Emerson XJAM-030Z-TFC-022, XJAL-050Z-TFC-012, XJAL-050Z-CFV-022, XJAM-030Z-TFC-012, XJAL-020Z-CFV-022 User Manual

...

TABLE OF CONTENTS

Safety Instructions ..................................................... 2

Safety Icon Explanation

.......................................... 2

Instructions Pertaining to Risk of Electrical Shock,

Fire, or Injury to Persons .......................................... 3

Safety Statements

................................................... 3

1. Introduction ......................................................... 4

2. Nomenclature/Features ...................................... 4

3. Understanding Actual vs. Standard Airflow .... 4

4. Performance Data ............................................... 4

5. Electrical / Physical Data ................................... 4

6. Generator Requirements ................................... 4

7. Physical Dimensions .......................................... 5

8. Installation / Piping Instructions ....................... 5

9. Condensing Unit Operational Control .............. 5

10. Control Features ............................................ 5

10.1. Fresh Start Program .................................... 5

10.2. Stop Program ............................................... 5

10.3. Automatic Liquid Injection (Medium

temperature units only) ............................................. 5

10.4. Compressor Phase Reversal ....................... 5

10.5. Loss of Phase Protection ............................. 6

10.6. Motor Current Overload ................................ 6

10.7. Non-Adjustable High Pressure Control ........ 6

10.8. Adjustable Low Pressure Switch .................. 6

10.9. Liquid Floodback Protection ......................... 6

10.10. Crankcase Heater ..................................... 6

10.11. Condenser Fan Speed Control ................. 6

10.12. Enhanced Vapor Injection (EVI) Control

(Low temperature units only) .................................... 6

11. Electronic Expansion Value (EXV) ................ 7

12. TXV selection .................................................. 7

13. Other Inputs to the Control Board ................ 7

13.1. Customer Supplied Control (Thermostat)..... 7

14. Other Outputs from the Control Board ........ 7

14.1. Defrost Control Board for Units Produced

Prior to Mid- 2013 ..................................................... 7

15. Updated Defrost Control Module .................. 8

16. Evaporator Fan Control ................................. 8

17. Diagnostic Display Board .............................. 8

APPENDIXES

Appendix 1 - Electronic Defrost Control Appendix 2 - Defrost Quickstart

Appendix 3 - XWeb Instructions Appendix 4- E2 Instructions

TABLE OF FIGURES

Figure 1 - Nomenclature and Features ........................ 9

Figure 2 - Physical and Installation Requirements .... 10

Figure 3 - Power Board / Control Board .................... 11

Figure 4 - Defrost Control Module.............................. 12

Figure 5 - Communication Board ............................... 12

Figure 6 - Emerson Supplied Defrost (-002/-012 Models

Only) ........................................................................... 12

Figure 7 - Quick Setup Guide for Electronic Low

Pressure Control ......................................................... 13

Figure 8 - Diagnostics Module Start Up Information .. 27

TABLES

Table 1 - Temperature Conversion Factors ................. 4

Table 2 - Altitude Conversion Factors (A2) .................. 4

Table 3 - Medium Temp Performance Criteria for R-

404A ........................................................................... 24

Table 4 - Low Temp Performance Criteria for R-404A

................................................................................... 24

Table 5 - Mechanical/Electrical Specifications ........... 25

Table 6 - Emerson Supplied Defrost Set Points ........ 25

Table 7 - Main Control Board Settings ....................... 26

Table 8 - Diagnostics Module Display ....................... 27

Table 9 - Refrigerant Liquid Temperature Valve

Capacity Multiplier Correction Factors ....................... 28

Table 10 - Pressure Control Settings for SJAL/M Units

.................................................................................... 28

Table 11 - System Diagnostic Information ................. 29

Table 12 - Sensor Information .................................... 33

AE5-1377 R3

June 2013

Copeland Scroll™ Outdoor Refrigeration Unit

AE5-1377 R3

Safety Instructions

Copeland Scroll™ compressors are manufactured according to the latest U.S. and European Safety Standards.

Particular emphasis has been placed on the user's safety. Safety icons are explained below and safety instructions applicable to the products in this bulletin are grouped on Page 3. These instructions should be retained throughout the lifetime of the compressor. You are strongly advised to follow these safety instructions.

Safety Icon Explanation

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE is used to address practices not related to personal injury.

CAUTION, without the safety alert symbol, is used to address practices not related to personal injury.

FLAMMABLE, Fire hazard! Sparking in a potentially explosive atmosphere! Explosion hazard!

WARNING

CAUTION

NOTICE

DANGER

CAUTION

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Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons

ELECTRICAL SHOCK HAZARD

• Disconnect and lock out power before servicing.

• Discharge all capacitors before servicing.

• Use compressor with grounded system only.

• Molded electrical plug must be used when required.

• Refer to original equipment wiring diagrams.

• Electrical connections must be made by qualified electrical personnel.

• Failure to follow these warnings could result in serious personal injury.

PRESSURIZED SYSTEM HAZARD

• System contains refrigerant and oil under pressure.

• Remove refrigerant from both the high and low compressor side before

removing compressor.

• Never install a system and leave it unattended when it has no charge, a holding charge, or with the service valves closed without electrically locking out the system.

• Use only approved refrigerants and refrigeration oils.

• Personal safety equipment must be used.

•

Failure to follow these warnings could result in serious personal injury.

BURN HAZARD

• Do not touch the compressor until it has cooled down.

• Ensure that materials and wiring do not touch high temperature areas of the

compressor.

• Use caution when brazing system components.

• Personal safety equipment must be used.

•

Failure to follow these warnings could result in serious personal injury or

property damage.

COMPRESSOR HANDLING

• Use the appropriate lifting devices to move compressors.

• Personal safety equipment must be used.

•

Failure to follow these warnings could result in personal injury or property

damage.

Safety Statements

• Refrigerant compressors must be employed only for their intended use.

• Only qualified and authorized HVAC or refrigeration personnel are permitted to install commission and

maintain this equipment.

• Electrical connections must be made by qualified electrical personnel.

• All valid standards and codes for installing, servicing, and maintaining electrical and refrigeration equipment

must be observed.

CAUTION

WARNING

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1. Introduction

Copeland Scroll™ Outdoor Refrigeration Units provide the many benefits of scroll compressor technology, coupled with advanced diagnostic controls, to ensure reliable performance and operation in foodservice applications. Electronics are used extensively in its protection and diagnostic features. These features are controlled by an electronic integrated control board. The control board provides base control functions related to temperature controller, defrost, evaporator fan control, compressor protection e.g. current overload, phase reversal, liquid/ vapor injection control, self diagnostics and warnings. These error codes can be seen by an LED display for easy and rapid troubleshooting and maintenance.

A complete product offering for medium and low temperature units is being offered in single and three phase 208/230 volts. The -002 and -012 BOM product is approved for operation in ambients from 120°F to 10°F.

XJAM/XJAL -022 models come factory equipped with a heated and insulated receiver (thermostat controlled), a check valve installed between the condenser outlet and receiver inlet, and a 6 second low pressure control time delay function.

XJAM/XJAL -022 models are approved to operate in ambient temperatures below -10°F (-24°C). Laboratory testing has confirmed successful operation at -30°F (34°C) with the factory supplied low ambient components. At low ambient conditions, a unit may recycle on low pressure several times during a restart. This is normal behavior.

2. Nomenclature/Features

See Figure 1 at the end of this bulletin.

3. Understanding Actual vs. Standard Airflow

To choose the proper coil for your application, the density of the incoming air needs to be known to calculate the actual capacity and performance of the system.

A coil’s required capacity can be calculated using the thermodynamic equation

Q = M x Delta hr Q = Heat transfer to or from the air (Btuh) M = Mass flow rate of air (lb/hr) Delta h ] Difference between the entering and leaving air

enthalpy or total heat (Btu/lb)

The mass flow rate is equal to the density of air times the face area of the coil times the velocity of the air at the coil or face velocity.

M = P x A x V P = Density (lb/cubic ft.) A =Face area of coil (square ft.)~Fin height x fin length V = Air Velocity (ft./min.)

For temperature conversions

(𝑨𝟏)

𝟓𝟑𝟎

𝑻+𝟒𝟔𝟎

Table 1 - Temperature Conversion Factors

Temp (°F)

Factor A1

Temp (°F)

Factor A1

1.15

1.02

1.13

1.00

1.10

.98

1.08

.96

1.06

100

.95

1.04

110

.93

Table 2 - Altitude Conversion Factors (A2)

Alt (ft.)

Factor A2

Alt (ft.)

Factor A2

1.00

3000

.895

500

.982

4000

.864

1000

.965

5000

.832

1500

.947

6000

.802

2000

.930

7000

.771

2500

.912

8000

.743

SCFM= CFM X A1 X A2 Note: all calculations and ratings are based on standard

air at 70°F dry bulb temp and 29.92 Hg atmospheric pressure (sea level). These tables convert non standard cfm to standard cfm.

4. Performance Data

See Table 3 and Table 4 at the end of this bulletin.

5. Electrical / Physical Data

See Table 5.

6. Generator Requirements

In situations or locations were an electrical power generator could be applied in the event of a power

outage, the Copeland Scroll™ outdoor condensing unit

will operate providing the generator will provide a supply

AE5-1377 R3

voltage range of 180-260 VAC along with a frequency of 47-63 Hz. The electronics control along with the power board will function properly providing the range of operating limits is in compliance!

7. Physical Dimensions

See Figure 2.

8. Installation / Piping Instructions

See Figure 2 for overall dimensions of the units. It is recommended that a clearance of 8 inches from the wall

(or the next unit) be maintained from the unit’s left and

rear panel whereas a clearance of 20 inches is to be maintained from the unit's right, top and front panels. Both service access and airflow have been considered in making these recommendations. Where multiple units are to be installed in the same location, careful consideration for proper clearance needs to be given to each individual unit.

Ideally, the unit should be mounted level on a solid concrete slab with rubber strips between unit feet and concrete. However, these units have been designed for mounting on suitable brackets for wall mounting. In this case it is equally important that the spatial guidelines given above are followed, and additional consideration needs to be given for possible air recycling if units are stacked above and below each other. In general terms, air by-pass around each condenser and between each unit should be avoided at all times.

Pipe sizing should not only be of sufficient size to ensure optimum performance and good oil return, but it also needs to take into account the full capacity range through which this particular unit will need to operate. Follow the ASHRAE guidelines for proper piping practices.

9. Condensing Unit Operational Control

The Digital Control electronic control board controls the operation of the condensing unit. Whenever there is a control input asking to start or stop the condensing unit, the control board will execute a set of pre-programmed procedures to do so. It also monitors the compressor operating parameters, so as to protect the system from unsafe operating parameters. See Figure 3.

For example, when the low temperature unit experiences an extreme temperature day, the control board decides to switch from vapor-injectionoptimization to discharge gas temperature control to allow the compressor to run safely and pass the extreme weather hours.

10. Control Features

The base control function is for the following standard features. See Figure 3 for additional input options and output options of the control board.

10.1. Fresh Start Program

This Fresh Start Program is a bump start procedure that will energize and start the compressor for 3 seconds and then will be followed by a 20 second off cycle time. This will occur for 3 cycles, and then continuous power will be supplied to the compressor for normal operation.

The Fresh Start Program will be executed on initial start up or any time power is reapplied when the ambient temperature is lower than 95°F. In addition, the Fresh Start Program will be executed for any start when the unit has been cycled off for more than an hour when the ambient temperature is lower than 95°F.

10.2. Stop Program

When the unit is satisfied, or there is any error which requires the unit to be shut down, the controller will execute a Stop Program. The compressor and the condenser fans will cycle off and the injection valves will close.

For low temperature units only, when the unit is satisfied the EXV will start closing immediately, but the compressor will delay 5 seconds before shut down to prevent reverse rotation of the compressor.

10.3. Automatic Liquid Injection (Medium temperature units only)

Automatic Liquid Injection ensures that the scroll compressor operates within a safe temperature limit. This unit employs a patented liquid injection system which injects a saturated refrigerant into the suction line at the compressor. Activation of the liquid injection valve is in response to a thermistor which is attached to the compressor discharge line. A signal is sent to the stepper motor of the injection valve, opening the valve in response to increasing discharge temperatures and injecting saturated refrigerant to reduce the discharge temperature.

10.4. Compressor Phase Reversal

Compressor Phase Reversal senses for the correct phase sequence on three phase applications. Reset is automatic once the correct phase sequence is sensed. An error message will be shown on the diagnostic LED.

AE5-1377 R3

10.5. Loss of Phase Protection

If three phase supply is incorrectly connected to the contactor terminals, or if a missing phase is sensed, an error message will be shown on the diagnostic LED.

Reset is automatic once the correct phasing is sensed.

10.6. Motor Current Overload

• All scroll compressors used in these condensing units have an internal inherit motor protector.

• The Copeland Scroll Outdoor Condensing Unit is also equipped with two current sensors (CT1, CT2) to monitor the electrical current of the condensing unit. If the condensing unit current exceeds a predefined current limit, the controller will take the following actions:

➢ Stop the compressor for 3 minutes ➢ LED signal will display an Over Current Error for 3

minutes

➢ After a 3 minute delay the compressor will go

through a normal start

➢ The system will lock out after 6 over current trips

within an hour

For this function to operate, two of the power leads are routed through the current sensing coils (CT1, CT2), prior to the contactor, from the factory. See Figure 3.

10.7. Non-Adjustable High Pressure Control

This pressure sensing device is a nonadjustable, low voltage pressure switch that will open at 435psig and reset at 348psig in the event of high discharge pressure. Its signal is monitored by the control board.

➢ In the event of a high pressure trip, the unit will stop

and then restart after a 3-minute delay.

➢ After 6 successive HP cut-outs within 1 hour, the

unit will lock-out.

➢ The lockout feature can be reset by disconnecting

the power source and then cycling power to the unit.

10.8. Adjustable Low Pressure Switch

An adjustable low pressure switch is provided as standard equipment on both the medium and low temperature condensing units. This control can be used for a pump-down cycle if so desired. See Table 10 - Pressure Control Settings for SJAL/M Units.

Units introduced in mid-2013 include an electronic low pressure control. The electronic low pressure control provides more accurate cut-in and cut-out pressure

settings and maintains these settings without drifting over time. See Figure 7 for setup procedure.

10.9. Liquid Floodback Protection

• Liquid refrigerant entering the compressor during the run cycle, in excessive quantities, can damage the compressor by diluting the lubricant, as well as excessive stress on several components in the compressor. Proper control of liquid refrigerant within the system is an application issue and is beyond control of this controller. However, the controller can perform checks and alert the user that liquid refrigerant floodback may be occurring and immediate field service is required. This is only a warning signal and will not terminate the operation of the unit. See Table 6.

• Liquid Floodback Protection is acquired by monitoring the compressor discharge temperature. When the discharge line temperature falls below a specified point, low suction line superheat may be the cause.

10.10. Crankcase Heater

The crankcase heater is wired through a normally closed contact of the compressor contactor which is energized whenever the compressor cycles off.

10.11. Condenser Fan Speed Control

The Condenser Fan Speed Control will vary the speed of the condenser fan motor for head pressure control under low ambient conditions. There are two thermistor type sensors that are connected to the control board. These sensors monitor the condenser mid coil temperatures and ambient air temperatures to control the fan speed.

10.12. Enhanced Vapor Injection (EVI) Control (Low temperature units only)

The EVI system improves low temperature operational efficiency and provides a reliable low temperature envelope. It is used to optimize performance and to prevent the scroll set from overheating. This is done by controlling the discharge line temperature (DLT) and vapor injection superheat (VISH).

Enhanced vapor injection is accomplished by utilizing a subcooling circuit. A heat exchanger is used to subcool the liquid refrigerant before it enters the evaporator. As a result of the subcooling done by the heat exchanger, refrigerant will also be evaporated. This evaporated refrigerant is then injected into the mid compression cycle of the scroll compressor for overheat temperature control.

AE5-1377 R3

There are two thermistors sensing the discharge line temperature, one is located at the discharge line of the compressor and the second one is placed at the inlet of the condenser coil. In order to have a higher temperature resolution, the discharge line thermistor and condenser coil inlet sensor cooperate to sense a temperature range from 50°F to 329°F. The discharge line thermistor has a sensing range from 163°F to 329°F and the condenser coil will sense temperature from 50°F to 176°F. The EVI system will keep the discharge line temperature below 230°F to ensure the safety of the compressor.

It is important to insulate the system liquid line from the condensing unit to the evaporator. The recommended insulation thickness is a minimum of ½ inch. Also the lower liquid temperature can increase the evaporator expansion valve capacities. Please follow the valve manufactures recommended liquid temperature correction factors for proper selection of the evaporator expansion valve.

11. Electronic Expansion Value (EXV)

The Electronic Expansion Value (EXV) is a key part of the EVI system. It will regulate vapor injection flow to optimize the performance of system and cool the scroll set. Every second, the control chip will collect the thermistors reading and do a four second averaging. The EXV opening will be changed every 20 seconds and the variation is calculated by different ways based on different purposes.

12. TXV selection

For EVI, Emerson recommends a balanced port TXV because it offers a wider operating range for floating liquid temperatures.

See Table 9 for specifics regarding balanced port sizing recommendations. Applied with the low temp units it is recommended that a balanced port expansion valve be used along with a complete review of the the distributor & nozzle (orifice) that is supplied with the Evaporator coil being matched with the applicable condensing unit. Typically nozzles are selected for standard TXV sizing using 100°F liquid, with the XJAL those typical selections could be grossly oversized. See Table 9 for the liquid correction safety factors when selecting those components.

13. Other Inputs to the Control Board

13.1. Customer Supplied Control (Thermostat)

The control board will accept a normal 220 volt AC input ON/OFF signal such as the switching action of a normal commercial thermostat and relay. If the system is controlled by low pressure control for a multiple

evaporator system and/or pump down system, the control board will accept the signal directly from the control. See Wiring Diagrams, for proper installation.

14. Other Outputs from the Control Board

14.1. Defrost Control Board for Units Produced Prior to Mid- 2013

(using the control module shown in Figure 4.) The defrost control board is a basic time initiated module which is standard on both low and medium temperature units. The defrost control board can control either offcycle or electric defrost.

The defrost control board will control the liquid line solenoid valve. When defrost is initiated the liquid line solenoid valve will close and the unit will go into a pumpdown cycle. When the suction pressure equals the setting of the low pressure control, the compressor will cycle off. After the defrost time has expired, the liquid line solenoid valve opens and then

the low pressure control will allow the compressor to restart.

On -002 and -012 models only, due to heater amperage loads, electric defrost requires an additional relay or contactor to energize the defrost heater. Relays capable of 30 amp loads are supplied on the -022 models

The defrost cycle can be executed either automatically or manually. There are two rotary dip switches by which the user can set up the defrost cycle, see Figure 4. One rotary dipswitch sets the defrost duration (SW1) and the second rotary dipswitch sets the time interval between defrost cycles (SW2). For automatic defrost set SW1 and SW2 as desired. See Table 6 for time settings. The defrost control board also incorporates a manual defrost button that enables a manual defrost as an override to the rotary switch setting the defrost interval. Upon the completion of a manual defrost, the system will reset to the refrigeration cycle with the same procedures as automatic defrost and then the automatic defrost timer will reset.

For setting manual defrost only set SW1 as desired and set SW2 to “0”. Whenever the manual defrost button is pressed, one defrost cycle will be executed and the duration of defrost will be determined by the setting of the rotary dipswitch SW1.

Note: There is no method to terminate a defrost cycle without resetting the control board.

Table 6 lists rotary dip switch settings for the Defrost Control Board.

An ON/OFF output connection is provided on the control board (JP10) for direct connection of a customer

AE5-1377 R3

supplied contactor coil/relay when the defrost option is used. Terminals are male spade type. Coil voltage rating should be 220VAC and current ratings, 30VA (hold) and 330VA (inrush). See Figure 6.

For customers using their existing defrost timer, remove the defrost cable connecting the defrost control board to the unit control board. Also on the unit control board change the mode setting dip-switch bit 2 to ON and proceed to standard defrost wiring. See Table 7.

15. Updated Defrost Control Module

Models produced after mid 2013 include an updated electronic control module that allows for both interval based defrost or real time based defrost. See Figure 7 for quick setup guide. See Appendix 2, Defrost

Quickstart, for detailed information.

16. Evaporator Fan Control

An ON/OFF output connection is also provided on the control board (JP9) for direct connection of a customer supplied contactor coil controlling the evaporator fans.

Terminals are the male spade type. Coil voltage rating is to be 220VAC and a maximum power rating of 30VA (hold) and 330VA (inrush). See Figure 6.

17. Diagnostic Display Board

Each condensing unit is supplied with a one-way communications and diagnostic display board, see Figure 5. A two character display will make up the diagnostic/error code. The first character will display the unit status as shown in Table 8. The second character will display the error/warning code as shown in Table 8. See Figure 5 for a detailed view of the diagnostics board assembly.

The Main Board Connector terminal will accept the cable connecting the display board to the main control board. The Reset Button will reset the diagnostic display board only. The Message Recall Button will display the last error signal received by the display board. See Figure 5.