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The scroll is a simple compression concept first patented in 1905. A scroll is an involute spiral which, when matched with a mating spiral scroll form as shown above, generates a series of crescent-shaped gas pockets between the two members. Scroll compressors work by moving one spiral element inside another stationary spiral to create a series of gas pockets that become smaller and increase the pressure of the gas. The largest openings are at the outside of the scroll where the gas enters on the suction side. As these gas pockets are closed off by the moving spiral they move towards the center of the spirals and become smaller and smaller. This increases the pressure on the gas until it reaches the center of the spiral and is discharged through a port near the center of the scroll. Both the suction process (outer portion of the scroll members) and the discharge process (inner portion) are continuous.

The moving scroll moves in an orbiting path within the stationary (fixed) scroll as it creates the series of gas pockets. During compression, several pockets are being compressed simultaneously, resulting in a very smooth process. By maintaining an even number (6 in a Copeland Scroll compressor) of balanced gas pockets on opposite sides, the compression forces inside the scroll work to balance each other and reduce vibration inside the compressor.

The scroll compressor design also provides more advantages vs. other compression technologies. By eliminating the use of a fixed cylinder and a piston or single sided compression mechanism, the compressor can use the scrolls to eliminate wasted space in the compression chamber and avoid recompression that you see in standard reciprocating compressors. This reduces energy wasted on compressing gas again and again during operation. The scroll compressor design also eliminates the need for suction and discharge reeds needed to control gas flow in single-sided compression processes like reciprocating and rotary compressors. These components are sensitive to problems in the refrigeration process like liquid and debris damage.

Copeland Scroll compressors are unlike other scroll compressors that use sealing devices and sensitive manufacturing processes to maintain the compression pockets. The scroll elements in a Copeland Scroll compressor are in contact only with each other and are designed to wear in to each other to eliminate imperfections that might cause leaks in other compressor designs. This allows Copeland scroll compressors to maintain their high levels of performance throughout their life.

In addition to this wear in process Copeland Scroll compressors also have design features to handle bigger problems inside the system. The scrolls are designed to separate temporarily if they encounter liquid or debris and pump the material out of the discharge before they come back into contact and resume compressing gas. This small amount of movement is designed in to allow the compressor to pass the material out of the gas pocket without damaging any of the surfaces and creating leaks or failures.

These design features of the Copeland Scroll compressor all work together to create the most efficient and reliable compressors available. They also have created opportunities for system improvements driven by compressor modulation (capacity changes) without a large number of external components. By taking the built-in capabilities for motion of the spirals and building in a control mechanism to actively control the separation time we created the Copeland Scroll Digital.  This simple solution allows the compressor to continue running while reducing the amount of gas compressed and the energy used to match exactly what is needed. This means that the compressor uses fewer power cycles (on and off) to manage the capacity and avoids the costly starts and stops that consumes large amounts of electricity. This creates a highly-efficient and simple to apply solution for all types of refrigeration and air conditioning systems.  For more details on the history of Copeland Scroll compressors and to learn why there are more than 60 Million Copeland Scroll compressors installed today see the Copeland Scroll compressor history below.

COPELAND SCROLL™ COMPRESSOR STORY

In 1987 Emerson Climate Technologies launched the first generation of Copeland Scroll compressors to meet the needs of manufacturers and consumers with the introduction of the ZR1 (1^st generation). This product provided a high-reliability alternative to the reciprocating compressors that dominated the market in 1987. With increased reliability and efficiency Copeland Scroll compressors grew over the next 21 years to the point that there are more than 60 million installed in systems worldwide. The reliability and performance standards which have been established by the Copeland Scroll compressor have yet to be matched by any other manufacturer of compressor technology in production today.

In an effort to prepare the industry for the increase in minimum efficiency requirements in 1992, Emerson Climate Technologies launched the ZR2 compressor in 1991– offering a higher EER and expanding scroll to 4-5 horsepower. The ZR2 compressor raised performance levels to 11.5 EER at ARI and 19.5 EER at CHEER while offering even higher levels of reliability. Very rapidly the ZR2 had become the compressor of choice by virtually every manufacturer of high efficiency systems.

Later, in 1993, Emerson Climate Technologies introduced the next generation of scroll technology – the ZR3 compressor. This model incorporated the latest engineering developments in Copeland Scroll compressors. As a result the ZR3 becomes the first compressor to break through the 20.0 CHEER rating barrier, offering up to twelve percent higher efficiency than advanced reciprocating compressors on the market at that time. This new performance plateau was established while maintaining the high standards of durability and liquid handling inherent in Copeland Scroll technology. The ZR3 product line includes 11/2 to 4 ton models designed for both residential air conditioning and heat pump applications.  In addition to this 3^rd generation of Copeland Scroll the ZRKC was launched as a new family of 2 ton to 6 3/4 ton Copeland Scroll compressors, designed specifically for 10.0 SEER unitary applications and 9.0 EER commercial applications.   

Since that time Copeland Scroll technology has been adapted and modified to fit any desired operating condition. By redesigning motors and making changes in the performance characteristics of the scroll sets, Emerson Climate Technologies can adapt the revolutionary Copeland Scroll compressor to meet any market need.

By broadening the scroll product offering, Emerson Climate Technologies now brings the advantages of scroll technology – higher efficiency, superior sound performance and unmatched reliability potential to more models. Each model employs the axial and radial compliance for which Copeland Scroll is famous, making it the most efficient hermetic compressor in its class.

Copeland Scroll technology has proven to be the ultimate technology for today's compressor designs, as well as those of the future. As the world leader in scroll technology, you can expect Emerson Climate Technologies to continue to advance state-of-the-art products to meet the industry's ongoing requirements for higher efficiency systems.

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