Emerson XJAL-020Z-CFV-012 User manual

© 2017 Emerson Climate Technologies, Inc.
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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

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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
WARNING
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
0
1.15
60
1.02
10
1.13
70
1.00
20
1.10
80
.98
30
1.08
90
.96
40
1.06
100
.95
50
1.04
110
.93
Table 2 - Altitude Conversion Factors (A2)
Alt (ft.)
Factor A2
Alt (ft.)
Factor A2
0
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

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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-injection-
optimization 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.

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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 pre-
defined 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.

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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 off-
cycle 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

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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.

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Figure 1 - Nomenclature and Features

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Figure 2 - Physical and Installation Requirements

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Figure 3 - Power Board / Control Board
* Note: Short Cycle Protection Option
a. Factory Jumper Intalled Three Minute Time Delay
b. Remove Jumper Twenty Second Time Delay

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Figure 4 - Defrost Control Module
Figure 5 - Communication Board
Figure 6 - Emerson Supplied Defrost (-002/-012 Models Only)

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Figure 7 - Quick Setup Guide for Electronic Low Pressure Control

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Drawings

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