Emerson PeC User Manual
Application Guidelines
PeC Solution Overview for
Commercial Comfort Applications
AGL_Sol_PEC_02_E_Rev01
About these guidelines ................................................................................................ 1
1 Safety instructions ............................................................................................ 1
1.1 Icon explanation ................................................................................................................. 1
1.2 Safety statements .............................................................................................................. 1
1.3 General warnings ............................................................................................................... 2
1.4 Use with flammable refrigerants ........................................................................................ 2
1.5 General recommendations................................................................................................. 2
1.6 Communication with Application Engineering and Development teams ........................... 3
2 Product description .......................................................................................... 4
2.1 General information about the Emerson PeC controller .................................................... 4
2.2 Refrigerants ....................................................................................................................... 4
2.3 Available PeC configurations ............................................................................................. 5
2.4 Main components and parts .............................................................................................. 5
2.4.1 Supported compressor range ................................................................................. 5
2.4.2 Supported variable speed drive ............................................................................. 6
2.4.3 PeC accessories .................................................................................................... 6
2.4.4 Supported electronic expansion valve range ......................................................... 6
2.4.5 Supported pressure transmitters ............................................................................ 6
2.4.6 Supported temperature sensors ............................................................................. 6
2.5 PeC system functionalities ................................................................................................. 7
2.6 System configuration ......................................................................................................... 7
3 Hardware configuration .................................................................................... 8
3.1 PeC Hardware configuration options ................................................................................. 8
3.2 Examples of application ..................................................................................................... 9
3.2.1 Monoblock air-to-water chiller system scheme with variable-speed & fixed-speed
compressors and 1 electronic expansion valve .................................................................. 9
3.2.2 Monoblock air-to-water reversible heat pump system scheme with variable-
speed & fixed-speed compressors and 1 electronic expansion valve .............................. 11
3.3 DLT sensor installation .................................................................................................... 12
4 OEM control strategy on PeC ......................................................................... 13
4.1 System controller with Modbus communication............................................................... 13
4.2 OEM capacity demand strategy ....................................................................................... 14
4.3 System controller with analog 0-10 V demand signal + 1 digital signal........................... 14
5 PeC functionalities .......................................................................................... 15
5.1 State machine matrix ....................................................................................................... 15
5.2 Functionalities .................................................................................................................. 16
5.2.1 Smart compressor operating map management .................................................. 16
5.2.2 DLT limitation control function with wet suction control ....................................... 17
5.2.3 Main superheat control ......................................................................................... 17
5.2.4 External capacity request via Modbus ................................................................. 17
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5.2.5 Start-up configuration function ............................................................................. 17
5.2.6 Compressor shutdown ......................................................................................... 17
5.2.7 Oil return function ................................................................................................. 17
5.2.8 Maximum speed during heating ........................................................................... 17
5.2.9 Speed control ....................................................................................................... 17
5.2.10 Envelope limitations ............................................................................................. 18
5.2.11 Variable-speed Scroll smart crankcase heater function ....................................... 18
5.2.12 FREMAR band protection (FREquency Management to Avoid Resonances) ..... 18
5.3 Alarm management .......................................................................................................... 18
5.3.1 "Alarm State" during compressor operation ......................................................... 18
5.3.2 Hardware alarms .................................................................................................. 19
5.3.3 Software alarms ................................................................................................... 19
5.3.4 Machine alarms summary .................................................................................... 20
5.4 Energy metering ............................................................................................................... 20
5.5 Modbus protocol specifications ........................................................................................ 21
6 Laboratory testing ........................................................................................... 22
6.1 Semi-manual mode .......................................................................................................... 22
6.2 Manual mode ................................................................................................................... 22
6.3 Starting lab testing with Modmonitoring software ............................................................ 22
6.4 Software update on the PeC ............................................................................................ 22
7 Electrical connection ...................................................................................... 23
7.1 General recommendations............................................................................................... 23
7.1.1 EMC ...................................................................................................................... 24
7.1.2 Ferrites ................................................................................................................. 24
7.1.3 Digital inputs and outputs wiring .......................................................................... 25
8 Items list for electronic solution package ..................................................... 26
9 Certification & approval .................................................................................. 27
10 Dismantling & disposal ................................................................................... 27
DISCLAIMER ............................................................................................................... 27
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About these guidelines
The purpose of these guidelines is to provide guidance in the application of the Emerson PeC
controller in users’ systems. They are intended to answer the questions raised while designing,
assembling, starting and operating a system with this product.
Besides the support they provide, the instructions listed herein are also critical for the proper and
safe functioning of the system. The performance and reliability of the system may be impacted if
the product is not used according to these guidelines or is misused.
These guidelines cover stationary applications only. For mobile applications, please contact the
Application Engineering department at Emerson as other considerations may apply.
1 Safety instructions
Emerson PeC controllers are manufactured according to the latest European safety standards.
Particular emphasis has been placed on the user’s safety.
The PeC controllers are intended for installation in systems in accordance with the European
Machinery Directive MD 2006/42/EC, the Low Voltage Directive LVD 2014/35/EU and the
Electromagnetic Compatibility Directive EMC 2014/30/EU. They may be put to service only if they
have been installed in these systems according to instructions and conform to the corresponding
provisions of legislation. For relevant standards please refer to the Manufacturer’s Declaration,
available on request or at www.climate.emerson.com/en-gb.
These guidelines form part of the product and must always be kept near the controller for easy and
quick reference. They should be retained throughout the lifetime of the controller.
You are strongly advised to follow these safety instructions.
1.1 Icon explanation
WARNING
This icon alerts the user of important
instructions to avoid personal injury and
material damage.
CAUTION
This icon alerts the user of instructions
to avoid property damage and possible
personal injury.
WARNING
High voltage!
This icon alerts the user of non-insulated
"dangerous voltage" within the product
area that is sufficiently high to constitute a
risk of electric shock to persons.
IMPORTANT
This icon alerts the user of important
operating and maintenance or
assistance instructions.
Danger of explosive atmosphere
This icon indicates a risk of explosive
atmosphere.
NOTE
This word indicates a recommendation
for easier operation.
1.2 Safety statements
▪ This product can only be used for purposes specified by the manufacturer.
▪ This product is designed to be used in HVAC/R systems and can only be installed,
operated or maintained by qualified electrical personnel with additional system-related
expertise. Please immediately contact the manufacturer for support if the user is
uncertain with any safety-related issue.
▪ Electrical connections must be made by qualified electrical personnel with additional
system-related expertise.
▪ All valid standards and local electrical regulations for connecting electrical and
refrigeration equipment must be observed.
▪ The national legislation and regulations regarding personnel protection must be
observed.
Use personal safety equipment. Safety goggles, gloves,
protective clothing, safety boots and hard hats should be worn
where necessary.
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1.3 General warnings
WARNING
Conductor cables! Electrical shock hazard! This product operates at
hazardous voltages which can cause severe personal injury or equipment
damage. Extreme care and precautions must be taken when handling the
product. Electrical connections must be made by qualified electrical
personnel.
Use a grounded system only. Moulded electrical plugs must be used in all
applications. Refer to original equipment wiring diagrams.
Do not operate system before all cable connections are completed.
Disconnect all voltages from system before installation or service. Allow drive
components to electrically discharge for a minimum of two minutes before
servicing.
WARNING
Conductor cables! Electrical shock hazard! The controller must always be
inserted inside an electrical panel that can only be accessed by authorised
personnel. The keyboard must be the only part that can be reached. The
device must never be hand-held while being used.
CAUTION
The controller cannot be used as a safety device. Verify the limits of
application before using the device.
IMPORTANT
Transit damage! Controller disfunction! Use original packaging.
1.4 Use with flammable refrigerants
WARNING
The PeC controller is not designed or qualified based on the ATEX directive!
The PeC controller fulfils the requirements of the mentioned system standard
with the usage of flammable refrigerants.
Usage with flammable refrigerants is limited to systems which are based on the IEC 60335-2-40
standard. For systems using flammable refrigerants A2L and A3 the following points must be
considered:
▪ The controller mounting area must be in Zone 2 or outside any ATEX zone and in line with
"Pollution Degree 2" classification.
▪ No airstream guided over the electronics.
▪ No condensation under normal operation.
▪ The IP class of the controller mounting area must be in line with the system standard.
1.5 General recommendations
The customer shall bear full responsibility and risk for product configuration in order to achieve the
results pertaining to installation and/or final equipment/system. Upon customer's request and
following a specific agreement, Emerson. may be present during the start-up of the final
machine/application, as a consultant. However, under no circumstances can Emerson be held
responsible for the correct operation of the final equipment/system.
Since Emerson products form part of a very high level of technology, a qualification/configuration/
programming/commissioning stage is required to use them as best as possible. Otherwise, these
products may malfunction, and Emerson cannot be held responsible.
It is good practice to bear the following in mind for all Emerson products:
▪ Prevent the electronic circuits from getting wet as contact made with water, humidity or any
other type of liquid can damage them. Comply with the temperature and humidity limits
specified in the guidelines in order to store the product correctly.
▪ The device must not be installed in particularly hot environments as high temperatures can
cause damage, eg, to electronic circuits and/or plastic components forming part of the casing.
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Comply with the temperature and humidity limits specified in the guidelines in order to store the
product correctly.
▪ Under no circumstances is the device to be opened – the user does not require the internal
components. Please contact qualified service personnel for any assistance.
▪ Prevent the device from being dropped, knocked or shaken as either can cause irreparable
damage.
▪ Do not clean the device with corrosive chemical products, solvents or aggressive detergents.
▪ The device must not be used in applications that differ from those specified in these guidelines.
1.6 Communication with Application Engineering and Development teams
When communicating with Application Engineering and/or development teams at Emerson during
the development and testing phases of programs using the PeC, please include:
1. log file
2. description file
3. configuration file
These will help them give you more precise and complete answers to your questions.
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2 Product description
2.1 General information about the Emerson PeC controller
The PeC (Performance Controller) controller has been specifically developed for Copeland™ scroll
compressors using R410A and R32 refrigerants in heating and cooling applications such as
reversible heat pumps, in both air-to-water and brine-to-water configurations.
PeC was developed to run and protect the refrigerant cycle with low control effort for the system
controller but also to provide detailed information around the refrigerant cycle.
Figure 1: PeC external view Figure 2: Internal view
The external dimensions of the PeC controller are 185 x 130 x 60 mm.
Figure 3: Top side view
Figure 4: Bottom side view
2.2 Refrigerants
The PeC controller operates with refrigerant systems using:
▪ R410A
▪ R32
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2.3 Available PeC configurations
The following tables show the hardware and software capabilities with PeC C100 and C200.
PeC C100
Circuit 1
VS compressor
+ EV3 drive
Fixed speed
Temperature
probe min-max
Pressure
EXV
(bipolar)
1-3
(1 can be a variable speed)
5-7 2 1
Table 1
PeC C200
Circuit 1
Circuit 2
VS
compressor
+ EV3 drive
Fixed speed
Temperature
.probe
min-max
Pressure
EXV
(bipolar)
VS
compressor
+ EV3 drive
Fixed speed
Temperature
. Probe
min-max
Pressure
EXV
(bipolar)
1-3
(1 can be a
variable speed)
5-7 2 1 0 0-3
4-6 2 1
Table 2
NOTE: The PeC factory default is unconfigured (-1) so configuration is needed. Invalid or
unconfigured compressor package selection will cause an alarm.
2.4 Main components and parts
For components and parts ordering please contact the Application Engineering or Sales
Department at Emerson.
2.4.1 Supported compressor range
The PeC controller has been specifically developed for Copeland Scroll variable-speed
compressors using R410A and R32 refrigerants. It is currently qualified for the following ranges:
R32
Fixed-speed
compressor
Variable-speed
compressor
YP137
YPV066
YP154
YPV096
YP182
YP232
YP292
Table 3: Qualified compressors for use with R32
R410A
Fixed-speed
compressor
Variable-speed
compressor
ZP104
ZPV066
ZP122
ZPV096
ZP154
ZP182
ZP232
ZP292
Table 4: Qualified compressors for use with R410A
NOTE: Additional fixed-speed compressors may be supported based on customer request.
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2.4.2 Supported variable speed drive
EV3150
EV3185
Compatible
compressor model
1 YPV066
1 ZPV066
1 YPV096
1 ZPV096
Table 5: Compatible compressor models
NOTE: The Emerson EV3 inverter drive is compliant with CAT 3 of EMC homologations.
2.4.3 PeC accessories
Plug-in connector
PeC C100
Screw terminals and/or cage clamp female
connectors
PeC C200
Screw terminals and/or cage clamp female
connectors
Table 6
USB adapter
XJ485-USB converter
Cable XJ485-USB
converter
Table 7
2.4.4 Supported electronic expansion valve range
Alco EX4
Alco EX5
Alco EX6
EXV-M30 (wires)
3.0 m
Table 8: Qualified expansion valves
NOTE: Additional expansion valves may be supported based on customer request.
2.4.5 Supported pressure transmitters
Alco PT5N-7 (7 bar max)
Low side
Alco PT5N-10 (10 bar max)
Alco PT5N-18 (18 bar max)
Alco PT5N-30 (30 bar max)
High side
Alco PT5N-50 (50 bar max)
Cable for PT5N
PT4-M30
3.0 m
Table 9: Qualified pressure transmitters
NOTE: Additional pressure transducers may be supported based on customer request.
2.4.6 Supported temperature sensors
TP1 series
100K (high temperature)
(for future use)
Table 10: Qualified temperature sensors
NOTE: Additional temperature sensors may be supported based on customer request.
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2.5 PeC system functionalities
The PeC controller controls and manages the refrigerant system comprising the Copeland Scroll
variable-speed compressor (ZPV066 or ZPV096 & YPV066 or YPV096), the drive, the electronic
expansion valves (EX range) and the 2- or 4-way valve. It is not a main system controller: it does
not control or manage the full unit (chiller / heat pump / others).
The OEM system controller and the PeC communicate via Modbus serial communication, in order
to exchange the fundamental parameters and information to provide an optimised combined control
of compressor and expansion devices for maximum performance and reliability.
Table 11 below gives an overview of the PeC features and benefits.
PeC
Features
Benefits
Smart
refrigerant circuit
management
▪ Variable speed & fixed speed
▪ Tandem/Trio capacity management
▪ Smart superheat control & EXV management
▪ Dynamic compressor operating maps
management
▪ Reverse cycle management
High efficiency &
reduced time-tomarket
Protection &
diagnostics
▪ Active compressor envelope protection
▪ Active floodback protection
▪ Oil recovery management
▪ Performance monitoring
Improved
protection &
increased
reliability
Communication
▪ RS485 Modbus OR analog interface
communication with system controller
▪ Pre-programmed Modbus communication with
CSD100 and alarms/parameters transfer
Modularity
Table 11
2.6 System configuration
Figure 5
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