Emerson PeC User Manual

Application Guidelines

PeC Solution Overview for Commercial Comfort Applications

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	CAUTION
This icon alerts the user of important	This icon alerts the user of instructions
instructions to avoid personal injury and	to avoid property damage and possible
material damage.	personal injury.

	WARNING				IMPORTANT
	High voltage!				This icon alerts the user of important
	This icon alerts the user of non-insulated				operating	and	maintenance	or
	"dangerous voltage" within the product				assistance instructions.
	area that is sufficiently high to constitute a
	risk of electric shock to persons.
	Danger of explosive atmosphere				This word indicates a recommendation
	This icon indicates a risk of explosive	NOTE
					for easier operation.
	atmosphere.

1.2Safety 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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1.3General 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.

1.4Use 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.

1.5General 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.

1.6Communication 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

2.1General 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

2.2Refrigerants

The PeC controller operates with refrigerant systems using:

▪R410A

▪R32

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2.3Available PeC configurations

The following tables show the hardware and software capabilities with PeC C100 and C200.

Circuit 1

PeC C100

VS compressor

Fixed speed

Temperature

Pressure

EXV

+ EV3 drive

probe min-max

(bipolar)

1-3

5-7

2

1

(1 can be a variable speed)

Table 1

Circuit 1

Circuit 2

PeC C200

<![if ! IE]> <![endif]>VS

<![if ! IE]> <![endif]>compressor

<![if ! IE]> <![endif]>+ EV3 drive

<![if ! IE]> <![endif]>Fixed speed

<![if ! IE]> <![endif]>Temperature

<![if ! IE]> <![endif]>.probe

<![if ! IE]> <![endif]>min-max

<![if ! IE]> <![endif]>Pressure

<![if ! IE]> <![endif]>EXV

<![if ! IE]> <![endif]>(bipolar)

<![if ! IE]> <![endif]>VS

<![if ! IE]> <![endif]>compressor

<![if ! IE]> <![endif]>+ EV3 drive

<![if ! IE]> <![endif]>Fixed speed

<![if ! IE]> <![endif]>Temperature

<![if ! IE]> <![endif]>. Probe

<![if ! IE]> <![endif]>min-max

<![if ! IE]> <![endif]>Pressure

<![if ! IE]> <![endif]>EXV

<![if ! IE]> <![endif]>(bipolar)

1-3

(1 can be a

5-7

2

1

0

0-3

4-6

2

1

variable speed)

Table 2

NOTE: The PeC factory default is unconfigured (-1) so configuration is needed. Invalid or unconfigured compressor package selection will cause an alarm.

2.4Main 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		Variable-speed
	compressor		compressor
	YP137		YPV066
	YP154		YPV096
	YP182
	YP232
	YP292

Table 3: Qualified compressors for use with R32

R410A

	Fixed-speed	Variable-speed
	compressor	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)
		Alco PT5N-10	(10 bar max)			Low side
		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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2.5PeC 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
	▪ Variable speed & fixed speed
Smart	▪	Tandem/Trio capacity management		High efficiency &
	▪	Smart superheat control & EXV management
refrigerant circuit				reduced time-to-
	▪	Dynamic compressor operating maps
management		management		market
	▪	Reverse cycle management
	▪	Active compressor envelope protection		Improved
Protection &	▪	Active floodback protection		protection &
diagnostics	▪	Oil recovery management		increased
	▪	Performance monitoring		reliability
	▪ RS485 Modbus OR analog interface
Communication		communication with system controller		Modularity
	▪	Pre-programmed Modbus communication with
		CSD100 and alarms/parameters transfer
Table 11

2.6System configuration

Figure 5

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