Emerson Copeland OLE-49 User Manual Download

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Application Guidelines

Copeland

™

Large Outdoor

Refrigeration Units

OMTE-76D to OMTE-152D

OLE-49 & OLTE-82D

Summary of Contents for Copeland OLE-49

Page 1: ...Application Guidelines Copeland Large Outdoor Refrigeration Units OMTE 76D to OMTE 152D OLE 49 OLTE 82D ...

Page 2: ... 2 OMTE 152D units 8 2 8 3 OLE 49 units 9 2 8 4 OLTE 82D units 10 2 9 Main components description 11 2 9 1 Bill of material 501 General description 11 2 9 2 Bill of material 502 General description 11 2 9 3 Compressor 11 2 9 4 Electrical cabinet 12 2 9 5 Condenser fan s 12 2 9 6 Housing 12 2 10XCM25D Electronic controller Features 13 2 10 1 Description 13 2 10 2 Functionality 13 2 10 3 Modbus Comm...

Page 3: ...program a Hot Key from the controller upload 24 2 18 5 How to program thecontroller using an Emerson Hot Key download 24 2 19Troubleshooting Alarm history 25 2 20Compressor motor protection 25 2 21System pressureprotection 25 2 21 1 High pressure safety switch 25 2 21 2 Low pressuresafety switch 25 2 22Other inputs of the XCM25D controller 25 2 22 1 Heat recovery mode 25 2 22 2 Ambient temperature...

Page 4: ...5 4 6 Pressurefluctuations in caseof digital unit 36 5 Maintenance repair 37 5 1 Opening the unit housing 37 5 1 1 To open the electrical cabinet 37 5 1 2 To open thecompressor chamber 37 5 1 3 To remove the fan safety grid 38 5 1 4 To access the inner parts of the condenser 38 5 2 Replacing a compressor 38 5 3 Electrical terminations 39 5 4 Condenser fins 39 5 5 Routine leak testing 39 5 6 Conden...

Page 5: ......

Page 6: ...ation For relevant standardspleaserefertotheManufacturer sDeclaration availableat www climate emerson com en gb These instructions should be retained throughout the lifetime of both the compressor and the refrigeration unit You are strongly advised to follow these safety instructions 1 1 Icon explanation WARNING This icon indicates instructions to avoid personal injury and material damage CAUTION ...

Page 7: ...g damage Do not operate compressors without refrigerant charge or without being connected to the system CAUTION Contact with refrigerant oil Material damage Polyolester oil POE must be handled carefully and the proper protective equipment gloves eye protection etc must be used at all times POE must not come into contact with any surface or material that it might damage including without limitation...

Page 8: ...tly This combined with Copeland scroll technology allows for high efficiency operation For the rated cooling capacity rated power input and rated COP value please refer to Copeland Select software at www climate emerson com en gb These guidelinesmeettherequirementsof Regulation2015 1095 Annex V section2 a withregard to product information namely v See chapter 2 6 Application range vi See chapters ...

Page 9: ...81 900 1069 345 383 OMTE 90D 348 386 OLE 49 314 352 OMTE 152D 2303 900 1150 508 566 OLTE 82D 511 569 Table 2 LOCU features The figures hereafter shows the overall physical dimensions of the LOCU refrigeration units Figure 2 Outer dimensions of models OMTE 76D OMTE 90D OLE 49 Figure 3 Outer dimensions of models OMTE 152D OLTE 82D ...

Page 10: ...as locked rotor amps maximum rated current safety pressures and weight The compressor has its own nameplate with all electrical characteristics Figure 4 Nameplate LOCU units 2 5 Nomenclature The model designation contains the following technical information about Copeland LOCU refrigeration units Figure 5 Nomenclature LOCU units ...

Page 11: ...rating conditions For lower ambient temperatures please contact your local Application Engineering representative 2 6 3 PED category The PED category is assigned according to the Pressure Equipment Directive PED 2014 68 EU Requirements apply to the relevant pressure levels in the refrigeration unit if a defined limit value of pressure relative to the environment and relevant internal free volume i...

Page 12: ...ischarge line thermostat130 C compressor 2 B13 Connection for pressure relief valve NPT PSL Mechanical low pressure switch PS1 PS1 A3A Alco Controls PSH High pressure cut outdevice PS3 W6S Alco Controls E1 Crankcase heater compressor 1 E2 Crankcase heater compressor 2 M1 High efficiency digital scroll compressor ZBD Compressor 1 M2 High efficiency standard scroll compressor ZB Compressor 2 M3 High...

Page 13: ...pressure switch PS1 PS1 A3A Alco Controls PSH High pressure cut outdevice compressor 1 PS3 W6S Alco Controls PSH High pressure cut outdevice compressor 2 PS3 W6S Alco Controls E1 Crankcase heater compressor 1 E2 Crankcase heater compressor 2 M1 High efficiency digital scroll compressor ZBD Compressor 1 M2 High efficiency standard scroll compressor ZB Compressor 2 M3 High efficiency EC fan FN071 ZI...

Page 14: ...quid level watch LW4 L120 Alco Controls B6 Ambienttemperature sensor AI6 NTC 10K B7 Connection for pressure relief valve NPT PSL Mechanical low pressure switch PS1 PS1 A3A Alco Controls PSH High pressure cut outdevice PS3 N15 Alco Controls E1 Crankcase heater LIV Liquid injection valve Alco Controls M1 High efficiency scroll compressor ZF M2 High efficiency condenser EC fan FN071 ZIQ 1 Condenser 2...

Page 15: ...chanical low pressure switch PS1 PS1 A3A Alco Controls PSH High pressure cut outdevice compressor PS3 W6S Alco Controls E1 Crankcase heater compressor 1 E2 Crankcase heater compressor 2 M1 High efficiency digital scroll compressor ZFD Compressor 1 M2 High efficiency standard scroll compressor ZF Compressor 2 M3 High efficiency EC fan FN071 ZIQ M4 High efficiency EC fan FN071 ZIQ Y1 Digital control...

Page 16: ...l in standard and heat recovery conditions as well as system safety Main safety features provided by the controller compressor oil level control only for OMTE 152D discharge temperature protection voltage sensing refrigerant chargelevel control and high and low pressure safety 2 9 2 Bill of material 502 General description The BOM 502 version is only available for OMTE units This version is prearr...

Page 17: ... IE4 IEC60034 31 efficiency class Extremely energy efficient thanks to EC technology Compact modular design Straightforward installation and commissioning Flexible customer interface easy to expand The fan type on LOCU units is FN071 ZIQ DG V7P3 2 9 6 Housing Copeland LOCU refrigeration units have the following housing features Redesigned electrical box accessible via a hinged cover with two posit...

Page 18: ...m humidity 90 at 48 C non condensing Board power 24 V AC 15 20 Voltage sensing capabilities three phase 200 240 380 460 575 V AC 10 The units of measure are selectable The factory default unit is bar always considered relative for pressure and C for temperature Figure 13 XCM25D Electronic controller 2 10 2 Functionality The controllerallowsforeasycommissioningby thetechnicianwiththefactory setting...

Page 19: ... Each unit is equipped with a high pressure transmitter The XCM25D controlsthecondensingpressureby regulatingthefanspeed correspondingtotheambient temperature The unit controller regulates the condensing pressure with a constant temperature difference to the ambient floating HP factory setting E66 8 K Different control options are available As soon as fan modulation is enabled E01 2 Modulated fan ...

Page 20: ...e high pressure alarm value can be adjusted with parameter E58 Discharge temperature protection Each unit is equipped with discharge line thermostats DLT The DLT s are in the same safety chain as the high pressure cut out switches and have a common alarm Each compressor has its own safety chain In addition there is a discharge line sensor installed on the discharge pipe of the digital compressor T...

Page 21: ...Programming mode On When browsing the service menu Flashing In fast access menu On When browsing the alarm menu Flashing A new alarm occurred On An alarm is occurring On Digital unloader solenoid On Table 11 LED functions description NOTE By default the local display will show the value of the suction pressure during operation This can be changed by choosing another value for parameter B03 Remote ...

Page 22: ...E Emerson recommends using a shielded cable twisted pair 2 x 0 5 mm The device must be connected to the VNR terminal on the unit controller according to the polarity Figure 18 shows the VNR terminal onthe unit controller Figure 18 VNR connection for the remote display Before connecting cables make sure the power supply complies with the hardware requirements Separate the terminal cables from the p...

Page 23: ... parameter or submenu using the arrows Show value Press the SET button Modify or Use the arrows to modify the value Confirm and store Press the SET button the valuewill blink for 3 seconds then the display will show the next parameter EXIT Press simultaneously to exit the programming mode or wait for 30 seconds MTO without pressing any key Table 15 Programming level 1 parameters When entering the ...

Page 24: ... available oPP Percentage of step valve opening not available LInJ Status of the liquid line solenoid On Off This information is available only if one relay is set as Liquid Line Solenoid SEtd Value of the dynamic setpoint condenser fan SET This information is available only if the dynamic setpoint function is enabled AOO Percentage of the analogue output 0 10 V or TRIAC PWM Mod This informationis...

Page 25: ...emperature condenser floating setpoint 0 0 to 25 5 C 8 8 8 T18 Access to Pr2 level 0 999 3 2 1 Pressure values are always relative 20 sec for OLTE 82D 30 for OLTE 82D Table 17 Parameters in programming level Pr1 NOTE The cycle time of the digital compressor C21 must not be reduced below 20 seconds and the minimum capacity of the digital compressor C24 must not be reduced below 30 for OLTE 82D NOTE...

Page 26: ...quirements 2 15 1 Functionality The emergency mode can be activated by means of the rescue mode switch S3 There are 2 circuit breakers S1 Compressor 1 ENABLE or STOP and S2 Compressor 2 ENABLE or STOP to activate the compressors the digital compressor will perform as the fixed speed compressor 100 capacity In emergency mode the system operator must decideif one or two compressors should be activat...

Page 27: ... of the suction pressure regulation It should be adjusted on a case by case basis per application requirements The factory settings of the low pressure limiter are defined for safety purposes not for emergency operating conditions Upper setpoint bar 1 0 5 7 Differential setpoint 3 0 5 5 Lowest setpoint bar 0 9 Factory setting bar 3 5 4 5 Leakage reset pressure bar 24 Connection port Solder 6 mm Ta...

Page 28: ...nsing temperature can be defined by parameter E67 Heat recovery condensing fan setpoint It is recommended to use 2 additional shut off valves ball valves in the lines to the external heat exchanger This allows independent unit operation without heat recovery in case of issues on the heat exchanger see Figure 23 below The control of the water cycle must be done by a third party controller This cont...

Page 29: ...on Hot Key 2 18 3 Location of the Hot Key plug connection on the XCM25D controller The Hot Key plug connection is located on the upper left corner of the XCM25D Figure 25 Location of Hot Key plug connection 2 18 4 How to program a Hot Key from the controller upload Program the controller with the front keypad Whenthe controlleris on insert the HotKey and presstheUP key the uPL messageappears follo...

Page 30: ...ty switch A non adjustable high pressure switch protects the system against excessive high pressure The device will open in the event of an abnormally high discharge pressure above 28 8 bar The unit will stop then restart automatically after a 5 minute delay and after theunit pressure has decreased to 24 bar 2 21 2 Low pressure safety switch In a way similar to the high pressure sensor the electro...

Page 31: ... level inside the receiver As a result system leakage can be detected and communicated at a very early stage The LW4 L120 device is connected to the digital input DI3 terminals X1 65 66 67 2 22 4 Fan failure Fan feedback Thanks to the introductionof EC fan technology the XCM25D system controller gets feedback from the fans about their condition In case of failure the digital input DI7 terminals X1...

Page 32: ...3 1 1 Transport and storage WARNING Risk of collapse Personal injuries Move units only with appropriate mechanical or handling equipment according to weight Keep in the upright position Respect stacking loads according to Figure 26 Do not stack anything on topof the unit packaging Keep the packaging dry at all times Respect the maximum number of identical packages which may be stacked on one anoth...

Page 33: ...Unsuitablerefrigerantflowrate Do notassumethat the service connection sizes on the unit at the service valves are in fact the correct size to run your interconnecting refrigeration pipes The service valve sizes have been selected for convenienceof installation and in some cases larger units these may be considered too small However for the very short pipe run within our units these service connect...

Page 34: ...e between 2 clamp supports 1 2 12 7 mm 1 20 m 5 8 16 0 mm 1 50 m 7 8 22 0 mm 1 85 m 1 1 8 28 5 mm 2 20 m Table 21 Maximum distance between 2 clamp supports NOTE It is strongly recommended to insulate both the suction and liquid interconnecting piping between the OLTE unit and the evaporator 3 2 2 Connection sizes Figure 29 Connection ports on suction liquid lines Unit Suction inlet Liquid outlet O...

Page 35: ...r be swept through the system and block screens such as those protecting capillary tubes thermal expansion valves and accumulator oil return holes Contamination or moisture Bearing failure Do not remove the plugs until the compressor is set into the unit This minimises any entry of contaminants and moisture Remove the discharge connection cap Remove the suctionconnection cap Open both valves mid w...

Page 36: ...supply before undertaking any task on electrical equipment 3 3 1 Power supply connections WARNING Electrical pins under voltage Electrical shock hazard There are unused fast on pins C1 DO2 on the XCM25D which could be under voltage They are covered by insulated fast on flags in the factory Handle carefully when removing insulating flags during service on site The electrical connection of the refri...

Page 37: ...ations Where multiple units are to be installed in the same location the contractor needs to consider each individual case carefully There can be many variations of unit quantities and available space and it is not the intention of this manual to go over these However in general terms air by pass around each condenser and between the units should always be avoided Ideally the unit should be mounte...

Page 38: ...ting lines to the pump IMPORTANT Care must be taken that all components solenoids expansion devices regulators shut off valves etc in the refrigerationcycle which separate a part of the installation when de energized are manually opened to guarantee successful evacuation in the wholepiping system Before the installation is put into commission it has to be evacuated with a vacuum pump The installat...

Page 39: ... line while simultaneously checking the sight glass Extreme care shall be taken not to overfill the system with ref rigerant The system manufacturer installer must respect the charge limitations according to valid standards such as but not limited to EN 378 NOTE In order to meet the requirements of the Ecodesign Directive 2009 125 EC with regard to efficient system operation ensure the refrigerant...

Page 40: ...account the maximum permittedstarts andstopsof thecompressorand also controls therunning time and minimal downtime It is recommended to change these settings only in exceptional cases 4 5 Checks before starting during operation IMPORTANT Liquid valves not fully opened Liquid trap Both valves should be fully opened on the liquid line in order to prevent liquid trapping Before a system runs for the ...

Page 41: ...at standard level after first compressor start 4 6 Pressure fluctuations in case of digital unit Digital scroll compressors are capable of capacity modulation A normally closed de energized solenoid valve is a key component for achieving modulation When the solenoid valve is energized thetwo scroll elementsmoveapart axiallyintotheunloadedstate Inthis state thecompressormotor continues running but ...

Page 42: ... unit housing and covers The unit allows easy access to all main components 5 1 1 To open the electrical cabinet WARNING High voltage Electrical shock hazard Turn off the main power supply to de energise the unit before opening the cabinet or undertaking any task on the electrical equipment Never open the electrical cabinet in rainy weather if the isolating switch is on Release the locks located o...

Page 43: ...equate lubrication Bearing destruction Exchange the accumulator after replacing a compressor with a burned out motor The accumulator oil return orifice or screen may be plugged with debris or may become plugged This will result in starvation of oil to the new compressor and a second failure In the case of a motor burnout most contaminated oil will be removed with the compressor The rest of the oil...

Page 44: ... the fins should be brushed lightly with a proper fin comb Condenserfins becomedirtyovertimeas ambient airis inducedto thecondenser Dirtycoil surfaces result in high condensing temperatures and poor unit performance Regular cleaning is recommended the frequency of doing so being dependent on the installation and the surrounding environment As a general guide it is advisable to do this at least onc...

Page 45: ... 8 R 1 3 4 70 Table 24 Torques of Rotalock connections NOTE In order to meet the requirements of the Ecodesign Directive 2009 125 EC with regard to efficient system operation ensure the refrigerant and oil chargesare sufficient 5 6 Condenser fans motors A yearly inspection of these items is recommended Fastenings can become loose bearings may wear and fans may require cleaning of solid deposits th...

Page 46: ...Part 3 11 Limits Limitation of voltage changes voltage fluctuations and flicker inpublic low voltage supply systems Equipment with rated current 75 A and subject to conditional connection EN 61000 6 3 Electromagnetic compatibility EMC Part 6 3 Generic standards Emission standard for residential commercial and light industrial environments The LOCU refrigeration units and their piping comply with t...

Page 47: ... band for compressor regulation 0 1 to 9 9 bar 0 1 to 99 9 PSI 0 1 C to 25 5 C 2 0 1 0 C21 Cycle time for digital compressor 10 to 40 sec 10 10 20 for OLTE 82D C24 Minimum capacity for digital compressor 0 to C25 10 10 30 for OLTE 82D C27 Time with digital compressor at PMi before switching off another load 0 to 255 sec 10 5 D29 Low pressure alarm value A02 to A03 0 8 E66 Delta temperature condens...

Page 48: ...g E06 AI6 error Probe 6 Ambient temperature sensor failure alarm Probe failure or out of range The functions related to Probe6 ambient sensor are disabled Automatically as soon as the probe restarts working E07 AI7 error Not used E08 Battery error The internal back up battery is not working properly Disable the clock function to restart the unit No reset required E09 Current sensor 1 error Probe o...

Page 49: ...y H08 delay time out L23 Overcurrent lockout compressor 1 Overcurrent happened H11 times within one hour The compressor will lock out if H11 equal to 0 no compressor lockout Hold start button for 5 sec or manual power off and on if H11 equal to 0 compressor starts automatically after H08 delay time out E24 Open run circuit error Not used L24 Open run circuit lockout Not used E25 Open start circuit...

Page 50: ... to 0 compressor starts automatically after H08 delay time out E32 No current detected on compressor 2 Alarm Automatically as soon as electrical current detected E33 E39 Reserved E40 High pressure switch High pressure switch open The compressor will trip Automatically as soon as high pressure switch closed and D14 delay time out L40 High pressure switch lockout High pressure switch open error happ...

Page 51: ...emperature higher than E58 for E59 minutes The compressor is activated according to E60 Automatically as soon as condenser temperature lower than E61 E47 EXV fully open only when EVI is applied Not used E48 Refrigerant shortage Not used E49 Pumpdown alarm Not used E50 High side floodback alarm Discharge temperature too low The differential temperature between discharge and mid coil is lower than H...

Page 52: ...and digital compressor active Warning signal only Check compressor protection E54 Fixed compressor down Digital input for fixed compressor open and compressor active Warning signal only Check compressor protection E55 Fan failure Fan alarm contact open Warning signal only Check fans protection E60 Max pressure alarm of superheating Not used E61 Min pressure alarm of superheating Not used E62 High ...

Page 53: ...igital compressor relay is configured no digital solenoid configuration Case 1 digital compressor relay is configured no digital solenoid configuration Case 2 no digital compressor relay configuration digital solenoid is configured Case 3 C05 3 digital compressor relay and digital solenoid are configured Correct the configuration Board must be reset E85 Injection probe configuration error Not used...

Page 54: ...4 76 1 870 105 0 858 39 178 3 10 42 45 19 12 56 48 4 444 77 1 817 106 0 836 38 168 9 9 40 56 20 12 09 49 4 300 78 1 766 107 0 816 37 160 1 8 38 76 21 11 63 50 4 161 79 1 716 108 0 796 36 151 8 7 37 05 22 11 20 51 4 026 80 1 669 109 0 777 35 144 0 6 35 43 23 10 78 52 3 897 81 1 622 110 0 758 34 136 6 5 33 89 24 10 38 53 3 772 82 1 577 111 0 740 33 129 7 4 32 43 25 10 00 54 3 652 83 1 534 112 0 722 ...

Page 55: ...rs level 1 42 Table 26 Alarm codeoverview 48 Table 27 B7 AI7 optional sensor Temperature resistance curve 49 Figures Figure 1 Front view of the Copeland LOCU refrigeration unit 3 Figure 2 Outer dimensions of models OMTE 76D OMTE 90D OLE 49 4 Figure 3 Outer dimensions of models OMTE 152D OLTE 82D 4 Figure 4 Nameplate LOCU units 5 Figure 5 Nomenclature LOCU units 5 Figure 6 P I diagram for OMTE 76D ...

Page 56: ...g Sectional view 30 Figure 31 Suction tube brazing areas 31 Figure 32 Fixing dimensions and distances inmm 32 Figure 33 Charging level in liquid receiver 34 Figure 34 Oil charging serviceports 35 Figure 35 Position of the locks 37 Figure 36 Opening the compressorchamber 37 Figure 37 Opening thefansafety grid 38 Figure 38 Accessing the innerparts of the unit 38 ...

Page 57: ...te Technologies GmbH and or its affiliates collectively Emerson as applicable reserve the right to modify the design or specifications of such products at any time without notice 3 Emerson does not assumeresponsibility for the selection use or maintenance of any product Responsibilityforproperselection useand maintenanceof any Emersonproduct remainssolely with the purchaser or end user 4 Emerson d...

Page 58: ... Free Zone South Dubai UAE Tel 971 4 811 81 00 Fax 971 4 886 54 65 mea sales emerson com ASIA PACIFIC Suite 2503 8 25 F Exchange Tower 33 Wang Chiu Road Kowloon Bay Kowloon Hong Kong Tel 852 2866 3108 Fax 852 2520 6227 CZECH REPUBLIC Hajkova 22 CZ 133 00 Prague Tel 420 733 161 651 Fax 420 271 035 655 Pavel Sudek emerson com SPAIN PORTUGAL C Pujades 51 55 Box 53 ES 08005 Barcelona Tel 34 93 412 37 ...

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