Emerson Copeland EazyCool OMQ-56-Nxx-TWD Series Instruction Manual

Copeland EazyCoolTM
outdoor condensing units
for refrigeration networks
Application Guidelines

Condensing Unit For Refrigeration Networks
A
Ap pp pl li ic ca at ti io on n G Gu ui id de el li in ne e
1SAFETY INSTRUCTIONS...........................................................................................2
1.1 ICON EXPLANATION..................................................................................................2
1.2 SAFETY STATEMENTS .............................................................................................. 2
1.3 GENERAL INSTRUCTIONS .........................................................................................3
1.4 ABOUT THIS GUIDELINE: ........................................................................................... 3
2PRODUCT DESCRIPTION..........................................................................................4
2.1 COPELAND EAZYCOOL™ CONDENSING UNITS FOR REFRIGERATION NETWORKS .........4
2.2 NETWORK CONFIGURATIONS .................................................................................... 4
2.3 PRODUCT NAMEPLATE ............................................................................................. 4
2.4 NOMENCLATURE ..................................................................................................... 5
2.5 APPLICATION RANGE ...............................................................................................5
2.6 MAIN COMPONENT DESCRIPTION ..............................................................................6
3INSTALLATION.........................................................................................................13
3.1 CONDENSING UNIT HANDLING................................................................................. 13
3.2 CONNECTION ACCESS ...........................................................................................15
3.3 ELECTRICAL BOX ACCESS ......................................................................................15
3.4 ELECTRICAL CONNECTION......................................................................................16
3.5 REFRIGERATION CONNECTIONS.............................................................................. 18
3.6 2 UNIT NETWORK : INSTALLATION ..........................................................................20
3.7 3 & 4 UNIT NETWORK ...........................................................................................23
3.8 ELECTRONIC CONTROLLER EC2-551..................................................................... 29
4STARTING UP & OPERATION.................................................................................31
4.1 CHARGING PROCEDURE ........................................................................................ 31
4.2 SOUND .................................................................................................................31
4.3 ROTATION DIRECTION OF SCROLL COMPRESSORS ...................................................31
4.4 MAXIMUM COMPRESSOR CYCLE ............................................................................. 32
4.5 CHECKS BEFORE STARTING & DURING OPERATION ..................................................32
5MAINTENANCE & REPAIR: REPLACING A COMPRESSOR................................32
6CERTIFICATION AND APPROVAL .........................................................................32
7DISMANTLING AND DISPOSAL..............................................................................32
C6.1.4/0305/E 1 Part no: 3136433

Safety
Instructions
Product
Description
InstallationElectrical
Connection
Starting up &
Operation
Maintenance
& Repair
Dismantling &
Disposal
Condensing Unit For Refrigeration Networks
1 Safety instructions
The Copeland EazyCool™ condensing units are manufactured according to the latest
and valid industrial standards.
Particular emphasis has been placed on the user safety.
These condensing units are intended for installation in machines and systems according
to the EC Machines directive. They may be put to service only, if they have been installed
in these machines according to the existing instruction and as a whole agree with the
corresponding provisions of legislation (standards to apply: refer to Manufacturers
declaration).
Manufacturer declaration and declarations of conformity are available on request.
Retain these operating instructions during the entire lifetime of the compressor as well as
the condensing unit.
We strongly advise to follow these safety instructions.
1.1 Icon explanation
WARNING
This Icon indicates instructions to avoid heavy personnel injuries and heavy material
damage.
High Voltage
This icon indicates operations with a danger of an electric shock.
Danger of burning or frostbite
This icon indicates operations with a danger of burning or frostbite.
Explosion Hazard
This Icon indicates operations with a danger of explosion.
CAUTION
This Icon indicates instructions to avoid property damage without or with low personnel
injuries.
IMPORTANT
This icon indicates instructions to avoid malfunction of the compressor.
NOTE this word indicates a recommendation for easier operations.
1.2 Safety statements
 Refrigerant compressors must be employed only for the use they are made for.
 Only qualified and authorised refrigeration personnel are allowed to do the
installation, commissioning and maintenance.
 Qualified electrical personnel must connect the condensing unit and its
accessories.
 All valid standards for connecting electrical and refrigeration equipment must be
observed.
Use personnel safety equipment. This is important to avoid
injuries from the refrigerant.
C6.1.4/0305/E 2 Part no: 3136433

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1.3 General instructions
WARNING
System breakdown! Personnel injuries! Never install a system in the field and leave it
unattended when it has no charge, a holding charge, or with the service valves closed
without electrically locking out the system.
System breakdown! Personnel injuries! Only approved refrigerant and refrigerating oils
must be used.
High Shell Temperature! Burning! Do not touch the compressor until it has cooled
down. Ensure that other materials in the area of the compressor do not get in touch with
it. Lock and mark accessible sections.
CAUTION
Overheating! Bearing damage! Do not operate compressors without refrigerant charge or
without being connected to the system.
IMPORTANT
Transit damage! Compressor malfunction! Use original packaging. Avoid collisions and
tilting.
Only qualified personnel should install and intervene on COPELAND condensing units.
The contractor, responsible for the installation of the unit, should ensure sufficient liquid
sub-cooling in the line to the expansion valve(s) to avoid “flash-gas” in the liquid line.
It is of vital importance that the discharge stop valve has been fully opened before the
compressor is started. If the discharge stop valve is closed or partly closed an
unacceptable pressure with accordingly high temperatures may develop in the cylinder
head. When operating with air the so-called diesel effect may occur, i.e. the air sucked in
is mixed with oil gas and can explode due to the high temperature in the cylinder head,
and thereby destroy the compressor.
1.4 About this guideline:
These guidelines ensure the safe installation, starting, operation and maintenance of
Copeland EazyCool™ condensing units.
In case of a failure, important topics are mentioned in the chapter causes of failure.
These guidelines are not meant to replace the system expertise available from system
manufacturers.
For additional information, please refer to the “Product Catalogue“ or to the “Copeland
Selection Software” accessible from the Copeland website at www.ecopeland.com.
C6.1.4/0305/E 3 Part no: 3136433

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Condensing Unit For Refrigeration Networks
2 Product Description
2.1 About Copeland EazyCool™ condensing units for refrigeration
networks
Copeland has developed a special version of Copeland EazyCool condensing units that
can be used to create medium and larger size refrigeration network systems. The range
consists of Copeland EazyCool condensing units for medium and low temperature
applications and covers units from 7.5 to 15 hp. It includes units with two compressors,
allowing modulation in two steps as well as Copeland EazyCool Digital Scroll™
Condensing Units, which feature continuous modulation from 10 to 100%.
The concept of a condensing unit refrigeration network is based on connecting up to four
condensing units mechanically (tubing) and electronically (control system). The control
and oil distribution system is a Master/Slave configuration in which the Master unit takes
care of:
Compressor staging based on suction pressure
 Oil distribution (oil reservoir in master unit)
 Communication for remote monitoring
The Slave unit takes care of:
 Fan speed control
 And emergency control in case of communication line disruption between the unit
(master/slave)
Each Network should have only one master unit.
2.2 Network configurations
Basically there are three different configurations possible: two-unit network, three-unit
network and four-unit network. The three and four condensing unit network requires an
external receiver. Copeland offers a LRU (Liquid Receiver Unit) which contains a 90 l
receiver. If a larger receiver is required, this should be obtained from a third party. The
two-unit network consists of units with internal receivers, which allow faster installation.
2 Unit Network 3 Unit Network with LRU 4 Unit Network with LRU
LRU: Liquid Receiver Unit
2.3 Product nameplate
The condensing unit nameplate shows model designation and serial number.
The compressor has its own nameplate with all electrical characteristics.
The medium temperature range features ZB Scroll compressors, some models include a
Digital Scroll™ compressor.
The low temperature range features ZF Scroll compressors with vapour injection using a
pre-installed sub-cooler.
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2.4 Nomenclature
The model designation contains the following technical information about the condensing
unit:
OM T Q 90 D NL O TFD
1 2 3 4 5 6 7 8 9
Specific for Network
models
1 - Condensing unit family:
OM = Medium temperature Copeland EazyCool™ unit
OL = Low temperature Copeland EazyCool™ unit
2 - Number of compressor: “blank” = single compressor, “T” = two compressors
3 - Quiet version
4 - Compressor size: 90 = 1 x ZBD45KCE (digital), 1 x ZB45KCE
5 - D = Copeland Digital Scroll™
- V = Low temperature:Copeland Scroll™ with vapour injection (EVI)
6 - N= Unit suitable for creation of a refrigeration network
7 - L= Liquid receiver included (only for 2 unit network)
8 - O= Oil reservoir included (always Master)
9 - Motor version: TFD or TWD: 380-420V/3Ph/50H
2.5 Application range
2.5.1 Qualified refrigerants and oils
OMQ-56-Nxx
~
OMQ-110-Nxx
OMTQ-60(D)-Nxx
OMTQ-76-Nxx
OMTQ-90(D)-Nxx
OLQ-24V-Nxx ~ OLQ-48V-Nxx
OLTQ-26V-Nxx & OLTQ-36V-Nxx
Qualified refrigerant R404A/R507
R134a,R407C
R22
R404A/R507
R22
R404A/R507
R22
ICI Emkarate RL 32 CF
Mobil EAL Artic 22 CC
Qualified Servicing Oil
Table 1: Qualified refrigerants and oils
2.5.2 Application limits
For Application envelope, please refer to the Compressor application envelope available
in Copeland Selection Software version 6.
Medium temperature range
Evaporating Temperature: from –30°C up to 12.5°C
Low temperature range
Evaporating Temperature: from –40°C up to 7°C
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2.6 Main component description
2.6.1 Compressor
Unit Model Compressor Model Unit Model Compressor Model
OMQ-56-Nxx-TWD ZB56KCE-TWD-551 OLQ-24V-Nxx-TWD ZF24KVE-TWD-551
OMQ-75-Nxx-TWD ZB75KCE-TWD-551 OLQ-33V-Nxx-TWD ZF33KVE-TWD-551
OMQ-92-Nxx-TWD ZB92KCE-TWD-551 OLQ-40V-Nxx-TWD ZF40KVE-TWD-551
OMQ-110-Nxx-TWD ZB11MCE-TWD-551 OLQ-48V-Nxx-TWD ZF48KVE-TWD-551
OMTQ-60-Nxx-TFD 2 x ZB30KCE-TFD-551 OLTQ-26V-Nxx-TFD 2 x ZF13KVE-TFD-556
OMTQ-60D-Nxx-TFD (*) 1 X ZBD30KCE-TFD-250
1 x ZB30KCE-TFD-551
OMTQ-76-Nxx-TFD 2 x ZB38KCE-TFD-551
OMTQ-90-Nxx-TFD 2 x ZB45KCE-TFD-551 OLTQ-36V-Nxx-TFD 2 x ZF18KVE-TFD-556
OMTQ-90D-Nxx-TFD (*) 1 X ZBD45KCE-TFD-250
1 x ZB45KCE-TFD-551
(*) Digital ScrollTM available in Master version only (NLO & NO)
Low TemperatureMedium Temperature
Two compressor unit
Single compressor unit
Table 2: Compressor type used in Copeland EazyCool™ condensing units for
refrigeration networks
2.6.2 Sound Blanket
The OM(T)Q and OL(T)Q units include one or two compressors, equipped with a sound
jacket.
The sound jacket developed by Copeland has no impact on the performance of the
compressor.
The design consists of a top cap cover and compressor shell cover with adjustable Velcro
system.
It has good characteristics in case of fire and is resistant to:
 Mineral and Polyolester oil
 Refrigerants R22/R404A
 Temperature up to 150°C
 Water
2.6.3 Condenser Fan(s)
The condensers of the OM (T) Q & OL (T) Q units for refrigeration networks are equipped
with single-phase fans, with low speed (910 rpm) 6 pole single-phase motor.
Medium Temp Low Temp
OMQ-56-Nxx OLQ-24V-Nxx
OMQ-75-Nxx OLQ-33V-Nxx
OMQ-92-Nxx OLQ-40V-Nxx
OMQ-110-Nxx OLQ-48V-Nxx
OMTQ-60(D)-Nxx OLTQ-26V-Nxx
OMTQ-76-Nxx
OMTQ-90(D)-Nxx OLTQ-36V-Nxx 2 301 8µF-400V 500 290 1.4 25
Electrical data @ 50 Hz
2
Fan
Model
145
301
145
Condensing unit N° of
Fan
2
2
420
Run Capacitor
Capacity
4µF-400V
8µF-400V
4µF-400V
Voltage
V/ph/Hz
220-240
1~50
Diameter
ø
(mm)
420
500
Power
input (W)
145
290
145
1.4
0.67
Current
input (A)
0.67
Winding
resistance
Ohm (Ω)
70
25
70
Table 3: Condenser fan: technical data
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2.6.4 Liquid receiver
Liquid receiver for 2 unit network system
Master and Slave units for 2-unit network configuration are equipped with a liquid
receiver.
The liquid receivers are equipped with:
 Rotalock service valves for connection of a liquid level equalisation line as well as
a gas pressure equalisation line between the receivers to ensure equal liquid
levels in both receivers. Both lines are partly pre-installed and protrude at the rear
of the units.
 Rotalock service valve on top of the receiver for liquid outlet line.
 3/8’’–14 NPTF connection for relief valve. Maximum allowable working pressure -
MAWP 33 Bar
Fitting a pressure relief device according to standard EN378-2 is the responsibility of the
installer.
Rotalockservicevalve
Receiver
volume
l
OMQ-56-Nxx to OMQ-110-Nxx
OLQ-24V-Nxx to OLQ-48V-Nxx
OMTQ-60-Nxx to OMTQ-90-Nxx
OLTQ-26V-Nxx to OLTQ-36V-Nxx
Model Type
24
Table 4: Receiver volume
It is recommended to charge the system with refrigerant via the Rotalock service valves.
Liquid receiver for 3 and 4 unit network system
With larger systems (refrigeration systems requiring 3 or 4 units in a network) a remote
liquid receiver should be used. The condensing unit models for systems with remote
receivers are provided without liquid receiver. The condenser liquid outlet line protrudes
from the rear of the unit to allow an easy connection to a remote liquid receiver.
Copeland offers a LRU (Liquid Receiver Unit), which contains a 90 litres liquid receiver
for remote use with filter drier, sight glass with moisture indicator and ball valves for liquid
inlet and outlet. If a larger receiver is required, this should be obtained from a third party.
C6.1.4/0305/E 7 Part no: 3136433

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The LRU collects liquid refrigerant from each condenser in a network. It has a single
liquid inlet and outlet line.
Receiver Depth / Width Height Dimensions Liquid Liquid Weight
Capacity T/B H (holes) Inlet diameter Outlet diameter Net/Gross
l 1) mm mm b x t,(ø mm) ø (inch) ø (inch) kg
Liquid
Receiver
Unit
90 630 / 1250 720 680 x 580 (12) 1 5/8 1 3/8 120 / 142
Table 5: Liquid receiver unit LRU
1) Receiver volume in litre also indicates the pump down capacity in kg (at 50°C Liquid
temperature) when the receiver is 95% filled – Receiver CE approved.
 1/2’’–14 NPTF connection for relief valve. Maximum allowable working pressure -
MAWP 33 Bar
 Fitting a pressure relief device according to standard EN378-2 is the
responsibility of the installer.
2.6.5 Electrical box: components
All electrical components are pre-wired into the panel.
This panel contains:
 Compressor contactor(s)
 Fuse
 Terminal blocks
 DIN rail mounted terminals
 Electronic controller
 Fan Speed controller
 Alarm relays
2.6.6 Pressure switch
All single compressor Copeland EazyCool™ condensing units for refrigeration networks
are equipped with:
 Single low pressure switch with automatic reset: ALCO PS1-W3A
 Electronic Condensing Unit Controller with HP and LP pressure transmitters
All two-compressor Copeland EazyCool™ condensing units for Refrigeration Network are
equipped with:
 Single low pressure switch with automatic reset: ALCO PS1-W3A
 Two high pressure switches ALCO PS3-WF4-HNS
 Electronic Condensing Unit Controller with HP and LP pressure transmitters
C6.1.4/0305/E 8 Part no: 3136433

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1) PS2-W7A: Alco Controls® dual pressure switch with automatic reset (for single
compressor unit)
The switch is equipped with display scale and pointers to indicate the
approximate settings. The display scales are printed in relative pressure
units “bar” and “psi”.
For precise setting of the control, external gauges must be used.
The PS2-W7A has the following characteristics:
 Automatic reset dual pressure controls
Combined pressure limiter for low pressure / high-pressure
protection.
On pressure rise above the upper setpoint, contacts 1-2 open and
contacts 1-4 close.
On decreasing pressure below lower setpoint contacts 1-4 open and
contacts 1-2 close.
 Adjustable dual pressure switch
Setpoint adjustment range: LP (left) = -0.5 to 7 bar and HP (right) = 6 to 31 bar.
Differential adjustment range: LP = 0,5 to 5 bar, HP = 4 bar.
Factory setting: LP = 3,5 / 4,5 bar, HP = 20 bar.
2 4
1
p
+
-
2) PS1-W3A: Alco Controls single low pressure switch with automatic
reset
The control is equipped with display scale and pointers to indicate the
approximate settings.
The display scales are printed in relative pressure units “bar” and “psi”.
For precise setting of the control, external gauges must be used.
The PS1-W3A has the following characteristics:
 Automatic reset single pressure controls
Pressure limiter for low-pressure protection.
On decreasing pressure below lower set-point contacts 1-4 open and
contacts 1-2 close.
2 4
1
p
+
-
 Adjustable single pressure switch
Setpoint adjustment range: = -0.5 to 7 bar.
Differential adjustment range: = 0,5 to 5 bar.
Factory setting: = 3,5 / 4,5 bar.
3) PS3-WF4-HNS: Alco Controls high pressure switch with an automatic reset
 Automatic reset single pressure switch
Pressure limiter for high-pressure protection.
Switches from 1-2 to 1-4 on rising pressure and from 1-4 to 1-2 on falling
pressure.
 Fixed switch point settings
Cut-out point: 22 bar
Cut-in point: 26.2 bar.
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