Digital Scroll Technology For

Variable Capacity A/C Systems

Vayut Suvanlak

August 2008
Today’s Agenda
1. Emerson Overview

2. Modulation Market Overview And Trends

3. Copeland Scroll

4. Copeland Digital Scroll

Emerson Business Overview

Climate Network
Technologies Power
Process Industrial
Management Founded In USA In 1890
Automation
Global Sales Of US$22.6 Billion In 2007
Global Product And Market Leadership
60+ Industry-leading Divisions Located In ~245
Locations In More Than 150 Countries
111,000 Employees Worldwide

Appliance
Professional
Solutions
Tools

Motor Storage
Technologies Solutions
Emerson Climate Technologies
$3B Portfolio Of Products & Services ($550M In Asia)
Asia-Pacific Profile
Fully Capable Entity Serving Over 100 Major Customers

Headquartered In Hong Kong, China

5 Manufacturing Facilities

15 Sales Offices And Support Locations

Engineering Centers In India And Suzhou

Over 2,000 Employees

Emerson Climate Technologies
Powering The Leading Air Conditioning Systems

Energy Saving
Reliability
Human Comfort
Today’s Agenda
1. Emerson Overview

2. Modulation Market Overview And Trends

3. Copeland Scroll

4. Copeland Digital Scroll

A/C Market Transition
Shift To Variable Refrigerant Flow (VRF)

Conventional Splits VRF A/C

Benefits Of VRF A/C Systems

• Precise Temperature Control
0.5C
• Precise Humidity Control
• Individual Room Comfort Control
• Superior Aesthetics & Prestige

Market Shift In Both Residential & Commercial

A/C System Overview
A/C System

Fix Speed Modulation or VRF

-Constant Capacity -Variable Capacity
-Constant Speed

Inverter Digital Scroll

-Constant Speed
VRF Configuration
Fixed Speed Systems Do Not Match
Load Requirements

Compressor Output
Capacity

Compressor
Cycling
Inadequate
(Inefficient) Cooling
Inadequate
Heating

-20 -10 0 10 20 30 40
Ambient Temperature (o C)
Heating Cooling
Modulated Compressor Matches Supply & Demand

• Capacity Matches Load

• Energy Savings
• High Comfort
Capacity

Compressor Output Inverter 40% - 100%

Digital Scroll 10% - 100%

-20 -10 0 10 20 30 40
Ambient Temperature (o C)
Heating Cooling
Global Modulated Market Overview
European VRF Market Gaining Share Against Traditional Chillers
– Korean & Chinese OEMs Started Competing Against Japanese VRF

Japanese Commercial Market Converting To Modulation

– OEMs Pushing Higher Efficiency, R410A

Korean Modulation Market Growing Very Rapidly

– Both Residential & Commercial
– Driven Heavily By Samsung & LG

Chinese Market Growth Of Over 50% For Central A/C Systems

– DX Systems Gaining Over Chillers/Ducted
– Major Players Aggressively Promoting VRF Systems

Australia, Taiwan, Thailand, India Market Rapidly Expanding

FY07 Global VRF Market Size 44-64
-64 HP
(Pieces 000)
# Of Outdoor
201 662K ODU, $6.7B System Market
200
175
150
125
100 90
100
80
75 60
50
50 40 41
25
0
China EU Korea Japan Russia MEA LA ROA
Value $1.4 $1.2 $1.0 $0.9 $0.7 $0.6 $0.5 $0.4

Growing At Over 2x Standard Market

Today’s Agenda
1. Emerson Overview

2. Modulation Market Overview And Trends

3. Copeland Scroll

4. Copeland Digital Scroll

5. Digital Scroll Heating

Scroll Compressor
Check Valve
Bi-Metallic Thermal Disc

IPR Valve Floating Seal

Fixed Scroll

Orbiting Scroll

Press & Stake

Main Bearing Housing DU Drive And
Main Bearings
Molded Plug

• Low Side Design

• Loss Of Charge Protection
• Vacuum Protection
Lower Bearing
• Quiet Shutdown
• IPR
16
Scroll Sets

Comprised Of Two Scroll Parts

17
How The Scroll Compressor Works

Fixed Scroll

Orbiting Scroll

18
How The Scroll Compressor Works

1. Gas Enters 2. Open Sealed Off As Gas

Drawn Into Spirals

3. Gas Compressed 4. Discharge Pressure Reached 5. Continuous Suction And

At Center Port Discharge
19
Copeland Scroll Features

1. Full Compliance (Axial And Radial)

2. Static Seals Vs. Dynamic Seals

3. DU Bearing

4. Built-In Protective Devices

20
Radial Compliance

Debris

• Ensures Scroll Contact

• But, Allows Scrolls To
Separate Sideways
• So Debris And Liquid Can
Pass Without Damage Radial Compliance

Scroll 666
Scroll
Scroll
21
Axial Compliance
Floating Seal
Upper
Scroll
(Fixed)
Maintains Constant, Even
Pressure On Scroll Tips

Floating Seal Is Key

• Optimizes Tip Loading
• Pressure Balanced
• Eliminates Leakage
• Patented Design
Lower Scroll
(Orbiting)

22
Advantages Of Full Compliance
1. High Efficiency
1. Scrolls Wear In Rather Than Wear Out
2. Less Performance Variability

2. Durability/Reliability Enhancement
1. Better Liquid Handling
2. Better Debris Handling
3. No Wear Out Unlike Tip Seal Design

3. Low Sound Level

1. Smooth Spectrum And Good Sound Quality

4. Unloaded Start

23
Static Seals Vs. Dynamic Seals

Dynamic Seal Static Seal

24
Tip Seal Operation
Cross-Sectional View Of Scroll Vane
Discharge Suction

Off-Cycle
Tip Seal

Tip Seal Recedes Into Groove At Top Of

Scroll Vane

Pressure

Tip Seal
During
Operation

High Pressure At The Discharge Port

Goes Under The Tip Seal, Pushing the Seal
Away From The Bottom Of The Groove,
Sealing The Scroll By Physical Contact
Static Seals Vs. Dynamic Seals

Dynamic Seals
– Wear

– Are Sensitive to Liquid and Debris

– Are More Quickly Damaged By Excess Heat

Static Seals
– Do Not Wear

– Are More Robust

26
Heavy Duty “DU” Bearings

Heavy Duty Material

– (1) Porous Bronze
– (2) PTFE-Lead Overlay
2 1
Allows Extended Operation
Rotating Without Full Lubrication
Surface – Exceptionally Low Friction

Used In Two Places

– Upper Main Bearing
– Orbit Eccentric

PTFE = DuPont “Teflon”

27
Protective Devices
1. Internal Motor Protector: Line Break
1. Senses Both Temperature & Current
2. Protects Against Low Voltage & Phase Loss

2. Floating Seal
1. Deep Vacuum Protection

3. Therm-O-Disc
1. Bi-Metal For High Scroll Temperature Protection

4. Internal Pressure Relief (IPR) Valve

1. High Discharge Pressure Protection

28
Today’s Agenda
1. Emerson Overview

2. Modulation Market Overview And Trends

3. Copeland Scroll

4. Copeland Digital Scroll

Copeland Digital Scroll Technology

Digital Scroll Compressor

Alternate Inverter Technology Is Complex
Resonant Frequency

Capacity Range From 40% to 100%, Not Wide Enough

Need Expensive Inverter And Electronic Controls

Oil Return Problem

EMC/EMI Issues

Complicated By-Pass Circuits

Not Easy To Service

Inverter loss & motor switching loss (15-20%)

Modulation With Inverter

System Environment
Control

~ Noise
Converter IPM Motor
Filter Desired
Speed
• A/C Signal
• Converts AC • Intelligent Power • A/C Variable
To DC Module Speed
• Generates OR
Appropriate
Motor Speed • Brushless
DC
Digital Scroll Compressor
Development History
1993 Concept Developed

1995 First Prototype Developed

1997 Completed Concept Design

1997 Tested In Constant Temp/Humidity A/C

1999 Refrigeration Application Completed

1999 Started To Develop A/C Product

2000 Stopped Variable Speed Compressor

2000 Started To Supply To Samsung

2002 Started To Supply Rest Of Asia

Digital Scroll: New Modulation Technology
New Scroll Modulation Concept
Enabled By Copeland Compliant Scroll
10~100% Continuous Capacity
Excellent Performance
Requires Simple Electronics
Scroll Movement During Operation
Floating
Seal
Fixed
Scroll



Orbiting
Scroll
Digital Scroll Capacity Modulation

Fixed Scroll
Made Unfixed

Orbiting Scroll
Modulation Mechanism

1.0 mm Scroll
Separation

Loaded (1) Unloaded (0)

Full Capacity Zero Capacity

Ex: 20% Output Ex: 50% Output

Full Capacity Full Capacity

Zero Zero
Capacity Capacity

2 8 5 5
Sec Sec Sec Sec
Seamless Capacity Delivery
Capacity = (Loaded Time x 100% + Unloaded Time x 0%)
Total Time

Example: Cycle Time = 10 Seconds

Capacity Loaded Time

10% 1.0 Second

11% 1.1 Second
12% 1.2 Second
…
…
25% 2.5 Second
…
50% 5.0 Seconds
…
90% 9.0 Seconds
Simplicity In Controls
Non Digital Scroll System Digital Scroll System

5x Electronic Hardware x
3x Valves x
Complex Oil Management Simple
Complex Programming Simple
Digital VRF 21HP System Tubing Layout
Japanese Inverter 8HP

Emerson Confidential
Copeland Scroll Operating Envelope
R-410A Digital Prototype Envelope
Evaporating Temperature (°C)
-40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20
180
81
170 76

Condensing Temperature (°C)

160 71
Condensing Temperature (°F)

150 66
140 61

130
56
51
120
46
110
41
100
36
90
31
80 26
70 21
-40 -30 -20 -10 0 10 20 30 40 50 60 70
Evaporating Temperature (°F)
Standard Operating Envelope

Inverter Scroll Has Several Restrictions In Operating Envelope

Digital Enhances End User Comfort
Temperature Control Capability To ± 0.5 ºC
Living Room On Dining Room Off Bedroom On

Room Air Temp. (C) 31

28

Bedroom
25
Set Temp 25C

22 Living Room
Set Temp 22C

19
19:19:12 19:26:24 19:33:36 19:40:48 19:48:00 19:55:12 20:02:24 20:09:36 20:16:48 20:24:00

Time
IPLV For Better Rating Of “Real” Usage
100%
100%

80%
Weighting

60%
40%
40% 30%
25%
20%
5%
0%
25% 50% 75% 100% 100%
Load

IPLV (Integrated Part Load Value) EER

A/C System Variable Capacity Fixed Speed

Weighting Close To Actual Usage 100% Load Only

 Digital Multi -System 10HP Test Data
Multi-System
As Per GB/T 18837 – 2002 & ARI210/240
COP (W/W)
4.5

Heating
4
IPLV(C) = 3.56
Cooling
IPLV(H) = 3.71
3.5

2.5

2
0 20 40 60 80 100
Capacity (%)

Test By China National Center For Quality Supervision And Test Of Electrical Appliances , June 2005
45
Energy Efficiency Performance
IPLV
4
3.56 3.45
3.00
3

2 Digital Best Average

Scroll Japanese Inverters
Inverter

IPLV – Integrated Part Load Value (Measure Of Seasonal Efficiency)

Japanese Inverter 8HP

Emerson Confidential
Testing Summary
COP At Full Load & IPLV
COP IPLV
COP

5
4.25
3.95
4
3.56
Down 34.7% Down 41% 2.95
3
2.58 2.51

0
Cooling Cooling Heating Heating IPLV Digital IPLV
Catalogue Testing Catalogue Testing

Emerson Confidential
High Ambient Cooling Capacity Performance
KW 35ºC OD, 27/19ºID KW 38ºC OD, 27/19ºID
15 15

10 10

13.63 13.52 13.20

12.42
5 5

0 0
Digital Inverter Digital Inverter

KW 43ºC OD, 32/23ºID KW 46ºC OD, 29/19ºID

15 15

10 10

13.94
12.72 11.92
5 5
7.48

0 0
Digital Inverter Digital Inverter
49
Digital Scroll: Better Dehumidification
Evap T
Digital
Digital Scroll
Scroll System
System Has
Has Lower
Lower Sensible
Sensible Heat
Heat Ratio
Ratio Curve
Curve (C)

20

16
Inverter Variable Speed

12
Digital Scroll
8

0
0 2 4 6 8 10 12 14
Capacity (KW)
Reliability - Easy Oil Return
• Easy Oil Return During Low Loads
• No Oil “Pump Out” During Unloading
• Loaded Cycle Gas Velocity Sufficient To Return Oil

• Don’t Need Oil Separator Or Oil Return Cycle

A/C Reliability (CFM) Tests
High Pressure Ratio 2,000 Hours For Lubrication / High Temperature

High Load 2,000 Hours For High Temperature / Pressure

Start / Stop 520,000 Cycles For Vibration

Flooded Start 1,000 Cycles At 100 To 150% Charge Limit For Slugging
And Lubricant Migration

Defrost Floodback 2,000 Hours At 100% Charge Limit For Liquid Slugging

Sequence 200 On / Off Cycles At Each Window Corner

30 Min / Cycle, Repeat Sequence 4 Times

Specific Tests Based On Field Data Recorder Input

Digital Solenoid Valve 40,000,000 Cycles

Digital Compressor
Asia Reliability Performance

Total Digital Compressor In

300,000+
Field

Total No. Of Compressors

~10
Field-Returned

Reliability 99.997%

Inverter Failure Rates ~2%+

 Comparison Of Electromagnetic Interference
Digital Scroll versus Inverter

Inverter EMC Regulation Digital Scroll System





 


  









Digital Scroll Is A Winning Technology
Gaining Industry Recognition
Date Country Award
Dec 2001 Korea Korea New Technology Award

Dec 2001 Korea Samsung Group Technology Award – Finalist

Dec 2001 Korea Grand Prize Of Korea Energy Award

Dec 2001 Asia Far East Economic Review Innovation Award Finalist

Dec 2002 Korea Korea New Technology Award

Nov 2002 China China Household Appliance – Best Technology

Jan 2003 USA AHR Expo Award For Technology Innovation

Mar 2006 Hong Kong Technology Achievement

2003 , 2007 AHR Expo Award
Korea’s Most Prestigious Project
Dogok Dong Condominium Complex, Seoul
Project Details
• Over 4,000 Apartments

• 1,500 – 4,000 Sq Feet

Why Digital Scroll?

• Global Technology

• International Credibility

• Best-In-Class

• Best Performance

• Superior Reliability
Dogok Dong Complex, Seoul 4,000 Digital Scroll Systems
ABP Business Park – Beijing, China
Largest Commercial Project In
China
10.2 Million Sq Feet
500 Individual Buildings
Samsung/Digital Scroll Won
Project
3 Month Field Test With
Competition
Digital Scroll Has Excellent Performance
• Energy Saving
• Excellent EER / SEER
• Better Comfort
• Precise Room Temperature Control
• Effective Room Humidity Control
• Wider Capacity Range
• Reliable
• Simple System
• No Oil Return Issue
• No Electromagnetic Interference Issue
www.digitalscroll.com