compressor side before
removing compressor.
• Use appropriate wrenches on rotalock fittings when servicing.
• Never install a system and leave it unattended when it has no charge,
a holding charge, or with the service valves closed without electrically
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.
• Personal safety equipment must be used.
• Failure to follow these warnings could result in serious personal injury
or property damage.
COMPRESSOR HANDLING
• Use the appropriate lifting devices to move compressors.
• Personal safety equipment must be used.
• Failure to follow these warnings could result in personal injury or
property damage.
Safety Statements
• Refrigerant compressors must be employed only for their intended use.
• Only qualified and authorized HVAC or refrigeration personnel are permitted to
install, commission and maintain this equipment.
• Electrical connections must be made by qualified electrical personnel.
• All valid standards and codes for installing, servicing, and maintaining electrical
and refrigeration equipment must be observed.
© 2015 Emerson Climate Technologies, Inc.
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INTRODUCTION
Power Supply
This bulletin provides instructions on how to apply a
Copeland Scroll™ variable speed compressor in a safe
and reliable manner. The Copeland Scroll variable
speed compressor will be referred to throughout this
bulletin as the 'variable speed scroll' or the 'compressor.'
The compressor and drive are an integral and optimized
combination. The drive will convert the input voltage
into a variable frequency and voltage to power the
compressor. For more information on the drive power
input requirements please see the Emerson EVC1 Drive
user guide.
Product Description
The ZPV063 variable speed compressor has a speed
range of 1000 (refer to operating envelope for low
speed operation) to 7200 revolutions per minute and
is intended for use in commercial air conditioning,
chiller, and heat pump applications. The variable speed
scrolls utilize three-phase brushless permanent magnet
(BPM) motors. The compressors have been qualified
for use with Emerson™ EVC1 Drives which have been
developed and qualified for BPM motor-compressors.
The Emerson drives offer the highest level of compressor
protection through the use of CoreSense™ protection
algorithms. If use of a non-Emerson drive is desired,
please work with Application Engineering to select an
appropriate drive for the compressor application. See
Third Party Drive requirements on the following page.
CAUTION
The variable speed compressor must be paired
with the appropriate variable speed drive. Do
not connect the power supply directly to the
compressor.
Nomenclature
The model number of the variable speed scroll includes
the approximate displacement in cubic centimeters per
revolution. Figure 1 provides a complete explanation
of all of the alpha and numeric characters in the
compressor model number.
Agency Approval
The ZPV063 compressors are U.L. recognized in file
SA2337, Volume 22. When the compressor is used with
the Emerson EVC1, the compressor and drive are a
U.L. listed 508C package. The package is listed in file
SA2337, Volume 22.
Compressor Data
Compressor drawings, mechanical, electrical,
and performance data are available by contacting
Application Engineering.
Locked Rotor Current (LRA):
OEM LAB TESTING
LRA is defined as the highest current input to the
MOTOR when the compressor is in a mechanically
locked condition. The LRA for the variable speed
scrolls will be much lower than the LRA values for
fixed capacity scrolls. The variable speed scroll is
started at a much lower frequency and voltage and
the result is the elimination of very high inrush current.
Application Engineering should be consulted during
the design, development, and production launch of the
variable speed system to help ensure that the variable
speed scroll is applied as intended, in a safe and reliable
manner.
Modeling System Performance
Modeling at any speed in the 1,000 to 7,200 range and
in any approved envelope is facilitated by 20 coefficient
data available from Application Engineering.
Rated Load Amps (RLA):
An electrical value that is used by the system designer
to size overcurrent protection devices and current
carrying conductors. RLA = MCC/1.4
COMPRESSOR DESIGN FEATURES
The variable speed scroll has a number of design
features that improve efficiency and reliability. Figure
8 shows the internal features that are unique to the
variable speed scroll.
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.
Compressor Motor
The brushless permanent magnet (BPM) motor in the
variable speed scroll consists of a three-phase stator
Please refer to Table 1 for more technical data for the
compressor.
© 2015 Emerson Climate Technologies, Inc.
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and a rotor embedded with high energy permanent
magnets. The input voltage is a series of pulses of
varying frequency at 120 degree intervals between
phases.
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. Figure 3 shows the
operating conditions of the oil boost cycle.
Oil Pump
The variable speed scroll is equipped with an oil pump
to ensure an adequate supply of oil to the bearing
system throughout the operating speed range of 1000
to 7200 RPM.
Motor Protection
The Emerson EVC1 drive includes motor protection
features for the compressor. The drive sets the
maximum current limit, low voltage fold back which
allows the compressor to ride through low voltage
situations, which helps keep the compressor running
to avoid nuisance trips. The drive also includes lost
rotor avoidance and locked rotor detection. The lost
rotor avoidance uses a custom algorithm to evade
a speed error by reducing the speed by 200 RPM
to 're-catch' the rotor.
APPLICATION CONSIDERATIONS
Compressor Temperature Protection
A discharge line thermistor must be used to protect the
compressor. The drive will shut down the compressor
when the thermistor temperature exceeds 275°F
(135°C). Please see the section Troubleshooting
Scroll Temperature Trip for more information on the
discharge line thermistor. Refer to Table 1 for more
information.
Reverse Rotation Protection
The Emerson EVC1 drive helps prevent reverse
rotation of the compressor. The drive checks for
reverse rotation during the first startup and looks
for a miswire at the compressor's motor. The drive
utilizes a torque profile method at startup.
Variable Speed Drive Options
Third Party Drive
The customer may use a third party drive. A third
party control system must include a discharge line
thermistor that will signal the drive to shut down if
the temperature exceeds 275°F (135°C), a soft start
and stopping routine, an oil boost cycle similar to the
Emerson EVC1 oil boost cycle, every two hours at
3600 RPM if operating below 1800 RPM, and include
the operating envelope in Figure 3. A third party drive
must include short cycle protection similar to the
Emerson EVC1 short cycle protection. Refer to Table
2 for compressor motor specifications and Table 5 for
speed adjustment requirements.
Missing Phase Protection
The Emerson EVC1 drive includes compressor
missing phase protection. The drive checks for a
missing phase connection.
Short Cycle Protection
The Emerson EVC1 drive includes short cycling
protection which checks the duration of the runtime
and quantity of short cycles. The amount of runtime
and the maximum allowable short cycles in 24
hours is adjustable. The default maximum short
cycles in 24 hours is four. The default short cycle
time is five minutes.
Emerson EVC1 Drive Features
It's recommended that the Emerson variable
speed drive (VSD) be used with the variable speed
compressor. The Emerson VSD has custom built
in features that may improve the longevity of the
compressor and efficiency of the system. Refer to the
Emerson EVC1 Drive user guide for more information.
(www.controltechniques.com)
Resonance Avoidance Feature
The Emerson EVC1 drive includes a resonance
avoidance feature which has the ability to skip a
single frequency or a range of frequencies.
Oil Boost
Discharge Temperature Protection
The Emerson EVC1 drive includes an oil boost
cycle when the compressor operates between 1000
and 1800 RPM. The oil boost cycle starts once the
The thermistor will signal the drive to shut down if
the temperature exceeds 275°F (135°C).
© 2015 Emerson Climate Technologies, Inc.
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Emerson EVC1 Operating Envelope
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. Sighttubed compressors for monitoring the oil level are
available by contacting Application Engineering.
When using the Emerson EVC1 drive, the
compressor is designed to operate within the
requirements of the operating envelope as shown
in Figure 3.
Emerson EVC1 Starting and Stopping Routine
The drive controls the starting and stopping routine
of the variable speed scroll. This routine allows
soft starting and controlled stopping, an advantage
over traditional on-off control of fixed capacity units.
Please refer to the Emerson EVC1 drive user guide
for an exact explanation of the starting and stopping
process.
The lower right boundary of the operating envelope is
the minimum compression ratio required to keep the
scrolls loaded. Operation below this boundary could
result in the compressor intermittently loading and
unloading and noisy operation.
The upper left boundary of the envelope represents
the maximum compression ratio when operating
with 20F° (11°C) suction superheat. If the operating
condition approaches this boundary of the envelope
the compressor discharge temperature will begin to
approach the maximum scroll temperature allowed by
the discharge line thermistor.
The variable speed scroll compressor incorporates
a fluid brake design to help mitigate reverse rotation
during shutdown. A momentary reverse rotation
sound may be heard. Refer to Table 5 for more
information.
Other Features
If operating the compressor below 1800 RPM, an oil
boost cycle is required for operation between 1000
and 1800 RPM. Refer to the note in Figure 3 for more
information on the oil boost cycle.
Refer to the Emerson EVC1 drive user guide for
more features and functions of the drive.
Emerson EVC1 Drive and Variable Speed
Scroll Set-Up
High Pressure Control
A quick start guide is available with the Emerson EVC1
drive. Application Engineering is available to assist
during any part of this process.
WARNING
A high pressure control must be used in all
applications.
Refrigerant
The ZPV063 compressors are approved for use with
R-410A only. Use of refrigerants other than R-410A
voids the UL recognition of these compressor models
since the motor overload system could be adversely
affected.
A high pressure control must be used with these
compressors since they do not employ an internal
pressure relief valve (IPR). The maximum cut-out
setting must not exceed 650 psig (45 bar). The switch
should be wired in series with the unit contactor to
immediately stop compressor operation if there is a high
pressure event. The high pressure control should have
a manual reset feature for the highest level of system
protection. If an auto reset high pressure control is
used, the compressor should be locked out after three
consecutive trips. If a pressure transducer is used to
protect against high discharge pressure events the
transducer and control logic should comply with U.L.
and/or local safety requirements.
Operating Envelope
The compressor operating envelope at each speed
represents the allowable range of operating conditions
for the compressor at a constant 20°F (11°C) suction
superheat, except as noted in Figure 3. Figure 3 is
a composite of the allowable operating envelope at
various speeds for the ZPV063 compressor.
Operating the compressor at evaporating temperatures
that are higher than those specified in the envelopes
for the given speed will result in a higher oil circulation
rate. A higher oil circulation rate can reduce heat
exchanger efficiency and possibly result in oil
© 2015 Emerson Climate Technologies, Inc.
Low Pressure Control
A low pressure control is required to protect against loss
of charge and other system fault conditions that can
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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.
lead to compressor overheating. A low pressure cut-out
switch located in the suction line with a cut-out setting
no lower than 20 psig (1.4 bar) is required in all heat
pump applications. For air conditioning units, a cut-out
setting no lower than 55 psig (3.8 bar) will adequately
protect against most low pressure faults. A higher level
of protection for air conditioning units can be realized
if the cut-out setting is increased to 95 psig (6.6 bar) to
prevent evaporator coil icing.
Maximum Tilt Angle
Applications, such as transportation air conditioning or
mobile radar applications, may require the compressor
to operate at some angle from vertical. Service
personnel may be required to maneuver a unit through
a stairwell or other cramped area that might require
tilting the unit. The maximum allowable tilt angles from
horizontal for individual compressors (not tandem or trio
applications) are summarized below:
Discharge Temperature Protection
CAUTION
Compressor top cap temperatures can be very
hot. Care must be taken to ensure that wiring or
other materials which could be damaged by these
temperatures do not come into contact with these
potentially hot areas.
Max. tilt angle with compressor running = 15°
Max. tilt angle with compressor not running = 60°
Contaminant Control
The ZPV063 compressors do not have an internal
discharge gas temperature protection. In order for the
variable speed drive to operate properly a thermistor
should be attached to the compressor discharge line
as close as possible and less than 6'' (15cm) from the
compressor discharge fitting. The thermistor is designed
for a 7/8" (22 mm) line and should be properly insulated.
See Table 6 of AE-1328 for thermistor temperature vs
resistance values. Refer to Table 1 for part numbers
of discharge line thermistors. Figure 7 illustrates the
discharge thermistor.
Copeland Scroll™ compressors leave the factory with
a miniscule amount of contaminants. Manufacturing
processes have been designed to minimize the
introduction of solid or liquid contaminants. Dehydration
and purge processes ensure minimal moisture levels
in the compressor and continuous auditing of lubricant
moisture levels assure that moisture isn’t inadvertently
introduced into the compressor.
Moisture levels should be maintained below 50 ppm
for optimal performance. A filter-drier is required
on all R-410A and POE lubricant systems to
prevent solid particulate contamination, oil
dielectric strength degradation, ice formation, oil
hydrolysis, and metal corrosion. It is the system
designer’s responsibility to make sure the filter-drier is
adequately sized to accommodate the contaminants
from system manufacturing processes that leave
solid or liquid contaminants in the evaporator coil,
condenser coil, and interconnecting tubing plus any
contaminants introduced during the field installation
process. Molecular sieve and activated alumina are
two filter-drier materials designed to remove moisture
and mitigate acid formation. A 100% molecular sieve
filter can be used for maximum moisture capacity. A
more conservative mix, such as 75% molecular sieve
and 25% activated alumina, should be used for service
applications.
Motor Overload Protection
The drive will provide motor over current protection in
the event the compressor becomes mechanically locked
or if the load on the compressor motor is abnormally
high. The input power supply to the drive must be
properly fused.
Oil Type
The variable speed scrolls are charged with polyolester
(POE) oil. See the compressor nameplate for the
original oil charge. A complete recharge should be
approximately four fluid ounces (118cc) less than the
nameplate value. Copeland™ Ultra 32-3MAF, available
from Emerson Wholesalers, should be used if additional
oil is needed in the field. Mobil Arctic EAL22CC,
Emkarate RL22, Emkarate 32CF and Emkarate 3MAF
are acceptable alternatives.
Refrigerant Piping
Particular attention must be given to the system
refrigerant pipe size with the variable speed scrolls.
ASHRAE guidelines for pipe sizing should be followed
CAUTION! POE oil must be handled carefully and
the proper protective equipment (gloves, eye
protection, etc.) must be used when handling POE
© 2015 Emerson Climate Technologies, Inc.
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to ensure that refrigerant velocities are high enough
at low speeds to ensure oil return to the compressor.
At the same time, high refrigerant velocities at high
speed operation can result in excessive pressure drop
and loss of system efficiency. A careful evaluation
and compromise in pipe sizing will likely have to be
settled upon. A compressor sample with a sight-tube
for monitoring the oil level should be used during
system development to ensure an adequate oil level is
maintained at operating conditions and speeds.
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 the compressor to
add additional oil if needed because of long lengths of
piping or high refrigerant charge. No attempt should
be made to increase the oil level in the sight-glass
above the 3/4 full level. A high oil level is not
sustainable in the compressor and the extra oil will
be pumped out into the system causing a reduction
in system efficiency and a higher-than-normal oil
circulation rate.
If testing shows a gradual, continuous loss of oil in
the compressor sight-tube over long run cycles at low
speed, an oil boost cycle should be incorporated into
the system logic. An oil boost cycle is accomplished by
ramping the compressor speed up to a higher speed to
increase the refrigerant flow rate to flush or sweep oil
back to the compressor. Frequency and duration of a
recovery cycle depends on many variables and would
have to be determined through testing for each system
type and configuration. A default method could be to
initiate a recovery cycle at regular intervals.
Discharge Check Valve
The ZPV063 compressor uses a shutdown valve
located in the discharge fitting. This check valve is not a
low-leak-back check valve and will leak when pressure
differential across the check valve is low.
Suction and Discharge Tube Design
Proper tube design must be taken into consideration
when designing the tubing connecting the variable
speed scroll to the system. The tubing should provide
enough 'flexibility' to allow normal starting and stopping
of the compressor without exerting excessive stress on
the tube joints.
Long Pipe Lengths / High Refrigerant Charge
Some system configurations may contain higher-thannormal refrigerant charges either because of large
internal coil volumes or long line sets. If such a system
also contains an accumulator then the permanent
loss of oil from the compressor may become critical.
If the system contains more than 20 pounds (9 kg)
of refrigerant, it is our recommendation to add one
fluid ounce of oil for every 5 pounds (15 ml/kg) of
refrigerant over this amount. If the system contains
an accumulator the manufacturer of the accumulator
should be consulted for a pre-charge recommendation.
Because the variable speed scroll has a broad
mechanical running frequency range, it will be almost
impossible to avoid all of the natural frequencies that
may exist in the system piping. The system designer
must carefully evaluate these resonant frequency
conditions and either a) avoid them by not allowing the
compressor speed to align with the resonant frequency,
or b) evaluate the risk and life of the piping system when
the compressor is allowed to run at frequencies that
are coincident with natural frequencies of the piping
system. To do part 'b', strain gauging the system piping
is required. For assistance in evaluating strain gauging
results contact Application Engineering.
Other system components such as shell and tube
evaporators can trap significant quantities of oil and
should be considered in overall oil requirements.
Reheat coils and circuits that are inactive during part of
the normal cycle can trap significant quantities of oil if
system piping allows the oil to fall out of the refrigerant
flow into the inactive circuit. The oil level must be
carefully monitored during system development, and
corrective action should be taken if the compressor
oil level falls more than 1.5"(40 mm) below the center
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.
In order to properly determine if a design is appropriate
for a given application, samples should be tested and
evaluated for stress under various conditions of use
including frequency, load fluctuations, and shipping
vibration. The guidelines above may be helpful;
however, testing should be performed for each system
designed. For further assistance and analysis of test
results please contact Application Engineering.
Compressor Mounting
These compressors are available to the OEM with a
production sight-glass that can be used to determine the
© 2015 Emerson Climate Technologies, Inc.
The ZPV063 compressors have pierced holes in the
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mounting feet so mounting grommets with a relief are
not required. Table 1 lists the recommended mounting
parts. It is extremely important to use the correct
durometer grommet and to have consistent durometer
quality. Wrong or inconsistent durometer of the
mounting grommets can result in sound and vibration
complaints. For additional information on grommet
durometer please consult with Application Engineering.
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 to be driven
completely closed during the off-cycle, minimizing offcycle migration.
Discharge Mufflers
Regardless of which expansion device is used, the
manufacturer's recommendations on the application of
the valve should be followed in all cases.
For a variable speed compressor, discharge pulse
will generally decrease as speed increases or if
compression ratio decreases. As speed decreases or
if compression ratio increases the discharge pulse will
increase. Fixed capacity or two-step capacity units have
typically had discharge gas pulsation mufflers only in
heat pump applications. A variable capacity heat pump
and/or air conditioner may both require a discharge
gas pulsation muffler. Discharge pulse amplitude and
frequency and their effects on the piping system must be
taken into account. If testing determines that a muffler
is needed to attenuate discharge pulse, a hollow shell
muffler such as the Emerson Flow Controls APD164S
must be used.
Reversing Valves
A variable speed scroll has a real advantage during the
defrost cycle. By taking advantage of the higher speeds
and flow rates, defrost time will typically be shorter than
a system with a fixed or two-step capacity compressor.
This reduces the time heat is required during the defrost
cycle.
CAUTION Reversing valve sizing must be within
the guidelines of the valve manufacturer. Required
pressure drop to ensure valve shifting must be
measured throughout the operating range of the
unit and compared to the valve manufacturer’s
data. Conditions that result in low flow rates and
low pressure drop across the valve can result in
a valve not shifting. This can result in a condition
where the compressor appears to be not pumping
(i.e. balanced pressure). It can also result in
elevated compressor sound levels. During a defrost
cycle, when the reversing valve abruptly changes the
refrigerant flow direction, the suction and discharge
pressures will go outside of the operating envelope. The
condition will usually cross the diagonal line representing
the lower right hand corner of the envelope. The sound
that the compressor makes during this transition period
is normal, and the duration of the sound will depend on
the coil volume, outdoor ambient, and system charge.
The mufflers should be located a minimum of six
inches (15 cm) to a maximum of 18 inches (46cm)
from the compressor for most effective operation. The
farther the muffler is placed from the compressor within
these ranges the more effective it may be. If adequate
attenuation is not achieved, use a muffler with a larger
cross-sectional area to inlet-area ratio.
Airborne Sound Control
In addition to structure and gas borne sound transmission,
special consideration needs to be given to compressor
airborne sound. A-weighted, steady-state sound data is
available from Application Engineering. Sound data is
also available at the nominal cooling condition of 50°F
(10°C) evaporating and 115°F (46°C) condensing at
5400 RPM. If airborne sound attenuation is required for
the application, Fabricating Services (www.fabsrv.com)
is one manufacturer of custom sound solutions
The reversing valve solenoid should be wired so
that the valve does not reverse when the system is
shut off by the operating thermostat in the heating or
cooling mode. If the valve is allowed to reverse at the
system shutoff, suction and discharge pressures are
reversed to the compressor. This will result in pressures
equalizing through the compressor which can cause
the compressor to slowly rotate backwards until the
pressures equalize. This condition does not affect the
compressor durability but can cause unexpected sound
Expansion Devices
The expansion device is a crucial component of
the variable capacity system. Fixed-orifice devices,
which are chosen or optimized at one particular
operating condition, will not have the ability to control
the refrigerant flow across a wide range of operating
pressures and flow rates required by the variable
© 2015 Emerson Climate Technologies, Inc.
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after the compressor is turned off.
used instead of the motor windings to provide heat
to the base.
Accumulators
CAUTION Stator heat for off-cycle migration must
not be energized when the system is in a vacuum
or if there is no refrigerant charge in the system.
The system low pressure cut-out control can be
used as an indicator of the presence of refrigerant
charge.
The use of accumulators is very dependent on the
application. The variable speed scroll has an inherent
ability to handle liquid refrigerant during occasional
operating flood back situations. Systems designed
with EXV or TXV refrigerant control may not require
an accumulator if testing assures the system designer
that there will be no fl ood back throughout the
operating range. To test for flood back conditions and
to determine if the accumulator or EXV/TXV design is
adequate, please see the Application Tests section.
A large-area protective screen no finer than 30x30
mesh is required to protect this small orifice from
plugging. Tests have shown that a small screen with
a fine mesh can easily become plugged causing oil
starvation to the compressor bearings. The size of
the accumulator depends upon the operating range
of the system and the amount of system refrigerant
charge. System modeling indicates that heat pumps
that operate down to and below 0°F (-18°C) will require
an accumulator that can hold around 70% to 75% of
the system charge. Behavior of the accumulator and
its ability to prevent liquid slugging and subsequent oil
pump-out at the beginning and end of the defrost cycle
should be assessed during system development. This
will require special accumulators and compressors
with sight tubes and/or sight glasses for monitoring
refrigerant and oil levels.
Manifolded Compressors
Multiple compressor assemblies are available for
purchase from Emerson. In lieu of purchasing the
assembled manifold, the OEM can choose to purchase
the manifold-ready compressor and perform the
assembly in their factory. Drawings of tandem and trio
compressor assemblies are available from Emerson
Climate Technologies by contacting your Application
Engineer. NOTICE: Customers who choose to
design and build their own manifolds for tandem
and trio compressor assemblies are ultimately
responsible for the reliability of those manifold
sets.
The suction manifold is close to a symmetrical layout
with the design intent of equal pressure drop to each
compressor. A straight length of pipe is connected to
the suction manifold "T" connection to serve as a flow
straightener to make the flow as uniform as possible.
The discharge manifold is the less critical of the two
manifolds in terms of pressure drop. Low pipe stress
and reliability are its critical design characteristics.
Support for the discharge manifold between the
compressors should be no closer than a straight
distance of 14" (356 mm) from the discharge tee.
Off-Cycle Migration Control
Off-cycle migration control is important for long term
compressor reliability and to minimize nuisance
complaints associated with flooded start conditions.
Off-cycle migration control is recommended when
the system charge exceeds 15.0 lbs (7 kg). Offcycle migration control is required when the system
charge exceeds 18 lbs (8 kg). In lieu of using a
conventional wrap-around crankcase heater, the drive
has a programmable feature that will utilize the motor
windings.
For tandem compressor applications, tubing stress
levels should be closely evaluated between a
frequency of 29 and 35 Hz. If excess stress levels
occur, the Resonance Avoidance Feature in the
Emerson EVC1 drive may be used.
Manifolded Applications
Manifolded compressors follow the same application
guidelines as single compressors outlined in this
bulletin. The refrigerant charge limit for manifolded
compressors is shown in Table 4. A manifolded circuit
with charge over the limit must have a crankcase
heater or stator heating applied to both compressors.
If off-cycle migration control is required, and no offcycle migration testing across the range of expected
indoor/outdoor temperatures is performed, the stator
heater must be powered 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
© 2015 Emerson Climate Technologies, Inc.
Oil levels in the individual sight-glasses will vary,
depending on whether one or more compressors in the
10
AE4-1402
manifolded set are operating and if the manifolded set
is made up of equal or unequal compressor capacities.
Because of the unequal oil levels that can exist, oil
levels should be viewed with the compressors off to
allow the oil level to stabilize between the compressor
sumps. With the compressors off, oil should be visible
in the individual compressor sight-glasses.
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 Tests
In addition to the tests outlined above, off-cycle
migration tests are recommended if the system charge
amount exceeds 11 pounds (7 kg) and less than 100
watts of the stator heat option is selected. The purpose
of the off-cycle migration test is to ensure that stator
heat is great enough to minimize off-cycle migration
after long compressor 'off' periods. System faults, such
as low or loss of indoor air-flow, loss of outdoor air-flow,
and low/overcharge conditions should all be evaluated
to ensure the compressor and service technician are
protected against any adverse condition.
Suction and discharge manifolds are not designed
to support system piping. Support means must be
provided by the system designer to support suction
and discharge lines so that stress is not placed on
the manifolds.
The compressors in a manifolded set can be started/
stopped in any desired sequence. To help reduce
inrush current, starting the compressors individually is
recommended. Should a compressor fail in the tandem
set the complete tandem should be removed from the
unit and replaced with a new tandem set. Replacing
individual compressors is discouraged because of
the care that must be used when installing the oil
equalization tube and the availability of manifolds to
the aftermarket.
NOTICE The tests outlined above are for common
applications of compressors in this family.
Please consult with Application Engineering on
applications outside of those outlined above for
the appropriate application tests.
ASSEMBLY LINE PROCEDURES
Please consult with Application Engineering during
the development of systems with trio compressor
assemblies. Trio compressor assemblies are
sensitive to system operating conditions and
configurations which will affect oil balancing. Trio
compressor assemblies must be qualified for each
application.
Installing the Compressor
WARNING
Use care and the appropriate material
handling equipment when lifting and moving
compressors. Personal safety equipment must
be used.
Manifolded compressor assemblies are available
for purchase from Emerson. In lieu of purchasing
the assembled tandem, the OEM has the option to
purchase the tandem-ready compressors to assemble
the compressors into a tandem configuration.
Drawings of the tandem manifolds are available
by contacting your application engineer. Manifold
ready compressors are designated with a -4XX bill of
material number at the end of the model number (e.g.
ZPV0631E-4X9-455). Customers that choose to
design and build their own manifolds for tandem
and trio compressors are ultimately responsible
for the reliability of those manifold sets.
Copeland Scroll compressors leave the factory
dehydrated, with a dry air holding charge. If
compressors are stored in a cold ambient (i.e. outside
during the winter), the suction and discharge plugs
should not be removed until the compressor has
had sufficient time to warm up to the plant ambient
temperature. The suggested warm up time is one
hour per 4°F (2°C) difference between outdoor and
indoor temperature. It is suggested that the larger
suction plug be removed first to relieve the internal
pressure. Removing the smaller discharge plug could
result in a spray of oil out of this fitting since some
oil accumulates in the head of the compressor after
Emerson’s run test. The inside of both fittings should
be wiped with a lint free cloth to remove residual oil
prior to brazing. A compressor containing POE oil
should never be left open longer than 20 minutes.
APPLICATION TESTS
New 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
© 2015 Emerson Climate Technologies, Inc.
11
AE4-1402
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 may
overheat the scrolls and cause early drive bearing
damage. NOTICE Do not use the compressor to test
the opening set point of a high pressure cutout.
Bearings are susceptible to damage before they have
had several hours of normal running for proper break in.
Assembly Line Brazing Procedure
WARNING
Personal safety equipment must be used during
brazing operation. Heat shields should be
used to prevent overheating or burning nearby
temperature sensitive parts. Fire extinguishing
equipment should be accessible in the event of a
fire.
Figure 5 discusses the proper procedures for brazing
the suction and discharge lines to a scroll compressor.
NOTICE It is important to flow nitrogen through the
system while brazing all joints during the system
assembly process. Nitrogen displaces the air and
prevents the formation of copper oxides in the system.
If allowed to form, the copper oxide flakes can later
be swept through the system and block screens such
as those protecting capillary tubes, expansion valves,
and accumulator oil return holes. Any blockage of oil
or refrigerant may damage the compressor resulting
in failure.
'Hipot' (AC High Potential) Testing
CAUTION
Use caution with high voltage and never hipot
test when compressor is in a vacuum.
Copeland Scroll compressors are configured with the
motor down and the pumping components at the top
of the shell. As a result, the motor can be immersed
in refrigerant to a greater extent than hermetic
reciprocating compressors when liquid refrigerant is
present in the shell. In this respect, the scroll is more
like semi-hermetic compressors that have horizontal
motors partially submerged in oil and refrigerant. When
Copeland Scroll compressors are hipot tested with liquid
refrigerant in the shell, they can show higher levels of
leakage current than compressors with the motor on
top. This phenomenon can occur with any compressor
when the motor is immersed in refrigerant. The level of
current leakage does not present any safety issue. To
lower the current leakage reading, the system should
be operated for a brief period of time to redistribute
the refrigerant to a more normal configuration and the
system hipot tested again. See AE4-1294 for megohm
testing recommendations. Under no circumstances
should the hipot test be performed while the
compressor is under a vacuum.
Pressure Testing
WARNING
Never pressurize the compressor to more than
475 psig (33 bar) for leak checking purposes.
Never pressurize the compressor from a nitrogen
cylinder or other pressure source without an
appropriately sized pressure regulating and relief
valve.
The pressure used on the line to meet the U.L. burst
pressure requirement must not be higher than 475
psig (33 bar). Higher pressure may result in permanent
deformation of the compressor shell and possible
misalignment or bottom cover distortion.
Assembly Line System Charging Procedure
Systems should be charged with liquid on the high side
to the extent possible. The majority of the charge should
be pumped in the high side of the system to prevent low
voltage starting difficulties, hipot failures, and bearing
washout during the first-time start on the assembly line.
If additional charge is needed, it should be added as
liquid to the low side of the system with the compressor
operating. Pre-charging on the high side and adding
liquid on the low side of the system are both meant to
protect the compressor from operating with abnormally
© 2015 Emerson Climate Technologies, Inc.
U.L. sets the requirement for dielectric strength testing
and they should be consulted for the appropriate voltage
and leakage values.
Final Run Test
Customers that use a nitrogen final run test must
be careful to not overheat the compressor. Nitrogen
is not a good medium for removing heat from the
compressor, and the scroll tips can be easily damaged
12
AE4-1402
with high compression ratios and/or long test times.
Copeland Scroll compressors are designed for use
with refrigerant, and testing with nitrogen may result in
a situation where the compressor does not develop a
pressure differential (no pump condition). When testing
with nitrogen, the compressor must be allowed to cool
for several minutes between tests.
CAUTION Energizing a variable speed scroll with a
grounded winding can cause irreversible 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.
Unbrazing System Components
WARNING
Before attempting to braze, it is important to
recover all refrigerant from both the high and low
side of the system.
Compressor Replacement After a Motor Burn
In the case of a motor burn, the majority of contaminated
oil will be removed with the compressor. The rest of the
oil is cleaned with the use of suction and liquid line filter
driers. A 100% activated alumina suction filter drier is
recommended but must be removed after 72 hours. See
AE24-1105 for clean up procedures and AE11-1297 for
liquid line filter-drier recommendations. NOTICE It is
highly recommended that the suction accumulator
be replaced if the system contains one. This is
because the accumulator oil return orifice or screen may
be plugged with debris or may become plugged shortly
after a compressor failure. This will result in starvation of
oil to the replacement compressor and a second failure.
If the refrigerant charge is removed from a scrollequipped unit by recovering one side only, it is very
possible that either the high or low side of the system
remains pressurized. If a brazing torch is then used
to disconnect tubing, the pressurized refrigerant and
oil mixture could ignite when it escapes and contacts
the brazing flame. Instructions should be provided
in appropriate product literature and assembly (line
repair) areas. If compressor removal is required, the
compressor should be cut out of the system rather than
unbrazed. See Figure 5 for proper compressor removal
procedure.
Start-Up of a New or Replacement Compressor
SERVICE PROCEDURES
It is good service practice, when charging a system with
a scroll compressor, to charge liquid refrigerant into
the high side only. It is not good practice to dump liquid
refrigerant from a refrigerant cylinder into the crankcase
of a stationary compressor. If additional charge is
required, charge liquid into the low side of the system
with the compressor operating. CAUTION Do not
start the compressor while the system is in a deep
vacuum. Internal arcing may occur when any type of
compressor is started in a vacuum. NOTICE Do not
operate the compressor without enough system
charge to maintain at least 55 psig (3.8 bar) suction
pressure. Do not operate with a restricted suction
or liquid line. Do not operate with the low pressure
cut-out disabled. Allowing suction pressure to drop
below 55 psig (3.8 bar) for more than a few seconds
may overheat the scrolls and cause early drive bearing
damage. Never install a system in the field and leave
it unattended with no charge, a holding charge, or with
the service valves closed without securely locking out
the system. This will prevent unauthorized personnel
from accidentally ruining the compressor by operating
with no refrigerant flow.
The drive offers a two wire 485 interface. This enables
the drive set-up, operation and monitoring to be carrier
out with a PC or controller if required. The drive only
supports Modbus RTU protocol. Refer to the Emerson
EVC1 drive user guide for more information.
Electrical Troubleshooting
CAUTION The compressor must always have the
green ground wire attached to the ground. The
other end of the green wire must be connected to
the appropriate ground terminal on the drive.
The BPM motors used in the variable speed scrolls
are three-phase. The winding resistance for each
compressor-motor is published in the Online Product
Information. The three windings should always have
line to line continuity because there is no internal
overload at the center of the motor windings to open and
take the motor off-line. If one or more of the windings
shows continuity to ground, the compressor must be
replaced.
© 2015 Emerson Climate Technologies, Inc.
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AE4-1402
Modulation
Model
Variation
V – Variable Speed
W – Variable Speed EVI
Optional 2nd Position
T – Even Tandem
U – Uneven Tandem
Cubic Centimeters
Per Revolution
Family Series
Z –Scroll
Misc. Protection
Type
Code
Enhanced External Protection
E
Protection Not Specified
X
1
2
S
3 numeric characters
Optional
Reserved, Future Use
E – POE Oil
P – POE R410A
9
Z P V T 0 3 82 E – 2 E 9 – X X X
1st Generation VS Only (K1)
Nominal Capacity
Capacity
at Rating Condition
Multiplier
2-3 numeric characters
Code
P
H
Motor Types
1
2
K-1,000
M-10,000
C-SCFM
Bill of Material
Product Variation
Application Range
Application
Refgn/Substance Compressed
AC/HP
Heat Pump Optimized
R-410A/B
R410A
Figure 1 – Compressor Nomenclature
Product Type
Generation
E: Electronics
1: First
Drive Type
EVC1150B-K1-XXX
Platform
Bill of Material
Product Variation
Nominal Power (KW)
V: Variable Speed
Figure 2 – EV Nomenclature
© 2015 Emerson Climate Technologies, Inc.
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AE4-1402
ZPV063 Operating Envelope
20°F (11°C) SH, 15°F (8°C) SC, 95°F (35°C) Ambient (Solid Line Boundaries)
OEM tesng is required to monitor the DLT in the dashed line boundaries.
Tevap (°C)
-29
-26
-24
-21
-18
160
155
150
145
140
135
130
125
120
115
110
105
100
95
90
85
80
75
70
65
60
55
50
45
40
-15
-13
-10
-7
-4
-1
1
4
7
10
12
15
18
21
24
26
29
32
71
68
65
62
60
57
54
51
48
46
43
40
37
35
32
29
26
23
21
18
15
12
10
7
4
DLT < 275°F
2200 -6000 RPM
2600 -6000 RPM
1800 -7200 RPM
1000* -7200 RPM
*Oil Boost Cycle
An Oil Boost Cycle Is Required For Speeds 1000RPM 1800RPM
Cycle Parameters: 1000RPM-1800RPM For 2 Hours,
Ramp To 3600RPM For 5 Minutes
Min Speed Of 1000RPM
-25
-20
-15
-10
-5
0
5
10
15
20
25
30
35
40
45
50
55
Tevap (°F)
Figure 3 – ZPV063 Operating Envelope
© 2015 Emerson Climate Technologies, Inc.
15
60
65
70
75
80
85
90
Tcond (°C)
Tcond (°F)
-32
AE4-1402
-30
-25
-20
-15
Evaporating Temperature (°C)
-10
-5
0
5
10
110
200°F (93.3°C)
Max Oil Temp
100
36
90
26
80
*See Note 1
70
16
60
50
6
40
30
Unacceptable
(Too Much Refrigerant Diluon)
20
-4
10
Compressor Sump Temperature (°C)
Compressor Sump Temperature (°F)
Acceptable
-14
0
-24
-10
-20
-10
0
10
20
30
40
50
Evaporating Temperature (°F)
Note 1: Operation in this refrigerant dilution area is safe in air-to-air heat pump heating mode. For other applications, such as
AC only, review expansion device to raise superheat. A cold sump may result in high refrigerant migration after shut down.
Figure 4 – Oil Dilution Chart
© 2015 Emerson Climate Technologies, Inc.
16
AE4-1402
1
}
2
}
}
3
Figure 5 – Scroll Suction Tube Brazing
New Installations
•
Field Service
The copper-coated steel suction tube on scroll
compressors can be brazed in approximately the
same manner as any copper tube.
•
Recommended brazing materials: Any silfos
material is recommended, preferably with a
minimum of 5% silver. However, 0% silver is
acceptable.
•
Be sure suction tube fitting I.D. and suction tube
O.D. are clean prior to assembly. If oil film is
present wipe with denatured alcohol, DichloroTrifluoroethane or other suitable solvent.
WARNING
Remove refrigerant charge from both the low
and high side of the compressor before cutting
the suction and discharge lines to remove
the compressor. Verify the charge has been
completely removed with manifold gauges.
•
To disconnect: Reclaim refrigerant from both the
high and low side of the system. Cut tubing near
compressor.
•
To reconnect:
• Using a double-tipped torch apply heat in Area 1.
As tube approaches brazing temperature, move
torch flame to Area 2.
○ Recommended brazing materials: Silfos
with minimum 5% silver or silver braze
material with flux.
•
○ Insert tubing stubs into fitting and connect
to the system with tubing connectors.
Heat Area 2 until braze temperature is attained,
moving torch up and down and rotating around
tube as necessary to heat tube evenly. 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.
© 2015 Emerson Climate Technologies, Inc.
○ Follow New Installation brazing
17
AE4-1402
Figure 6
© 2015 Emerson Climate Technologies, Inc.
18
AE4-1402
Figure 7
Discharge Thermistors
7/8” (22.3mm)
Discharge Fitting
Fixed Scroll
Floating Seal
Orbiting Scroll
1-1/8” (28.7mm)
Suction Fitting
Counterweight Cup
for Oil Circulation
Management
BPM Motor
Sight Glass
Fluid Brake
Positive Displacement
Oil Pump
Figure 8
ZPV063 Cross Sectional View
© 2015 Emerson Climate Technologies, Inc.
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AE4-1402
Table 1 - Compressor Accessories & Service Parts
Part
Category
Mounting
Oil
Crankcase
Heater
Electrical
Protection
Suction &
Discharge
Part
Number
Models
Compressor Mounting Kit
527-0239-01
ZPV063
Oil Adjustment Fitting
510-0715-00
Part Description
Notes
35-45 Durometer
Oil Sight-Glass
070-0040-00
Sight-Glass Rotalock Nut
005-1514-00
O-Ring Seal For Sight-Glass
020-0028-05
Crankcase Heater, 240V, 70W
018-0095-00
21' Leads
Crankcase Heater, 480V, 70W
018-0095-01
21' Leads
Crankcase Heater, 575V, 70W
018-0095-02
Crankcase Heater, 120V, 70W
018-0095-07
Crankcase Heater, 400V, 70W
018-0095-08
Crankcase Heater Junction Box
998-7024-00
Terminal Cover
005-1494-00
Terminal Cover Gasket
020-1390-00
Terminal Block
021-0227-03
ZPV063
ZPV063
21' Leads
48' Leads
48' Leads
ZPV063
All Voltages
Terminal Block Screw
100-0550-01
Grounding Screw
100-0605-00
10-32 x 8mm Long, Taptite Screw
Molded Plug
529-0099-00
8 Gauge Wire, 42" Leads
Discharge Line Thermistor
085-0261-00
ZPV063
Fits 7/8' Tube
Discharge Line Thermister, Molex
Connector
085-0211-00
ZPV063
Fits 7/8' Tube
ZPV063
7/8' Clip
Thermistor Clip
032-0688-00
Discharge Rotalock Pipe Plug
036-0008-16
Discharge Rotalock O-Ring Seal
020-0028-02
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 Rotalock Adapter to 7/8' Sweat
998-0034-08
Suction Rotalock Adapapter to 1-3/8' Sweat
998-0034-13
7/8' Discharge Stub to 1-1/4'-12 Rotalock
Adapter
998-0034-02
1-1/8' Suction Stub to 1-3/4'-12 Rotalock
Adapter
998-0034-03
(3) Required, 10-32 Screw x 1/2'
1/8'-27 NPTF
ZPV063
Suction Manifold
Discharge Manifold
Oil Equalization Tube
Manifolds are not available for sale to the aftermarket. Contact
Application Engineering if drawings of manifolds are needed.
Gas Equalization Manifold
Multiples
Mounting Kit, Compressor To Rails
527-0182-01
ZPV063
tandem
2 kits required per tandem; Includes
bolts, washers, and steel spacers
Tandem Mounting Kit, Rails To Unit
527-0177-00
ZPV063
tandem
Includes sleeves, washers, and
grommets (65-75 durometer)
Tandem Rail
574-0053-00
ZPV063
tandem
2 rails required per tandem
© 2015 Emerson Climate Technologies, Inc.
20
AE4-1402
Table 2 – Compressor Motor Specifications
Attribute
Unit
Dielectric Strength Leakage Current
ZPV063
mA
10
Dielectric Strength Test Voltage
Volts-AC
2500
Dielectric Strength Test Time
Seconds
1
#
6
Motor Input Frequency
Hertz
50-360
Recommended Switching Frequency
Hertz
6,000
Motor Poles
Table 3 - Emerson Compressor & Drive Selection
Drive Model EVC1110B-K1-114 EVC1150B-K1-114 EVC1110B-L1-114 EVC1150B-L1-114 EVC1110B-J1-114 EVC1150B-J1-114
Compressor
Model
ZPV0631E-4E9
ZPV0631E-4E9
ZPV0631E-4E9
ZPV0631E-4E9
ZPV0631E-5E9
ZPV0631E-5E9
Drive
Voltage Input
380-480
380-480
500-575
500-575
200-240
200-240
Drive
Nominal
Power
11 KW
15 KW
11 KW
15 KW
11 KW
15 KW
Drive Max
Continuous
Output
Current
24 Amps
31 Amps
22 Amps
22 Amps
50 Amps
58 Amps
Choke
TBD
TBD
TBD
TBD
TBD
TBD
Filter
TBD
TBD
TBD
TBD
TBD
TBD
Fuse
TBD
TBD
TBD
TBD
TBD
TBD
Notes
1
1
1
Operating speed may be restricted to the maximum current at specific operating conditions.
© 2015 Emerson Climate Technologies, Inc.
21
1
AE4-1402
Table 4 - Compressor Refrigerant Charge Limits
Model
Charge Limit
120% x Limit *
Tandem Charge Limit
Pounds
kg
Pounds
kg
Pounds
kg
15
7
18
8
18
8
ZPV063
* Charge allowance for system
Table 5 - Speed Adjustment
Speed Range
(RPM)
Default (RPM)
Start
3600-7200
3600
Run
1000-7200
+/- 200 RPM/S
Stop
1000-7200
3600 or Envelope Minimum
Acceleration
RPM/Sec
Deceleration
RPM/Sec
Notes
Range
Default
Range
Default
400-1000
1.0
NA
NA
1
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 envelope control is active, reduce the speed by 30% for a default of three minutes. After three
minutes and the command has not changed, decelerate to the minimum envelope speed and shut
down the compressor.
3. If envelope control is not active and the speed is above 3600 RPM, decelerate 3600 RPM for a default
of three minutes. After three minutes and the command has not changed, shut down the compressor.
4. If envelope control is not active and the speed is below 3600 RPM, maintain current speed for a default
of three minutes. After three minutes and the command has not changed, shut down the compressor.
The contents of this publication are presented for informational purposes only and they are not to be construed as warranties or guarantees, express or implied, regarding the products or
services described herein or their use or applicability. Emerson Climate Technologies, Inc. reserves the right to modify the designs or specifications of such products at any time without
notice. Emerson Climate Technologies, Inc. does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of
any Emerson Climate Technologies, Inc. product remains solely with the purchaser and end-user.
© 2015 Emerson Climate Technologies, Inc.
22
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