Emerson PeC controller User Guide

Emerson PeC controller

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 variablespeed & 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 5.2.2 5.2.3

Smart compressor operating map management ………………………………………….. 16 DLT limitation control function with wet suction control ………………………………… 17 Main superheat control …………………………………………………………………………….. 17

5.2.4 External capacity request via Modbus ……………………………………………………….. 17

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5.2.5 5.2.6 5.2.7 5.2.8

Start-up configuration function ………………………………………………………………….. 17 Compressor shutdown …………………………………………………………………………….. 17 Oil return function ……………………………………………………………………………………. 17 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

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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

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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.
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.
Danger of explosive atmosphere This icon indicates a risk of explosive atmosphere.

NOTE

CAUTION This icon alerts the user of instructions to avoid property damage and possible personal injury. IMPORTANT This icon alerts the user of important operating and maintenance or assistance instructions.
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 CopelandTM 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

VS compressor + EV3 drive

Fixed speed

Circuit 1
Temperature probe min-max

Pressure

EXV (bipolar)

1-3 (1 can be a variable speed)

5-7

2

1

Table 1

Circuit 1

Circuit 2

PeC C200

V S compressor + EV3 drive Fixed speed Temperature
.probe min-max Pressure
EXV (bipolar)
V S compressor + EV3 drive Fixed speed Temperature
. Probe min-max Pressure
EXV (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.

2.4 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 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 1 1
Table 5: Compatible compressor models

EV3185
1 1

Compatible compressor model
YPV066 ZPV066 YPV096 ZPV096

NOTE: The Emerson EV3 inverter drive is compliant with CAT 3 of EMC homologations.

2.4.3 PeC accessories

Plug-in connector
Table 6

PeC C100 PeC C200

Screw terminals and/or cage clamp female connectors
Screw terminals and/or cage clamp female connectors

USB adapter

XJ485-USB converter

Cable XJ485-USB converter

Table 7
2.4.4 Supported electronic expansion valve range

Alco EX4

Alco EX5

EXV-M30 (wires)

Alco EX6 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)

Alco PT5N-18 (18 bar max) Alco PT5N-30 (30 bar max)

Cable for PT5N

Alco PT5N-50 (50 bar max) PT4-M30

Table 9: Qualified pressure transmitters

Low side
High side 3.0 m

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
Smart refrigerant circuit management
Protection & diagnostics
Communication
Table 11

Features
Variable speed & fixed speed Tandem/Trio capacity management Smart superheat control & EXV management Dynamic compressor operating maps
management Reverse cycle management Active compressor envelope protection Active floodback protection Oil recovery management Performance monitoring RS485 Modbus OR analog interface
communication with system controller Pre-programmed Modbus communication with
CSD100 and alarms/parameters transfer

Benefits
High efficiency & reduced time-tomarket
Improved protection & increased reliability
Modularity

2.6 System configuration

Figure 5

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3 Hardware configuration

3.1 PeC Hardware configuration options

The controller board owns digital inputs and outputs that can provide customized use to the OEM. Configuration can be set via Modbus using “Configuration Parameters”.

Factory default of digital inputs
& outputs DI1 DI2 DI3 DO1 DO2 DO3 DO4
Table 12

Description
Input for high-pressure switch signal Input for demand On/Off selection Input for heating or cooling mode selection Relay for switching 2 or 4-way valve Relay for fixed-speed compressor start/stop Relay for fixed-speed compressor start/stop Relay for fixed-speed compressor start/stop

Type
Fixed function Future use Future use
Fixed function Fixed function Fixed function
See below

Configuration parameter options on DO1: Register [94] if Defrost is enabled 0 = Cooling open circuit, heating closed circuit 1 = Cooling closed circuit, heating open circuit

Configuration parameter options on DO4: Register [150] if compressors 1,3 installed (refer to index 86 bit 3) then relay can be used to indicate PeC status 0 = Alarm negative logic (Alarm = Relay contact open) 1 = Alarm positive logic (Alarm = Relay contact closed) 2 = Drive active positive logic (speed <> = 0 relay closed)

Figure 6: PeC controller top side ­ Power supply, digital outputs & inputs & EXV connections
NOTE: For more information please refer to Application Guidelines AGL_Sol_PEC_01 “PeC Solution Controllers for commercial Comfort Applications ­ PeC C100 & PeC C200” or contact your local Application Engineering representative at Emerson.

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3.2 Examples of application

3.2.1 Monoblock air-to-water chiller system scheme with variable-speed & fixed-speed compressors and 1 electronic expansion valve

The schematic in Figure 7 shows an air-to-water chiller designed for cooling applications.

I/O P1
P2 T1
T2 T3 T4 T5 T6 T7
DO1 DO2 DO3 DO4 DI1 DI2 DI3 EXV/BIP An.In. Bus Inverter Bus Ctrl Bus Slave
Table 13

Type
PT5N-7-10-18
PT5N -30-50
TP1
TP1 TP1 TP1
TP1 TP1 TP1 24 VAC 24 VDC Relay Relay Relay
Relay Digital input Digital input Digital input Stepper out –
bipolar 0-10 V analog
input Modbus RS485 Modbus RS485
Modbus RS485

PeC controller
Function Suction pressure for superheat (SH) control, high SH protection and envelope management Discharge pressure for envelope management Evaporator outlet gas temperature for SH control and high SH protection Compressor suction gas temperature for SH control and high SH protection Ambient temperature Liquid temperature before main EXV for energy counter function & EXV management Variable-speed compressor discharge temperature Fixed-speed compressor discharge temperature Fixed-speed compressor discharge temperature Power supply
Supercap XEC mono valve
4-way Fixed-speed compressor command #1 Fixed-speed compressor command #2 Fixed-speed compressor command #3 indicates if the drive is running or not Feedback safety
Not used
Not used
EXV control
Not used
Communication with EV3 inverter Communication with system controller Modbus slave (may be used for monitoring and/or flashing)

Comments Configurable Mandatory

Configurable Configurable

Mandatory Optional

Configurable Configurable Configurable

Mandatory Mandatory Mandatory

Configurable
Configurable
Configurable Fixed Optional Fixed Configurable
Configurable

Mandatory Mandatory Mandatory
Not needed

Configurable

Fixed State readable by Modbus State readable by Modbus
Fixed
State readable by Modbus
Fixed

Optional Optional
Optional

Fixed

Fixed

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Figure 7: Air-to-water chiller for cooling application

Figure 8: PeC C100 bottom side ­ Digital inputs, Modbus communication, pressure and temperature inputs
NOTE: For more information please refer to Application Guidelines AGL_Sol_PEC_01 “PeC Solution Controllers for commercial Comfort Applications ­ PeC C100 & PeC C200” or contact your local Application Engineering representative at Emerson.

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3.2.2 Monoblock air-to-water reversible heat pump system scheme with variable- speed & fixed-speed compressors and 1 electronic expansion valve

The schematic in Figure 9 shows an air-to-water reversible chiller/heat pump with the ability for reverse cycling for defrost and heating modes. The main expansion valve, 4-way valve and compressors are controlled by PeC.

I/O
P1
P2
T1
T2 T3 T4
T5 T6 T7 P1 P2 DO1 DO2 DO3
DO4 DI1 DI2 DI3 EXV/BIP An.In. Bus Inverter Bus Ctrl
Bus Slave
Table 14

Type
PT5N-7-1018
PT5N -30-50
TP1
TP1 TP1 TP1
TP1 TP1 TP1 24 VAC 24 VDC Relay Relay Relay
Relay Digital Input Digital Input Digital Input Stepper out –
bipolar 0-10 V analog
input Modbus RS485 Modbus RS485
Modbus RS485

PeC controller
Function Suction pressure for superheat (SH) control, high SH protection and envelope management Discharge pressure for envelope management Evaporator outlet gas temperature for SH control and high SH protection Compressor suction gas temperature for SH control and high SH protection
Ambient temperature
Liquid temperature before main EXV for energy counter function & EXV management Variable-speed compressor discharge temperature Fixed-speed compressor discharge temperature Fixed-speed compressor discharge temperature
Power supply
Supercap XEC mono valve
4-way
Fixed-speed compressor command #1 Fixed-speed compressor command #2 Fixed- speed compressor command #3 indicates if the drive is running or not
Feedback safety
Not used
Not used
EXV control

Comments Configurable Mandatory

Configurable Configurable

Mandatory Optional

Configurable
Configurable
Configurable
Configurable Configurable Configurable Fixed Optional Configurable Fixed Fixed
Configurable
Fixed Fixed Fixed Fixed

Mandatory Mandatory Mandatory Mandatory Mandatory Mandatory
Not needed
Optional Optional

Not used
Communication with EV3 inverter Communication with system controller Modbus slave (may be used for monitoring and/or flashing)

Fixed Fixed Fixed Fixed

Optional

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Figure 9: Air-to-water reversible chiller/heat pump
3.3 DLT sensor installation
The DLT sensor assembly improves the accuracy and response time of the temperature management.
The high-pressure safety input was designed to fulfill the requirements of standard EN 378.
Please follow the recommendations below for sensor assembly:
The temperature sensor has to be installed along the straight or bended pipe at a distance of 120 mm from the compressor shell.
The discharge pipe including the sensor must be insulated to reduce the impact of ambient temperature.
Use thermal compound to improve heat transfer to the sensor. The thermal compound must be approved for maximum system operating temperatures (usually 150 °C for R32).
Protect the sensor from being moved or removed from its position by transport, vibration or any other incident.
The sensor must be installed in a copper sleeve to improve response time and to reduce setoff. The copper sleeve must be brazed on the surface of the discharge pipe. Use thermal compound to improve the heat transfer from the sleeve to the sensor.

Figure 10: Discharge temperature sensor mounting 12

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4 OEM control strategy on PeC

4.1 System controller with Modbus communication

OEM system controller with Modbus RS485 RTU

System controller or separate hardware

Bus

Digital I/O

……

……

……

Operating mode
Heating/Cooling Standby/Off

Capacity

Defrost Start/Stop

Refrigerant cycle info
Measured & calculated values

Alarms and warnings Hardware & software

Manual control 3 EXV’s & speed
& 2 relays
4/2-way valve

Digital Switches/Input

……

……

……

Bus

Digital I/O

PeC

Table 15

The 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.

The system controller has to provide operating mode and capacity request to run the system.

PeC operating modes can be Off, Heating, Cooling, Standby or Manual.
Modbus communication also gives the possibility of enhanced use of all PeC functions shown above.
Accessories (pumps, fan, etc.) have to be controlled directly by the OEM controller to ensure problem-free conditions for running the refrigerant cycle, eg, water flow on condenser around compressor activity.

The OEM is responsible for developing a mitigation strategy in response to the occurrence of alarms and warnings on the PeC.

There are different alarm conditions: “Alarm”, “Warning” and “Alarm State”.

Alarms and warnings may not lead to direct system shutdown. The system controller can monitor these and take preventive action with the capacity request in order to avoid system shutdown by an “Alarm State”. The occurrence of an “Alarm State” will force immediate system shutdown.

When not acting on the PeC during an “Alarm State” phase, the PeC will recover, if possible, after a recommended waiting phase (Alarm Pause).

The OEM has to consider the best response to specified alarms, eg, continue to activate the system or let the system run, lock the system to protect it against damage, etc.

An advantage of Modbus communication is that it provides the full PeC functionality such as:

1. Operation control Gives precise control on operating mode and capacity request given %.
2. Monitoring all sensor values and system status Gives opportunity to use these data for OEM processing the system by the system controller and for data logging. This provides valuable information to analyse the system operation.
3. Explicit warning and alarm information The OEM controller can get explicit fault and warning information for preventive actions on the system, as well for service and maintenance.
4. Manual control options For customized individual control strategy, the OEM controller can take control on the compressor speed, the EXV’s and the 4-way valve instead of PeC internal control function.
5. Additional hardware functionality 1 Digital input + 2 potential free relays can be used by the system controller via Modbus or internal pre-defined function.

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4.2 OEM capacity demand strategy
The OEM controller should adapt the capacity demand signal to variable speed operation. Common P, PI or PID control strategy should be used to avoid strong setpoint exceeding. This will enhance the system efficiency and reduce useless high speeds, temperatures and sound on the system. An optimal strategy has to be figured out via OEM system qualification process.
Figure 11
4.3 System controller with analog 0-10 V demand signal + 1 digital signal
Currently unused ­Option available in future.

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5 PeC functionalities 5.1 State machine matrix

EXV

Compressor pack

4-way valve

Off Start-up Shutdown Standby
Cooling
Heating
Transition to cooling / defrost
Transition to heating
Defrost Manual Emergency shutdown Alarm Table 16 AGL_Sol_PEC_02_E_Rev01

After shutdown all valves are closed, the 4-way valve switches to cooling

position

Normal start-up with predefined opening (function of ambient temperature)

Normal start-up with predefined speed and duration

Swappable
Heating or cooling active

Combination of

The compressor speed

suction pressure and is reduced and the

compressor speed

valve is closing.

Stator heater

Normal operation (dynamic setpoint graph)

Normal capacity matching

Low superheat operation (IPsensitive)

Exceptions (protections, prevention)

Exceptions

Floodback operation (protections,

prevention)

Normal operation (dynamic setpoint graph)

Normal capacity matching

Discharge

temperature

protection

Floodback operation

With unit stop: close With unit stop: shut

With unit stop: wait

valves in relation with down all compressors for pressure band to

capacity

regularly

swap

Without unit stop: proceed to cooling

Without unit stop:

Without unit stop: ramp wait for defined

down to defined

capacity to swap

start-up opening

capacity on each circuit Low delta pressure protection

With unit stop: close valves in relation with capacity

With unit stop: shut down all compressors regularly

With unit stop: wait for pressure band to swap

Without unit stop: proceed to cooling start-up opening

Without unit stop: ramp down to defined capacity on each circuit

Without unit stop: wait for defined capacity to swap Low delta pressure

protection

Suction pressure regulation

Suction pressure regulated capacity band

Full manual mode

Full manual mode

Full manual mode

Valve closing by capacity

Fast capacity shutdown

No action

Valve closing by capacity

Fast capacity shutdown

No action

15

The application is governed by a state machine of which the various states can be described as follows:
Off: The compressor shutdown procedure is executed. After shutdown, all valves are closed, the 4-way valve switches to cooling position. The stator heater function is active for both variable and fixed-speed scrolls.
Shutdown: The compressor speed is reduced and the valve is closing. Standby: The compressor shutdown procedure is executed. After shutdown all valves are
closed and the 4-way valve switches to cooling position. The stator heater function is active. Cooling: The compressor is running, the expansion valve is active and the 4-way valve is in cooling position. Heating: The compressor is running, the expansion valve is active and the 4-way valve is in heating position. Alarm: The unit has encountered a problem and stopped. When the PeC enters this state, it shadows and clears the alarms. To avoid immediate restart, the unit is moved into waiting state for a configurable amount of time. Transit cooling: The normal shutdown procedure is applied to switch off the compressors then restart the system to cooling mode. Transit heating: The normal shutdown procedure is applied to switch off the compressors then restart the system to heating mode. Defrost: The compressor is running, the expansion valve is active, the 4-way valve is in cooling position. Waiting: The unit is in delayed restart after an alarm occurred during operating mode. Manual: The user takes control of every component individually. Compressor start: The unit has a heating request but the 4-way valve is in cooling mode, so the unit starts in cooling mode to build up the necessary pressure to switch the 4-way valve. Duration: 10 seconds at 2700 rpm.
5.2 Functionalities
5.2.1 Smart compressor operating map management
The operating envelopes of the variable-speed Scroll (VSS) are stored in the controller.
Based on measurements of suction and discharge pressures the possible speed range is calculated for every operating point. Protection algorithms prevent the operating point to leave the operating map by acting on compressor speed and expansion valve opening. Envelope alarm limits are defined in order to avoid operation out of the envelope.
Additional fallback protection is implemented as safety software function in the drive. Torque and discharge temperature limitation are the major protective features.

Figure 12 16

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5.2.2 DLT limitation control function with wet suction control
The PeC will monitor the discharge line temperature. In case the high DLT area is entered, superheat control will change into Discharge Temperature Protection control. The smart logic on the EXV control ensures that the portion of liquid refrigerant droplets at the inlet of the compressor is sufficient to keep the discharge line gas temperature below the allowed limit, while COP is kept as good as possible, following the strategy “As much as needed and as little as possible”.
The discharge gas temperature limitation is compressor-type dependent.
5.2.3 Main superheat control
One bipolar expansion valve per circuit can be controlled by PeC for heating and cooling mode.
The superheat control is based on pressure/temperature control strategy involving a self-adapting PID control algorithm in order to adapt to different operating conditions. The main superheat setpoint is being adapted in a pre- defined range in order to achieve stable and optimal operating conditions.
NOTE: To test the control behaviour at special conditions, fixed and non- adaptive PID parameters can be used in the “Manual Control mode”. Please contact the Application Engineering department at Emerson in case this functionality needs to be configured.
5.2.4 External capacity request via Modbus
The capacity request for heating and cooling modes can be sent by the system controller via Modbus communication. In addition to the capacity, the operating mode has to be set separately.
The capacity input request, sent via Modbus communication, is an absolute value expressed in %.
The maximum available capacity for the current operating conditions is accessible by the system controller via Modbus communication.
5.2.5 Start-up configuration function
During variable-speed compressor start-up, the compressor will run to the start-up speed with a given ramp-up rate. When the 4-way valve position is correctly set, the compressor will go to the mode-based start-up speed. The compressor speed is stabilized at the start-up speed for a given time (start- up duration). After that, the controller will modulate the speed to meet the capacity requirement of the system.
5.2.6 Compressor shutdown
If the controller receives a compressor shutdown command, it will switch off the fixed-speed compressor(s) first if it is (they are) running. Then the variable-speed compressor will shut down according to a pre-determined procedure.
5.2.7 Oil return function
To ensure sufficient oil level in the compressor at all times, the system has to be properly designed and qualified by the OEM. To qualify oil return performance of the system, Emerson can provide compressors with sight tubes.
All the parameters associated to the oil return function are configurable. If the compressor speed goes below a threshold value for a certain amount of time, the oil return function triggers. This function forces the compressor to an “oil return” speed for a brief period.
5.2.8 Maximum speed during heating
Maximum speed during heating restricts the speed of the compressor, to limit the load on it and the heating capacity of the system.
5.2.9 Speed control
The speed regulation algorithm is used in heating and cooling modes. The PeC calculates the speed that has to be applied to the compressor in order to match the requested capacity.
However, if the operating point reaches the lower limit of evaporating temperature, the compressor speed is decreased in order to stay inside the envelope.
When the condensing temperature reaches the upper limit of the envelope, the speed is also decreased.

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5.2.10 Envelope limitations
To avoid overload of the compressor motor, the MOP function of the PeC limits the evaporating pressure to a pre-determined value, defined according to the safe operating envelope of the compressor(s). The evaporating temperature is limited by decreasing the main expansion valve opening causing higher superheat values.
The speed request has to respect the allowed envelopes according to the unit’s operating point. This means that for the evaporating and condensing temperatures of the unit, the controller runs through all the envelopes of the compressor to find the lowest and highest envelopes containing the point.
The calculated envelope gives the minimum and maximum speeds allowed for the operating point. Note that for each limit, the controller progresses to refine the envelope (up to a precision of 50 rpm).
If the evaporating temperature of the unit goes around the left side of the largest envelope allowed (equivalent to 4500 rpm) or if the condensing temperature goes around the top side of the largest envelope, a smart control algorithm is implemented to attempt to bring back the unit’s operating point inside the allowed envelopes. The resulting speed is not filtered but it is still bound according to the allowed envelopes.
5.2.11 Variable-speed Scroll smart crankcase heater function
The PeC controller uses a smart crankcase heating function to prevent the risk of liquid migration. It keeps the scroll temperature in a temperature band of 5-10 K above the evaporating temperature. The heater function is only active in “Standby” mode of the PeC. By using “Standby” and “Off” modes, the heater can be switched on and off by the OEM system controller.
This function is available only when there is one variable-speed compressor on the circuit.
5.2.12 FREMAR band protection (FREquency Management to Avoid Resonances)
Due to system design and the wide speed range of the compressor, harmful or disturbing resonance vibrations can occur in the mechanical system. If such resonances are measured during the OEM system qualification process and cannot be avoided, the Fremar band protection can be used to cut out the critical speed range(s) by defining the Fremar bandwidth and up to 3 separate frequencies.
5.3 Alarm management
5.3.1 “Alarm State” during compressor operation
Exceeding hard-programmed or configured operating limits leads to an alarm or warning to the alarm registers. Depending on the delay time and the different alarms and warnings, the system may continue to run.
The PeC will react, on a delayed warning or alarm, by changing the speed and valve opening to avoid getting into an “Alarm State”. The OEM system controller can also trigger preventive actions by, eg, reducing demanded capacity, increasing pump speed, fan speed, etc.
If there is no delay time on an alarm or if the delay time has expired, the PeC goes into “Alarm” state. “Alarm” state means:
1. Compressor is shut down as fast as possible and valves will close accordingly. a. Alarm registers are copied as a snapshot into shadow alarm registers and cleared. b. Hardware and software alarm words are written to the alarm history. c. The alarm relay is activated (the relay status can be monitored via Modbus communication, “Read parameter”).
2. After the alarm cause has disappeared, the application state goes into “Waiting” state (alarm pause) before a restart is attempted.
3. When the alarm pause time has expired, all the alarms, alarm shadows and relay/bit are cleared and the PeC goes back to normal operating mode.
NOTE: For more information please refer to Technical Information TI_Sol_PEC_01 “Performance Controller PeC ­ Modbus Interface Description” or contact your local Application Engineering representative at Emerson.

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5.3.2 Hardware alarms
On occurrence of any hardware alarm, the system will shut down immediately. If not mentioned specifically, all hardware alarms are self-resetting and the system will restart when the alarm disappears and the forced waiting time (Alarm Pause) has expired.
Valve alarms: A complete valve check is performed at start-up. This test is repeated on a valve if it has been detected as faulty. Upon regular operation, at the end of each valve movement, the energized coils are checked.
Sensor failures: These alarms are evaluated permanently regardless of application state. VSS & bipolar drive communication: Every second the PeC reads the variables available
from the bipolar drive unit and the VSS drive. After 5 successive failed attempts, the associated alarm will be raised and the associated data will be invalidated. Note that during the first four failures, the old values are kept. During HP alarm or EVU lock, the VSS communication alarm is disabled (drive is unpowered). High-pressure switch alarm: This alarm is raised whenever the digital input 2 is released. During HP alarm, the VSS communication alarm is disabled (drive is unpowered). Compressor alarm: This alarm is raised if there are major or minor faults on the VSS drive. The details of the compressor alarm cause are reported in the VSS fault structures. EEPROM failure: The EEPROM memory holding configuration parameters and energy counter values are checked at reset. This alarm is resettable only by power off ­ power on. COM timeout: When the analog input is not used on the controller, the communication to the system controller has a timeout of 60 sec. When this timeout expires, the compressor shuts down. When communication resumes, the system restarts in the state present on the write variables.
5.3.3 Software alarms

Delay counter triggers an “Alarm State” when configured delay time is exceeded

Delay counter increases

Over limits

Limit value

Delay counter stopped

Inside limits

Dead band

Limit value – Bandwidth

Delay counter cleared

Inside limits

Table 17: Dead band function on alarms
Low pressure alarm: This alarm works in a dual fashion. If the pressure is above the threshold, the alarm is cleared.
Low superheat: This alarm works in a dead band fashion with an incremental counter.
High superheat alarm: This alarm works in a dead band fashion with an incremental counter and can indicate low refrigerant charge in the system.
Valve large opening: Raised only as warning. This alarm works in a dead band fashion with an incremental counter and can indicate low refrigerant charge in the system.
High condensing pressure: This pressure alarm is one of the system protection functions: when the maximum condensing pressure (adjustable) after a time delay (adjustable) is exceeded, the high condensing pressure alarm is triggered and the compressor is shut down to protect the system before the mandatory high-pressure switch triggers. This does not replace the high- pressure switch limiter imposed by EN 378.
Freeze alarm: This alarm is currently inactive. It will be implemented in future in order to protect the heat exchanger in cooling mode.
Envelope Tc low: Raised only as warning. This flag is raised if the condensing temperature is below the minimum allowed value. No preventive action is performed and the allowed time outside the envelope is 30 minutes.
Envelope Tc high: Raised only as warning. This flag is raised if the condensing temperature is above the maximum allowed value. Compressor speed is decreased in order to stay inside the allowed application envelope.
Envelope Te low: Raised only as warning. This flag is raised if the evaporating temperature is below the minimum allowed value. Compressor speed is decreased in order to stay inside the allowed application envelope.

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Envelope Te high: Raised only as warning. This flag is raised if the evaporating temperature is above the maximum allowed value. Valve opening is decreased in order to stay inside the allowed application envelope (MOP protection).
Envelope alarm: The envelope alarm is triggered if one of Tc low, Tc high, Te low or Te high flags are raised for the respective durations. This alarm stops the system.
High discharge temperature: This alarm is triggered immediately if the discharge temperature exceeds 130 ºC.

5.3.4 Machine alarms summary

Alarm description

Alarm Status

Any sensor failure Inverter communication Oil sensing controller communication Inverter alarms Circuit safety 1, 2 Power loss Valve 1, 2 High discharge temp. 1, 2, 3, 4, 5, 6 Low pressure 1, 2 Low superheat 1, 2 High superheat 1, 2 High pressure 1, 2 Envelope 1, 2 Freeze protection 1,2 Supervisor communication
Valve large opening 1,2
Envelope Tc low 1, 2
Envelope Te high 1,2

Alarm
Alarm Warning Warning (for 30
min.) Warning (for 10 s)

Inverter speed
Shutdown
OFF Normal control Normal control Normal control

Circuit 1 fixedspeed comp.
Switch off
OFF Normal control Normal control Normal control

Circuit 2 fixedspeed comp.
Switch off
OFF Normal control Normal control Normal control

Valve 1
Closing
OFF Normal control Normal control MOP control

Envelope Tc high 1,2

Warning Speed

OFF

OFF

Normal

(for 10 s) reduction (after 5 s) (after 5 s) control

Envelope Te low 1,2 Table 18

Warning Speed

OFF

OFF

LOP

(for 10 s) reduction (after 5 s) (after 5 s) Control

Valve 2

System controller
action

Closing

Force immediate
system shutdown

OFF Normal control Normal control MOP control
Normal control
LOP Control

Force graceful system
shutdown
Can monitor these and take
preventive action
(increase fan or pump speed)

5.4 Energy metering
PeC provides information on system performance: power, COP, SCOP, SEER, heating and cooling capacity and minimum / maximum capacity.
PeC calculates the energy from compressors performance maps and values measured from the refrigerant cycle: Heating energy + electrical energy in heating mode Cooling energy + electrical energy in cooling mode
These values can be read once per second in Wh (2 X 16 bit).

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Accumulated values for SCOP and SEER calculation are stored once every 24 hours in read-only registers. Resetting the PeC or a “power off” cycle will lead to a loss of non-stored information.
All these values can be accessed via Modbus communication.
For SCOP and SEER calculation, accessory power for fan, pump, etc. is included in the calculation (constant 150 W by default). Static accessory power can be pre-set, from 0 to 3000 W, on configuration parameter.
For greater accuracy, it is possible to give the actual accessory power consumption, eg, for variable fan, pump, etc. via Bus communication to the PeC, to be considered for SCOP and SEER calculation.
Variable accessory power has to be written to the “Accessory Power value” write register.
On PeC power up, the “Accessory Power” write register is initialized by the “Accessory Power” configuration parameter value.
5.5 Modbus protocol specifications
NOTE: Please read carefully Technical Information TI_Sol_PEC_01 “Performance Controller PeC ­ Modbus Interface Description” to avoid system-controller communication problems and to be able to use the latest PeC features. If further information is needed, please contact your local Application Engineering representative at Emerson.

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6 Laboratory testing
6.1 Semi-manual mode
For lab testing purposes and/or to achieve special running parameters or conditions, it is possible to activate the semi-manual mode in heating or cooling mode. It is possible to change the control mode from automatic to manual on the compressor speed or the expansion valves, to get manual control over the device(s).
Heating/cooling capacity, compressor speed or valve openings are set as absolute values of kW, RPM or % valve opening.
Defrost can be activated and deactivated via push button registers.
NOTE: The semi-manual mode is only available via Modbus communication and for experienced users.
6.2 Manual mode
To test the system components attached to the PeC, it is possible to handle all active components manually.
No automatic function and no safety or alarm functions are active in this mode.
All components must be controlled manually, eg, for component function test.
To go into the manual mode, the “Analog command” must be deactivated (“Analog command inhibits” configuration parameter).
NOTE: The manual mode is only available via Modbus communication and for experienced users.
6.3 Starting lab testing with Modmonitoring software
To quick-start lab testing, Emerson provides a Modbus communication-based PC software with which all the PeC functionalities are available and the testing on the prototype can be performed.
NOTE: For more information please contact your local Application Engineering representative at Emerson.
6.4 Software update on the PeC
For lab testing purposes or during the qualification process, an update of the PeC firmware may be needed. To this end, Emerson can supply a programming tool and an instruction sheet about how to flash the new firmware on the PeC controller.
The PeC software may be updated via a Modbus cable through the “Modbus Slave” port.
NOTE: For more information or to get the programming tool or instruction sheet, please contact your local Application Engineering representative at Emerson.

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7 Electrical connection
7.1 General recommendations
WARNING Conductor cables! Electrical shock hazard! The controller operates at hazardous voltages which can cause severe personal injury or equipment damage. Extreme care and precautions must be taken when handling the product. 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. Insert the probe where it cannot be reached by the end-user. Disconnect all the electric connections before performing any maintenance or servicing work. The device must never be hand-held while being used.
CAUTION Wrong supply voltage! Material damage! Verify that the power supply voltage is correct before connecting the controller. Consider the maximum current that can be applied to each relay.
IMPORTANT Make sure that the wires for the probes, the loads and the electrical power supply are separated and sufficiently distant from each other, without crossing or intertwining with each other. Separate the power of the controller from the rest of the electrical devices connected inside the electrical panel. The secondary of the transformer must never be connected to the earth. In the case of applications in industrial environments, it may be useful to use the main filters in parallel to the inductive loads.
During the installation process, follow the recommendations below to prevent the device from malfunctioning:
Separate the cables of the analog inputs from those of the digital inputs, and the serial line cables from the power cables, to avoid malfunction due to electromagnetic interference.
Separate the power of the device from that of other electrical components. Never connect the secondary of the supply transformer to the earth. Separate the signal cables from the power cables. It is recommended to follow the diagram in
Figure 13 below as far as possible.

Figure 13: Example of wrong connection
The example in above diagram shows how improper connection can generate a wrong signal to the EXV valve and the possibility to lose steps.

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7.1.1 EMC
Separate drive-to-compressor supply from controls, sensor lines and communication lines. Keep a distance of 10 cm between clean and dirty lines and components if possible. Do not disable EMC measures by:
o wrong mounting of components (position & orientation); o crossing or bringing together clean and dirty cables or components; o putting components too close together; o not keeping enough clearance distance.

Drive supply

RCD type B/B+

1 DC choke internal

EV3

VSS supply screened cable

VSS

EMC measures, eg, filter, Ferrites, etc.
Figure 14
7.1.2 Ferrites Ferrites should be positioned close to input and output of the drive. Do not pass input and output wires which would make the ferrite useless.

Figure 15: Example of good practice 4 turns with one ferrite
NOTE: For more information, please refer to Application Guidelines AGL_Sol_EV3 “EV3 Inverter Drive for ZPV Variable Speed Compressors” and AGL_AC_VS_YPV “Copeland Scroll Variable Speed Compressors for R32 Applications ­ YPV066 & YPV096*” or contact your local Application Engineering representative at Emerson.

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7.1.3 Digital inputs and outputs wiring

PeC
Modbus master
DO3 (FS Scroll #6) DO2 (FS Scroll #5) DI1 (Feedback safety)

Figure 16: Digital inputs and outputs wiring for variable-speed circuit 1 (proposal)
PeC
DO8 (FS Scroll #6) DO7 (FS Scroll #5) DO6 (FS Scroll #4) DI4 (Feedback safety)

Figure 17: Digital inputs and outputs wiring for fixed-speed circuit 2

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8 Items list for electronic solution package

Description

Type

Item number

PeC series

PeC C100 (single circuit) PeC C200 (double circuit)

Electronic expansion valves EX4 ­ 7 Bipolar stepper motor valves, uniflow Cable connector assembly Pressure transmitter Suction pressure 18 bar
Discharge gas pressure 50 bar
Plugged cable assembly for pressure sensor
Temperature sensor with
Accessories

EX4-I21 EX5-U21 EX6-M21
EXV-M60 (6-m cable)
PT5N-18M PT5N-18T PT5N-50M PT5N-50T (Type: xxM = screwed, xxT = brazed) PT4-M15 (1.5-m cable) PT4-M30 (3-m cable) PT4-M60 (6-m cable)
TP1 NP3 (3-m cable) TP1 NP6 (6-m cable) TP1 NP12 (12-m cable)

Connectors kit

PeC C100 PeC C200

PeC ­ EV3 Drive Modbus connection

XJ485-USB converter

8418438 8418449
800615 800618 800621
804665
805351 805381 805353 805383
804803 804804 804805 804489 804490 804491
807983 807984
3185902

PeC Firmware flash cable
Table 19

Cable XJ485-USB converter

8416512

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9 Certification & approval
The controllers PeC C100 and C200 comply with the Low Voltage Directive LVD 2014/35/EU. The applied harmonised standards are:
– EN 60335-1:2012/A11:2014: Household and similar electrical appliances – Safety – Part 1: Part 1: General requirements;
– EN 60335-2-40:2003/A13:2012: Household and similar electrical appliances – Safety – Part 2-40: Particular requirements for electrical heat pumps, air conditioners and dehumidifiers.
Other applied standards:
– DIN IEC 60335-2-40:2018-05: Household and similar electrical appliances – Safety – Part 240: Particular requirements for electrical heat pumps, air- conditioners and dehumidifiers;
– EN 60079-15:2010: Explosive atmospheres – Part 15: Equipment protection by type of protection “n”.
The controllers PeC C100 and C200 comply with the Electromagnetic Compatibility Directive EMC 2014/30/EU. The applied harmonised standards are:
– EN 55014-1:2006/A2:2011: Electromagnetic compatibility – Requirements for household appliances, electric tools and similar apparatus Part 1: Emission;
– EN 55014-2: 1997/A2:2008: Electromagnetic compatibility – Requirements for household appliances, electric tools and similar apparatus Part 2: Immunity – Product family standard.
Other applied standards:
– DIN EN 55014-1:2018-08: Electromagnetic compatibility – Requirements for household appliances, electric tools and similar apparatus Part 1: Emission;
– DIN EN 55014-2:2016-01: Electromagnetic compatibility – Requirements for household appliances, electric tools and similar apparatus Part 2: Immunity – Product family standard.
The controllers PeC C100 and C200 comply with RoHS 2011/65/EU, (EU) 2015/863.

10 Dismantling & disposal

With reference to the Waste Electrical and Electronic Equipment (WEEE)

Directive 2012/19/EU and to the relative national legislation, please note that:

There lies the obligation not to dispose of electrical and electronic

waste as municipal waste but to separate the waste.

Public or private collection points must be used to dispose of the goods in accordance

with local laws. Furthermore, at the end of the product’s life, it is also possible to return

this to the retailer when a new purchase is made.

This equipment may contain hazardous substances. Improper use or incorrect disposal

can have adverse effects on human health and the environment.

The symbol shown on the product or the package indicates that the product has been

placed on the market after 13 August 2005 and must be disposed of as separated waste.

Should the product be disposed of incorrectly, sanctions may be applied as stipulated in

applicable local regulations regarding waste disposal.

DISCLAIMER
1. The contents of this publication are presented for informational purposes only and are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability.
2. Emerson Climate Technologies GmbH and/or its affiliates (collectively “Emerson”), as applicable, reserve the right to modify the design or specifications of such products at any time without notice.
3. Emerson does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any Emerson product remains solely with the purchaser or end user.
4. Emerson does not assume responsibility for possible typographic errors contained in this publication.

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AGL_Sol_PEC_02_E_Rev01

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Emerson Commercial & Residential Solutions Emerson Climate Technologies GmbH – Pascalstrasse 65 – 52076 Aachen, Germany Tel. +49 (0) 2408 929 0 – Fax: +49 (0) 2408 929 570 – Internet: www.climate.emerson.com/en-gb
The Emerson logo is a trademark and service mark of Emerson Electric Co. Emerson Climate Technologies Inc. is a subsidiary of Emerson Electric Co. Copeland is a registered trademark and Copeland Scroll is a trademark of Emerson Climate Technologies Inc.. All other trademarks are property of their respective owners. Emerson Climate Technologies GmbH shall not be liable for errors in the stated capacities, dimensions, etc., as well as typographic errors. Products, specifications, designs and technical data contained in this document are subject to modification by us without prior notice. Illustrations are not binding.
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References

• Copeland is Engineered for Sustainability | Copeland GB

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