Emerson Copeland XC643 User guide

Application Engineering
B U L L E T I N
AE8-1386 R1 October 2013
Application Guidelines for the
Emerson Closed Loop Digital Controller (XC643)
Table of Contents
Safety
Safety Instructions....................................................2 How to See and Modify the Set Points..................... 11
Safety Icon Explanation............................................2 How to Modify the Set Point of Compressors
Instruction Pertaining to Risk of Electrical Shock, and/or Fans.........................................................12
Fire, or Injury to Persons...........................................3 The Info Menu.........................................................12
Safety Statements ....................................................3 How to Enter the “Pr1” Parameter List .....................12
How to Enter in Parameters List “Pr2” .....................12
Introduction How to Change Parameter Values..........................12
Overview ..................................................................4 Keyboard Locking....................................................13
Product Specifications ..............................................4 Parameters .............................................................13
Components.............................................................5 Compressor Regulation...........................................13
Digital Compressor Regulation................................14
Installation and Controller Operating Instructions Fan Regulation........................................................15
Wiring & Electrical Connections................................6 Use of the Programming "HOT KEY".......................15
Probes Connection...................................................6 Parameter Default Values and Descriptions ............16
Probe Wiring.............................................................6 Commissioning the XC643CX.................................17
Systems with Compressor Pumpdown Cycle............8 Commissioning the XC643 in the E2.....................17-21
Mounting & Installation..............................................8
Controller Display......................................................9
Controller Startup.....................................................10
First Installation......................................................10
How to Set the Kind of Refrigerant.........................10
How to Set the Kind of Probes............................... 11
Programming Procedure........................................ 11
Probe Errors.......................................................... 11
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Application Engineering
B U L L E T I N
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Safety Instructions
Copeland™compressors are manufactured according to the latest U.S. and European Safety Standards.
Particular emphasis has been placed on the user's safety. Safey 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.
SafetyIconExplanation
DANGER
WARNING
CAUTION
NOTICE
CAUTION
© 2013 Emerson Climate Technologies, Inc.
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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.
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Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons
WARNING
WARNING
WARNING
CAUTION
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.
•
•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.
•install, commission and maintain this equipment.
•
•All valid standards and codes for installing, servicing, and maintaining electrical and
refrigeration equipment must be observed.
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Application Engineering
B U L L E T I N
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INTRODUCTION
The XC643CX is designed to manage one Copeland™
digital compressor on a single-compressor condensing
unit, or two compressors in parallel, with one digital
compressor in addition to a fixed-speed compressor.
The controller also manages condenser fans. Control
is based on the pressure or temperature sensed in the
low pressure suction (compressors) and high pressure
(condenser) circuits.
The front panel offers information on the system status,
the status of loads, and any alarm conditions. The
controller can be easily programmed through a hot key.
The controller can be connected to a monitoring system
via the serial TTL output, using the standard ModBus
RTU protocol.
Overview
On refrigeration applications where the load may vary
over a wide range, some means of capacity control is
often desirable for optimum system performance and
control. In addition, compressor capacity modulation
can reduce power and energy consumption, reduce
Table 1 - Modulation Ranges
Modulation Range
Compressor Family of Full Load
Capacity
Scroll Digital ZBD/ZRD/ZFD/ZPD 10-100%
3D Discus Digital 10-100%
4D Discus Digital 55-100%
6D Discus Digital 70-100%
compressor cycling, and decrease the starting
electrical load. In order to achieve these objectives,
Emerson Climate Technologies has developed the
Copeland Discus Digital™and Copeland Scroll Digital™
compressors.
The XC643 is one module (one part number) which
can support scroll and Discus digital (3D, 4D, 6D)
compressors. See Table 1 for specific modulation
ranges.
For more details on Copeland digital compressors refer
to the following Application Engineering guidelines
or contact your Emerson Climate Technologies
representative:
AE21-1319, Digital Capacity Control for Refrigeration
Scroll Compressors
AE21-1355, Digital Capacity Control for Copeland and
Intelligent Store Discus Refrigeration Compressors
AE4-1357, Upgrade Procedures for Parallel Applications
Using Digital Capacity Control for Copeland and
Intelligent Store Discus Refrigeration Compressors (for
3D Discus)
AE4-1373, Upgrade Procedures for Parallel Applications
Using Digital Capacity Control for Copeland and
Intelligent Store Discus Refrigeration Compressors (for
4D & 6D Discus)
The simplest way to apply the XC643 digital controller
is with one suction pressure transducer or evaporator
temperature sensor. The controller reads the suction
pressure and modulates the digital compressor as
Table 2 - Product Specifications
Housing: Self extinguishing ABS.
Case: Front panel 32x74 mm (1.26x2.91 inch), depth 70mm (2.76 inch)
Mounting: “CX”format panel mounting in a 29x71 mm panel cut-out (1.14x2.80 inch)
Protection: IP20
Frontal protection: IP65
Connections: Removable terminal block 6 and 14 wires
Power supply: 24Vac/dc * 10%, 50-60Hz.
Power absorption: 5VA max
Display: 4 digits red led and 4 digit orange led.
Serial output : TTL standard Communication protocol: ModBus - RTU
Operating temperature: -28 to +60°C (-20 to +140F); Storage temperature: -25-60°C (-13-140F)
Relative humidity: 20-85% (no condensing)
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needed. If condenser fan control is also needed, a
second pressure transducer or condenser temperature
sensor can be added to read the high side pressure at
the exit of the condenser (reading liquid pressure or
liquid temperature).
This digital controller will also work with temperature
sensors rather than pressure transducers. The two
different types of sensors (temperature and pressure)
cannot be mixed. For example, you cannot use a
pressure transducer for suction and a temperature
sensor for condensing in an application.
Pressure transducers and NTC temperature sensors
are available with the controller kit. If you want to use a
different pressure transducer, consult your Application
Engineer.
Table 3 - Components
Part Number
998-0189-00
943-0017-00
929-0005-00
939-0007-00
939-0008-00
939-0009-00
943-0018-00
943-0019-00
962-0007-00
Description
Complete kit with controller, wire harnesses, pressure and NTC temperature
transducers
Controller only
Wire harness only
Pressure transducer only, PP11 suction
Pressure transducer only, PP30 discharge
Temperature transducer only
TTL/ RS485 Serial Converter
Hot key
Optional terminal box
PP11 - PP30 - Bar
7/16”-20UNF
18,5 12,5 17
48
Figure 1 - XC643CX 14 and 6 Pin Connectors
The XC643CX is provided with 2 socket connectors with
14 and 6 pins. These cable harnesses must be used.
© 2013 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
Figure 2 - Standard Pressure Transducer
PP11 -0.5 to 7 bar (-7 to 100 psig) suction, female
PP30 0 to 30 bar (0 to 435 psig) discharge, female
Note: Alternative pressure transducers may be used.
Refer to Table 7.
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TTL/RS485 external converter: used to convert the
TTL output into a RS485 (+) and (-) signal for the
monitoring system MODBUS_RTU compatible.
(XWEB).
Note! When connecting to an E2 System controller for
supervisory control, the polarity from the XC643 should
be reversed from the polarity at the E2 communication
port. The XC643CX uses a 9600 baud rate.
Figure 3 - TTL / RS485 Serial Converter
INSTALLATION AND CONTROLLER OPERATING
INSTRUCTIONS
Wiring and Electrical Connections
Before connecting cables make sure the power supply
complies with the rated voltage requirements. Separate
the probe cables from the power supply cables, the
outputs and the power connections. Do not exceed
the maximum current allowed on each relay (3A
resistive). In case of heavier loads use a suitable
external relay or contactor. Always use a Class 2
transformer with minimum power 5VA.
The power supply for the controller is 19-28VAC,
48-62Hz. The maximum load is 5 VA. 24V power to
the module must be on any time the unit is on and
should not be interrupted by any control. Center tap
transformers are not to be used.
Probes Connection
If using terminal ends be sure there are no bare parts
which could cause short circuiting or introduce noise
disturbance at high frequencies. To minimize the
induced disturbances use shielded cables with the
shield connected to earth.
Pressure probe (4 - 20 mA): respect the polarity.
Pb1 is suction; Pb2 is condenser.
Temperature probe (NTC 10K): Temperature probes
should be insulated from direct air streams to correctly
measure the temperature.
Probe Wiring
The XC643CX is capable of regulating the compressors
and condenser fans on any of the following types of
pressure/temperature sensors. The user must use the
same type of sensor to control the compressors and
the fans.
- 4-20mA pressure transducers (refer to Figure 4a)
- 0.5-4.5V ratiometric pressure transducers (refer
to Figure 4b)
- NTC 10K temperature sensors (refer to Figure 4c)
Note! The 14-pin connector consists of low voltage
wires. Keep the cables away from the power cables.
Use shielded cable to lengthen the cables.
PIN 4 is the common line for the temperature probes PIN
6 gives a 12Vdc supply for the 4-20mA pressure
transducers
PIN 10 is the ground connection for ratiometric pressure
transducers
Digital Line O
Fan2 Fan1 Comp2 Comp ut
15 17 19
16 18 20
Pb1*Pb2*
1 5 7
Hot Key/TTL
2 4 6 8 10
Supply
24V
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12V
40mA
Figure 4 - XC643 Module Connections
6

Pb1
Pb2
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PP11, PP30, 4-20mA pressure transducers
respect the polarity. Pb1 Pb2
dEU= Pr4 5 7
Suction
Brown (+) to terminal 6 ; white (-) to terminal 5 4 6 8
Condenser
12V §
Brown (+) to terminal 6 ; white (-) to terminal 7
40mA
Figure 4a - Wiring Diagram for 4-20 mA Pressure Transducer
Pb1 Pb2
Temperature probes (NTC 10K)
dEU= tPr
Suction: 4-5
Condenser: 4-7
5 7
4 6 8
Figure 4b - Wiring Diagram for NTC 10K Temperature Probes
Ratiometric transducers (0.5 -4.5Vdc)
dEU= Pr5 Gnd
Suction
In In
5 (control); 4(+); 10 (gnd) 1 5 7
Condenser 2 4 6 8 10
7 (control); 4(+); 10 (gnd) + Gnd
5V §
40mA
Figure 4c - Wiring for Ratiometric Pressure Transducers
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•1.5”
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Systems with Compressor Pumpdown Cycle Mounting and Installation
In systems that require a compressor pumpdown,
special attention should be paid to the control logic
for the digital unloader coil. Inherent to the digital
control, the compressor will effectively ramp down and
track the suction pressure by loading and unloading
to decreasing modulation rates. In order to avoid an
extended compressor pumpdown cycle, the digital
solenoid should be wired/controlled such that when a
pump down cycle is initiated the coil is de-energized.
This will force the compressor to run fully loaded (100%
capacity). Refer to AE-1182 and AE-1221 for more
details on pumpdown cycles.
Note: The Digital unloader solenoid is always energized
for 2 seconds upon start-up and at shut down of the
compressor.
PANEL
BRACKET
If this controlleris used outside,it should be enclosed in a
box with IP65 rating. Controllers should be mounted on
panel, in a 29x71 mm (1.14x2.80 inch) hole, and
fixed using the special brackets supplied. The controller
should not be mounted on the compressor nor in the
compressor terminal box.
The ambient operating temperature range is between
14-140 degrees F. (Can operate in ambients as low as
-40°F when applied with an enclosure.)
Ensure ventilation around the controller.
Note! For systems applied in low ambient conditions,
special attention should be paid to the digital
compressor's minimum allowable pressure differential
(Absolute Discharge Pressure - Absolute Suction
Pressure). Copeland Scroll compressors must maintain
at least a 75 PSID while the Copeland Discus must have
a 45 PSID to operate correctly.
(PUSH TO RELEASE)
•3.1”
•Front
•2.6”
•Back
•Side
Figure 5 - XC643 Dimensions and Mounting
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Application Engineering
B U L L E T I N
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Table 4 - Display Legend
UPPER DISPLAY LOWER DISPLAY ICONS
Suction temperature or Discharge temperature - Active loads
pressure or pressure - Measurement unit
Active Loads Suction
Pressure or
Temperature
Discharge
KPa
Temperature
or Pressure
XC
Figure 6 - Controller Display
Table 5 - Icon Legend
LED FUNCTION MEANING
ON Celsius degrees
ON Fahrenheit degrees
bar ON bar displaying
PSI ON PSI displaying
kPa ON KPA displaying
ON Copeland Scroll Digital compressor on
Digital compressor is waiting to start (flash once per second) or
Flashing digital input alarm for DIGITAL COMPRESSOR (flash twice per
second) or DIGITAL COMPRESSOR in maintenance status.
ON Compressor 2 on
Flashing Compressor 2 is waiting to start (flash once per second)
ON Fan 1 on
Flashing Fan 1 is waiting to start (flash once per second)
ON Fan 2 on
Flashing Fan 2 is waiting to start (flash once per second)
ON The digital solenoid valve coil is energized
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Keyboard
(SET)
Standard view: to see or modify the set point. In programming mode use SETP to
select a parameter or confirm an operation.
(UP)
In programming mode: used to browse the parameter codes or increase the displayed value.
With Hot key inserted: UP starts the Hot key programming procedure.
To access the INFO menu: push and release UP to access the INFO menu.
(DOWN)
In programming mode: used to browse the parameter codes or decrease the displayed value.
Not used Displays running hours for each load Not used
Key Combinations
+ Lock and unlock keyboard
+ Exit programming mode
+ Enter programming mode
Table 6 - Value Pre-Set According to the Kind of Refrigerant
R-404A R-22 R-410A R-507 R-134a R-407A R-407C
SETC (psig) 55 43 78 55 17 42 37
SETF (psig) 220 181 295 220 114 194 179
LSE (psig) 5 1 11 5 -7 -1 -1
HSE (psig) 114 93 155 114 51 99 95
LSF (psig) 170 131 245 169 63 143 130
HSF (psig) 270 231 345 269 163 243 230
Pbd 10 10 10 10 10 10 10
Pb 58 58 58 58 58 58 58
Controller Start-Up
First installation
At first installation:
1. Select the kind of refrigerant.
2. Select the kind of transducer
3. For systems with master controller
supervisory control, set the module node
address.
How to Set the Kind of Refrigerant
The controller has been programmed with several
refrigerants.
The pre-set refrigerant is: R-404A.
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By modifying the refrigerant (FtyP), other defaults will
also change. Refer to Table 6.
If another refrigerant is used:
1. Enter the Programming mode by pressing the
Set and DOWN key for 3s.
2. Select the FtyP, kind of refrigerant,
parameter.
3. Press the “SET”key: the value of the
parameter will start blinking.
4. Use “UP”or “DOWN”to change the refrigerant
among the following:
r22(0) - 134(1) - 404(2) - 407A(3) - 407C(4) -
410(5) - 507(6)
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