Emerson Copeland Scroll Reference manual

Copeland ScrollTM

ZB digital compressor

About Emerson Climate Technologies

Emerson Climate Technologies, a business segment of Emerson, is the world’s leading provider of heating, air-

conditioning and refrigeration solutions for residential, industrial and commercial applications. It combines best-in-class

technology with proven engineering, design, distribution, educational and monitoring services to provide customized,

integrated climate-control solutions for customers worldwide. Climate’s innovative solutions, which include industry-

leading brands such as Copeland ScrollTM, improve human comfort, safeguard food and protect the environment. For

more information, visit EmersonClimateAsia.com.

Emerson Climate Technologies, With Our Partners,

Will Provide Global Solutions To Improve Human Comfort,

Safeguard Food And Protect The Environment.

Our Vision:

Index

Introduction 01

Digital Scroll Advantage for Rack Systems 02

Intelligent StoreTM 03

Nomenclature 04

Bill of Material 04

ZBD Rack Specication 05

Operating Envelope 06

Performance Table 07

Technical Data 13

Dimensional Drawings 14

Flow Controls Parts 21

OMB Crankcase Oil Level Protective Control 21

A-W/A-F Oil Separators 22

AOFD-553 Oil Filter Drier 24

STAS Steel Liquid and Suction Line Filter Drier 25

ADKS Liquid And Suction Line Filter Drier 26

Filter-Drier Cores And Filters 28

HMI-Hermetic Moisture Indicators 29

PS1 Single Pressure Controls 31

APD Pulsation Dampener/Mufer 33

Scroll Rack Application Guidelines 34

Digital Compressor Rack Controller-XC645CX 40

Contact List 49

Leading Innovations in Digital Scroll Technology

Emerson Climate Technologies has revolutionized the industry with the introduction of its scroll technology, which was launched in 1987.

In 2012, Emerson produced its 100 millionth scroll - a signicant achievement and further demonstrating Emerson’s position as a world

leader in the development and application of scroll technology.

Energy-efcient Refrigeration Through Capacity Modulation

Today, Emerson is the world’s largest manufacturer of refrigeration compressors, underscoring Emerson Climate Technologies’ thrust of

ensuring food safety and protecting the environment. Leveraging on Emerson’s vast global network and R&D resources, the company also

continues to develop the ultimate in climate technology for various businesses. Emerson helps provide solutions to achieve high efciency

systems for cold storage warehouses, supermarkets, quick service restaurants, meat trading and processing facilities, seafood import and

export establishments, agricultural depots and retail outlets - green technologies with less environmental impact.

With today’s growing need to address energy efciency and precise temperature control, Emerson developed ZBD compressors – digital

scroll technology in a simplied, compact design that is very reliable.

The ZBD features continuous capacity modulation range of 10-100%. This eliminates hot gas bypass, which causes waste of electricity,

and complications arising from variable speed drives. Precise capacity modulation control proves benecial in a number of applications,

including precise temperature control for precision cooling and humidity control as well as parallel compressor operations or rack systems

– intermediate and more precise part load operation of a compressor to perfectly match varying evaporator loads. Compared to cycling

compressors, smoother and more precise load matching is enabled by stepless capacity control with the ZBD.

Key Features and Benets

•Digital Scroll technology provides higher efciency compared to hot gas bypass systems or

compressor cycling

•Less complicated compared to variable speed technologies

•More reliable compared to other modulation technologies due to elimination of oil return issues

•Suitable for rack systems due to its varying load requirements

•Proven scroll technology paired with mechanical unloading system provides greater

reliability and efciency

Digital Scroll Advantage for Rack Systems

Digital scroll compressors having modulation capabilities from 10%–100% naturally t refrigeration rack systems. Rack systems need to

fulll varying evaporator load requirements due to changing case loads, not to mention variations due to cases undergoing routine defrost.

This can be attained by complementing xed-speed compressor racks with a digital scroll of the same capacity. The refrigeration load will

be matched by running xed-speed compressors to handle the base load and the peaks by the digital scroll. This leads to a smooth and

almost constant system suction pressure (see charts below). Compared to xed-speed scroll racks where unloading is achieved by cycling

the lead compressor, this results in a saw tooth prole of the system suction pressure and will reduce the life of the lead compressor due to

frequent on and off action. Fluctuating suction pressures lead to varying evaporator temperature and humidity conditions—a condition

that is not advisable for refrigerated products.

Compressor modulation by cycling compressor on and off

Saw tooth prole of suction pressure for

xed speed compressor

Compressor modulation by digital scroll

Smooth system suction pressure

Suction Pressure

Time

Suction Pressure

Time

An innovative approach to enterprise facility management, Emerson’s Intelligent Store architecture integrates hardware and services

to help hyper mart, supermarket, convenience store, and box retail operators make better facility decisions while reducing operational

costs. The Intelligent Store architecture implements best practices for facility management and transforms data from store equipment

and controls into actionable insights. Designed to deliver value in both new and existing stores, the Intelligent Store architecture can help

retailers signicantly improve their bottom line results. The Intelligent Store solution constitutes:

• Energy efcient store infrastructure components

• State-of-the-art control technologies: XWeb Supervisory Platform

• Field services: Commissioning and project management

• Remote services: Alarm Management, Setpoint Management, Demand Response, Condition Based Maintenance, Energy Monitoring

and Targeting, Smart Dispatch, Food Quality Reports and Site Administration

Rack with

ZB Digital Scroll

Digital Compressor

Rack Controller Power Meters Dewpoint

Controller

Lighting and

HVAC Control

Superheat Controller

and EEV

ProAct Services

Intelligent StoreTM

XWeb Supervisory

Platform

Nomenclature

Generation

Compressor

Family

High/Medium Temp

Refrigeration

Capacity at 60Hz

(Medium Temperature

Condition: Btu/h)

Base Capacity

K x 1000

Bill of Material

Lubricant

Blank: Mineral Oil

E: Ester Oil

Compressor Motor

Code Description

T: Three-phase

Motor Voltages

Compressor Motor Protection

Code Description

F: Inherent internal line break

motor protector

Digital Modulation

50 Hz 60Hz

380/420-3

200/220-3

460-3

200/230-3

380-3

Bill of Material

BOM 558 559 588 589

Sight Glass ✓✓✓✓

Stub Tube ✓

Rotalock ✓ ✓

Digital Valve ✓ ✓

Solenoid Coil ✓ ✓

Digital Rack Controller Kit ✓ ✓

Discharge Line Temperature Sensor ✓ ✓

Condenser Mid Coil Temperature Sensor ✓ ✓

OMB ✓ ✓

OMB Adaptor ✓ ✓

Family Items Unit ZBD Rack Package ZBD Rack Recommendation

STD BOM 10HP 15HP

Compressor

Digital Scroll Compressor EA ✓ZBD38KQ ZBD38KQ

Standard Scroll Compressor EA - ZB38KQ ZB38KQ

- - ZB38KQ

Digital

Accessory

Thermistor1EA ✓043-0130-00 043-0130-00

Valve Body EA ✓010-0125-00 010-0125-00

Solenoid Coil2EA ✓023-0088-00 023-0088-00

Rack Control

Kit

Controller (XC645CX) EA ✓085-0254-00 085-0254-00

4-20mA Suction Pressure Transducer EA ✓085-0233-00 085-0233-00

Condenser Mid Coil Temperature

Sensor EA ✓043-0168-02 043-0168-02

4-20mA Condenser Pressure

Transducer3EA - Optional Optional

TTL / RS485 Serial Converter3EA ✓029-0502-00 029-0502-00

Hot Key EA - 085-0234-00 085-0234-00

Transformer EA ✓037-0025-00 037-0025-00

Wiring Kit 3m ✓029-0501-00 029-0501-00

Digital Input and Analog Out

Connector 3m ✓029-0472-01 029-0472-01

System

Protector

Oil Regulator, OMB-JB1 ASC 2 24/50 EA ✓085-0245-00 085-0245-00

Adapter for ZBD Sight Glass EA ✓034-0236-00 034-0236-00

HP EA - PS1-A5A PS1-A5A

LP EA - PS1-A3A PS1-A3A

Oil Separator EA - A-W55877 A-W55889

Oil Filter Drier EA - AOFD553 AOFD553

Filter Drier EA - Shell STAS-487T Shell STAS-489T

EA - Core H-48 Core H-48

Sight Glass EA - HMI HMI

Pulsation Damper EA -APD APD

ZBD Rack Specication

Solenoid Coil Part Code

Part Code Description

023-0088-00 220V 50/60Hz

023-0088-04 240V 50/60Hz

023-0088-05 200V 50/60Hz

023-0088-07 24V 50/60Hz

Notes: 1. Thermistor: Only for ZBD29KQ, PCN 043-0130-00

2. Solenoid coil part code

3. Please contact Emerson sales representative if the part is required

Operating Envelope

ZBD29 - ZBD48 ZBD29 - ZBD48

-20 -15 -10 -5 0 5 10

Evaporating Temp. oC

Condensing Temp.oC

-15-10 -5 0510 15

Evaporating Temp. oC

Condensing Temp.oC

1. En

velope in unshaded region, max return gas temperature of 18.3°C

2. En

velope in shaded region, max superheat of 11K only

1. Envelope in unshaded region, max return gas temperature of 18.3oC

Notes:

Note:

R22

ZBD29 - ZBD48

-20 -15 -10 -5 0 5 10

Evaporating Temp. oC

Condensing Temp.oC

-15-10 -5 0510 15

Evaporating Temp. oC

Condensing Temp.oC

1. Envelope in unshaded region, max return gas temperature of 18.3°C

2. Envelope in shaded region, max superheat of 11K only

1. Envelope in unshaded region, max return gas temperature of 18.3oC

Notes:

Note:

R404A

Performance Table

Q=Capacity (kW) P=Power input (kW) 3-Phase R22 50 Hz

Compressor

Condensing

Temperature

Evaporating Temperature (oC)

-12 -10 -5 0 5 10 12.5

ZBD29KQ

15 7.90 8.53 10.30 12.40

20 7.58 8.19 9.89 11.90 14.20

30 6.99 7.55 9.11 10.90 13.00 15.45 16.75

40 6.37 6.89 8.32 9.98 11.90 14.10 15.30

50 5.60 6.09 7.45 8.96 10.70 12.70 13.80

55 5.62 6.91 8.41 10.05 11.95 13.00

60 6.34 7.75 9.38 11.20 12.20

65 7.07 8.62 10.35 11.30

15 1.46 1.48 1.52 1.57

20 1.62 1.64 1.68 1.74 1.80

30 1.98 2.01 2.06 2.11 2.17 2.24 2.28

40 2.44 2.46 2.52 2.57 2.62 2.67 2.69

50 3.05 3.08 3.14 3.18 3.21 3.24 3.25

55 3.46 3.52 3.56 3.58 3.60 3.60

60 3.96 3.99 4.01 4.01 4.00

65 4.49 4.50 4.49 4.47

ZBD38KQ

15 8.72 9.20 10.60 12.30

20 9.12 9.69 11.30 13.25 15.50

30 8.86 9.55 11.45 13.60 16.10 18.95 20.50

40 7.95 8.64 10.50 12.70 15.15 17.95 19.50

50 7.20 7.79 9.48 11.35 13.50 16.00 17.40

55 7.71 9.12 10.80 12.75 14.95 16.20

60 9.10 10.45 12.15 14.05 15.15

65 10.50 11.80 13.35 14.25

15 2.24 2.35 2.65 3.00

20 2.21 2.28 2.48 2.70 2.97

30 2.55 2.58 2.65 2.72 2.81 2.92 2.99

40 3.14 3.17 3.23 3.27 3.29 3.32 3.34

50 3.65 3.73 3.90 4.01 4.09 4.15 4.17

55 3.90 4.16 4.36 4.51 4.62 4.67

60 4.32 4.63 4.88 5.08 5.16

65 4.79 5.17 5.48 5.62

ZBD45KQ

15 10.25 10.85 12.50 14.50

20 10.75 11.45 13.35 15.60 18.30

30 10.50 11.30 13.55 16.10 19.00 22.40 24.20

40 9.48 10.30 12.50 15.05 17.95 21.30 23.10

50 8.70 9.40 11.40 13.60 16.15 19.10 20.70

55 9.35 11.00 13.00 15.30 17.90 19.40

60 11.05 12.65 14.65 16.90 18.20

65 12.80 14.30 16.15 17.20

15 2.63 2.76 3.12 3.52

20 2.61 2.70 2.93 3.19 3.50

30 3.02 3.06 3.15 3.23 3.34 3.48 3.57

40 3.73 3.77 3.85 3.90 3.94 3.98 4.00

50 4.36 4.46 4.66 4.80 4.91 4.98 5.01

55 4.68 4.99 5.23 5.42 5.56 5.62

60 5.20 5.57 5.88 6.12 6.22

65 5.79 6.24 6.62 6.79

Notes: Suction Return Temperature 18.3oC

Suction Superheat 11.0K

Liquid subcooling 0.0K

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