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Related Manuals for Emerson Copeland EazyCool OME-4MTL-05X
Summary of Contents for Emerson Copeland EazyCool OME-4MTL-05X
- Page 1 Application Guidelines Copeland Eazycool ™ Refrigeration Units...
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Page 2: Table Of Contents
About these guidelines ....................1 Safety instructions ..................1 1.1 Icon explanation ....................... 1 1.2 Safety statements ......................1 1.3 General instructions ......................2 Product description ..................3 2.1 General information about Copeland EazyCool™ CO refrigeration unit ......3 2.2 EU Ecodesign Directive 2009/125/EC ................3 2.3 Main product features ...................... - Page 3 2.9.10 How to set the date and time ................21 2.9.11 How to check the operating values of the frequency inverter M200 ....22 2.9.12 Controller setting ....................22 2.9.13 Manual compressor run ..................22 2.9.14 How to reset the controller to factory settings ............ 23 2.9.15 How to save user’s settings................
- Page 4 4.2 Charging procedure ....................... 43 4.2.1 Refrigerant charging procedure ................. 43 4.2.2 Oil charging procedure ..................43 4.3 Maximum compressor cycle ..................43 4.4 Checks before starting & during operation ..............44 Maintenance & repair ..................45 5.1 Opening the unit housing ....................45 5.1.1 To open the electrical cabinet ................
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Page 6: About These Guidelines
Besides the support they provide, the instructions listed herein are also critical for the proper and safe functioning of the refrigeration units. Emerson will not guarantee the performance and reliability of the product if it is misused in regard of these guidelines. -
Page 7: General Instructions
General instructions WARNING System breakdown! Personal 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! Personal injuries! Only CO and approved refrigeration oils must be used. -
Page 8: Product Description
Product description General information about Copeland EazyCool™ CO refrigeration unit Emerson has developed the Copeland™ EazyCool CO refrigeration unit to meet primarily the demands of the food retail and food service sectors. It is an air-cooled refrigeration unit that uses the latest Copeland™... -
Page 9: Main Product Features
Main product features Copeland EazyCool refrigeration units are released for CO (R744) refrigerant only. They are available in one cabinet size and are always equipped with one fan. The units are designed for medium temperature applications only. The inverter is calculated to drive the compressor in subcritical and transcritical applications. -
Page 10: Product Nameplate
Product nameplate The refrigeration unit nameplate shows model designation and serial number, as well as nominal power and safety pressures. The compressor has its own nameplate with all electrical characteristics. Figure 3: Nameplate of CO units Nomenclature The model designation contains the following technical information about Copeland EazyCool CO refrigeration units: Figure 4: Nomenclature of CO units... -
Page 11: Application Range
Always operate the system with adequate superheat to avoid oil viscosity decrease. Additional measures in system design might help to avoid unacceptable lubrication conditions. For the application envelope, please refer to Select software at www.climate.emerson.com/en-gb. Recommendations for minimum suction superheat – Lubrication conditions 2.6.3... -
Page 12: Pressure Levels Of Co Vs. Other Refrigerants
2.6.4 Pressure levels of CO vs. other refrigerants Figure 5 below compares the evaporating pressures of R744 to those encountered with R410A and R404A. It can be observed that R744 systems will require to operate at much higher pressures than conventional systems. -
Page 13: Main Components Description
Main components description Figure 7: Main components of CO unit 2.7.1 Compressor The compressor is installed in the chamber below the electrical cabinet. The standard delivery is with shut-off valve on discharge, CoreSense Protection module, oil watch system connected to one of the sight glass connections. -
Page 14: Liquid Receiver
2.7.3 Liquid receiver The liquid receiver (24.9 litres for the whole range of units) is installed below the condenser / gas cooler. It is equipped with a shut-off valve on the outlet and a safety group (2 pressure relief valves 90 bar, connected to a switch-over valve). -
Page 15: Housing
If a system does not require cooling capacity and the ambient temperature around the unit is high, the pressure in the flashtank section will increase. When reaching a critical pressure limit defined by parameter GC78 (factory-set at 40 bar) inside the flashtank during compressor stop, the compressor will start and perform a short pumpdown cycle to reduce the pressure level in the flashtank area. -
Page 16: Exploded View Of The Co Unit
2.7.8 Exploded view of the CO unit Figure 12: Exploded view of the unit C6.1.11/0718-0619/E... -
Page 17: P&I Diagram For Co Units
2.7.9 P&I diagram for CO units Figure 13: P&I diagram for CO units Position Description Position Description Copeland Stream compressor Compressor inverter Discharge mufler Suction pressure Gas cooler/condenser Discharge pressure Flash tank Liquid receiver pressure Filter-dryer Suction gas temperature unit Sight glass Suction gas temperature compressor Ball valve... -
Page 18: Co Unit Control - General
NOTE: The design pressure Ps is a safety-related value. The restrictions for reliable operation of the unit are defined by the application envelope which can be found in Select software at www.climate.emerson.com/en-gb. Unit control – General Copeland EazyCool CO refrigeration units are equipped with an iPro controller (IPR215D) and a Visograph display. -
Page 19: Ipro Ipr215D Controller Description
The controller is factory-set for -10°C evaporating temperature. To achieve the required temperatures, Emerson recommends to change only the evaporating temperature as the rest of the parameters are already pre-set. NOTE: The other factory settings can be found in Technical Information CC7.8.11 "Copeland Refrigeration Units –... -
Page 20: How To Use The Ipro Ipr215D Controller
To switch the controller off. Press for 10 seconds to switch the controller off OFF1 (enabled only if parameter OT5 = yes) PARAM To enter the parameter programming menu SERVICE To enter the service menu Measurement unit: to switch the probe visualization and setpoint from UNIT pressure to temperature and vice versa ALARM... -
Page 21: Parameter Grouping
2.9.2 Parameter grouping The parameters are grouped in sub-menus. Parameter grouping Parameter grouping Setpoint (SETC1, SETF1) Analog outputs 4 (AO4_1- AO4_26) Compressor rack setup (CF1, CF16) Analog outputs 5 (AO5_1- AO5_26) Regulation (CF18, CF20-CF22, CF24) Analog outputs 6 (AO6_1- AO6_26) Display (CF26-CF27) Auxiliary outputs (AR1-AR18) Analog inputs (AI1-AI31) -
Page 22: Service" Menu
2.9.3 "Service" menu The main functions of the controller are available from the "Service" menu and are listed below: ▪ check the values of analog outputs; ▪ check the status of compressor relays; ▪ operate a maintenance session; ▪ check the status of safety and configurable digital outputs; ▪... -
Page 23: How To Check The Values Of Analog Outputs
2.9.5 How to check the values of analog outputs Enter the "Service" menu Use the UP and DOWN keys to select the "Analog outputs" sub-menu Press ENTER Figure 23: iPro "Analog outputs" screen Analog Wiring Factory setting Description Function output diagram 2 - 0-10V output inverter 1 suction –... -
Page 24: How To Perform A Maintenance Using The "Compressors Service" Sub-Menus
2.9.7 How to perform a maintenance using the "Compressors service" sub-menus The "Compressors service" sub-menus allow to perform a maintenance session consisting of: ▪ disabling an output; ▪ checking and (possibly) erasing the running hour of a load. NOTE: Disabling an output will exclude it from the regulation. NOTE: The "Compressors service"... -
Page 25: How To Check The Values Of Digital Inputs
2.9.8 How to check the values of digital inputs Enter the "Service" menu Use the UP and DOWN keys to select the "Digital inputs" sub-menu Press ENTER Figure 26: iPro "Digital inputs" screen Digital Wiring Factory setting Description Function input diagram o63 - Inverter suction VF drive failure... -
Page 26: How To Check The Values Of The Probes
2.9.9 How to check the values of the probes Enter the "Service" menu Use the UP and DOWN keys to select the "Probes" sub-menu Press ENTER. The "Probes" sub-menu displays the probe values in the following format: Figure 27: iPro "Probes" menu NOTE: To change the measurement unit for probes PB1, PB2, PB3 and PB4, press the UNIT key as per Figure 27. -
Page 27: How To Check The Operating Values Of The Frequency Inverter M200
2.9.12 Controller setting IMPORTANT Never adjust the suction pressure to a value that is outside of the envelope approved by Emerson. To change the suction pressure: Press the PARAM key to access the programming menu Use the UP and DOWN keys to select the Pr1 menu... -
Page 28: How To Reset The Controller To Factory Settings
2.9.14 How to reset the controller to factory settings Enter the "Service" menu Use the UP and DOWN keys to select the "Conf file management" sub-menu Press the SET key. The parameter map will be transferred from "Backup.conf" file to "default_10D.conf"... -
Page 29: Active Alarm(S) Log Menu
Variable Description Suction pressure [bar] SuctPrss_BAR Condensing pressure [bar] Cond/GCPrss_BAR Liquid receiver pressure [bar] LiqRecPrss_BAR Suction temperature unit [°C] Aux2Temp_C Suction temperature compressor [°C] SuctTemp_C Discharge line temperature [°C] DLT_C Gas cooler outlet temperature [°C] GCoutletTemp_C Oil temperature [°C] Aux3Temp_C Ambient temperature [°C] DynCondTemp_C Cabinet temperature [°C]... -
Page 30: Ipro Ipr215D Controller - Functionality
2.10 iPro IPR215D controller – Functionality The iPro IPR215D controls the complete refrigeration unit. It provides a lot of customization features like alarms and special operating modes. Thanks to the high degree of flexibility, the user can either use the factory-set alarms or set up his own alarms according to the application requirements. The following functionalities are pre-programmed: ▪... -
Page 31: Pumpdown Mode
Factory Parameter Description Level Min value Max value setting Differential to be subtracted from SPF1 the compressor setpoint 100% Compressor frequency during SPF2 (min speed (max speed pumpdown 25 Hz) 60 Hz) SPF3 Pumpdown maximum time 0 min 25 min 3 min SPF4 Automatic pumpdown... -
Page 32: Alarms
Figure 34: Sensoring in subcritical mode 2.10.3.2 Transcritical operation For temperatures typically above 27°C (AIC7 > GC1), the system operates in transcritical mode. ▪ According to the gas cooler outlet temperature detected by the AIC7 probe, the high-pressure valve modulates to maintain a pressure that maximizes the COP (Coefficient of Performance). ▪... -
Page 33: Figure 36: Ipro "Alarm" Key
Press the ALARM key to enter the "Alarm" menu: Figure 36: iPro "Alarm" key The header of the corresponding menu will be flashing. Four alarm menus are available from the display: ▪ Compressor alarms Circuit 1 ▪ Fan alarms Circuit 1 ▪... -
Page 34: Ipro Ipr215D Controller - Peripheral Devices
Figure 38: XEV20D stepper valve actuator 2.11.2 Variable frequency drive M200 The Emerson variable frequency drive M200 has been designed for applications that require flexible integration with systems via industrial Ethernet protocols and fieldbuses, together with advanced RFC-A open-loop motor control. Connection to RS485 networks using Modbus RTU allows for communication with the iPro unit controller. -
Page 35: Compressor Safety
2.12.1 Compressor motor protection Copeland EazyCool CO units are equipped with a Stream 4MTL compressor including CoreSense Protection technology. All relevant electrical protection features are covered by the Emerson M200 variable frequency drive. For more details see the M200 Inverter Handbook. -
Page 36: Pressure Relief Valve - High-Pressure Side
Figure 41: Pressure transmitters in the CO unit 2.12.4 Pressure relief valve – High-pressure side A 120-bar pressure relief valve is installed in the gas cooler outlet. This valve protects the high- pressure side including the gas cooler. In case of blocked HPV the high-pressure cut-out will switch the compressor off before the pressure relief valve opens. -
Page 37: Low-Pressure Safety Control
Figure 43: Liquid receiver with safety group Figure 44: Pressure relief valves with changeover valve 2.12.6 Low-pressure safety control As on discharge and liquid sides, a suction pressure transmitter (B1 = AIC1) provides information about suction pressure to the system controller. This value is used to evaluate the load requirement and to protect the unit / system against low pressure on suction side. -
Page 38: Oil Level Monitoring Device Ow5 Traxoil
2.13 Oil level monitoring device OW5 TraxOil The compressor in the Copeland EazyCool CO refrigeration unit is equipped with an OW5 TraxOil oil level monitoring system. This device is intended to prevent the compressor from operating with insufficient oil. The OW5 uses a hall sensor to measure the oil level. Unaffected by foaming oil or light, a magnetic float changes its position according to the oil level. -
Page 39: Installation
Installation WARNING High pressure! Injury to skin and eyes possible! Be careful when opening connections on a pressurized item. Never install the unit at such a height that if the pressure relief valve opens, the gas flow can reach an individual’s head. IMPORTANT Always install the unit in such a way that all installation, commissioning and servicing works can be carried out safely and easily. -
Page 40: Lifting
3.1.3 Lifting Always lift the unit by points marked with red arrows on pictures below. Figure 49: Lifting points for CO units When lifting the unit with slings, always use the spreader bar mounted above the unit to avoid squeezing the unit. Figure 50: Lifting unit with slings and centre of gravity C6.1.11/0718-0619/E... -
Page 41: Refrigeration Piping Connections
Refrigeration piping connections 3.2.1 Refrigeration piping installation and connections WARNING High pressure! Risk of personal injury! The units are pressurized with dry air. Be careful when opening connections on a pressurized item. IMPORTANT Tubing quality! Installation contamination! All interconnecting piping should be of refrigeration grade, clean, dehydrated and must remain capped at both ends until installation. -
Page 42: Brazing Recommendations
Be sure tube fitting inner surface and tube outer surface are clean prior to assembly. Both tubes are extended from the condensing unit housing, therefore Emerson recommends isolating the housing by using a wet cloth on the copper tubing. -
Page 43: Electrical Connection
Figure 53: Brazing – Sectional view Electrical connection WARNING Earth leakage current! Danger of electric shock! This product includes a three-phase frequency drive. Additional protection devices could be necessary. This must be decided by the electrical network supplier or by the electrician company which provides the electrical connection. -
Page 44: Electrical Wiring
NOTE: When a TN-C system is applied a jumper (part of the delivery) must be added between N & PE (X5.N & X5.PE) as per Figure 54. Figure 54: Power supply terminals with jumper 3.3.2 Electrical wiring Ensure that the neutral wire "N" and the ground protection wire "PE" are connected to the main switch before commissioning. -
Page 45: Figure 55: Dimensions And Distances Required For Unit Installation (In Mm)
1600 Figure 55: Dimensions and distances required for unit installation (in mm) Another factor to consider in finding a good installation site is the direction of the prevailing wind. For example, if the air leaving the condenser faces the prevailing wind, the air flow through the condenser can be impeded, causing high refrigeration temperatures and ultimately resulting in reducing the lifetime of the unit. -
Page 46: Start-Up & Operation
Start-up & operation WARNING High pressure! Risk of personal injury! Always keep sufficient distance from the pressure relief valve to avoid serious injury in the event of a sudden pressure release. WARNING Hot surfaces! Burning! Do not touch the compressor’s heads or discharge line as their surfaces can reach high temperatures both during operation and at standstill. -
Page 47: Figure 57
Figure 57 Starting the evacuation function: The evacuation mode will start when pressing the ENB key only if all 3 of the following conditions are met: ▪ suction pressure probe P1 value < SPF6 ▪ gas cooler (condenser) pressure probe P2 value < SPF6 ▪... -
Page 48: Charging Procedure
The factory settings of the system controller take into account the maximum number of permitted starts and stops of the compressor, as well as the running time and minimal downtime. Emerson recommends to change these settings only in exceptional cases, eg, when the liquid line pressure cannot be kept by the factory settings. -
Page 49: Checks Before Starting & During Operation
Checks before starting & during operation IMPORTANT Liquid valves not fully opened! Liquid trap! Both valves on the liquid line should be fully opened in order to prevent liquid trapping. Before a system runs for the first time: ▪ Check that the valves on the liquid line are fully opened except for HPV and BPV valves. ▪... -
Page 50: Maintenance & Repair
CAUTION Unauthorized parts! Unit damage! Only parts authorized by Emerson can be used for maintenance and replacement. As part of standard servicing and maintenance it may be necessary to open the unit housing and covers. -
Page 51: To Open The Compressor Chamber
5.1.2 To open the compressor chamber ▪ Unscrew the two screws located on the top of the compressor chamber cover, unplug the green/yellow grounding cable by pulling, then lift the cover. Figure 60: Opening the compressor chamber 5.1.3 To remove the fan safety grid WARNING Uncovered rotating parts! Personal injuries! Always de-energize the unit before removing the condenser fan grid. -
Page 52: Replacing A Compressor
As a general guide, it is advisable to do this at least once every two months. As a general rule and for a clean environment Emerson recommends that the fins be cleaned with liquid detergent diluted with clean water. The refrigeration unit has a well-designed chassis with falling levels towards a large drainage hole, and provided the unit is installed level, any cleaning solution should be able to drain away. -
Page 53: Electrical Connections
NOTE: In order to meet the requirements of the Ecodesign Directive 2009/125/EC with regard to efficient system operation, ensure the heat exchangers remain clean at all times. Electrical connections WARNING Isolating switch "On"! Danger of electric shock! Turn off the main power supply to de-energise the unit before undertaking any task on electrical equipment. -
Page 54: Disclaimer
3. Emerson does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any Emerson product remains solely with the purchaser or end user. -
Page 55: Appendix 1: Alarm Menu Ipro Ipr215D Controller
Appendix 1: Alarm menu iPro IPR215D controller Alarms Circuit 1 Name on Code Description Cause Action Reset Visograph Automatically if the number of activations is less than AL12 in the AL13 time when the input is disabled. Compressors restart working according to the working algorithm. - Page 56 Alarms Circuit 1 Name on Code Description Cause Action Reset Visograph Automatically as soon as the pressure ▪ If AC1 = REL: or temperature reaches: Minimum pressure Suction pressure or ▪ If AC1 = REL: (temperature) temperature ≤ SETC1 - AL3 SETC1 - AL3 + differential value LAC1 LAC1...
- Page 57 Alarms Circuit 1 Name on Code Description Cause Action Reset Visograph Proper digital input enabled Liquid level alarm (the input is configured as Automatically as soon as the input is Only signalling in Circuit 1 DI1 = 109 liquid level Circuit 1) disabled After delay CDI1 Pre-alarm for...
- Page 58 Compressor alarms Name on Code Description Cause Action Reset Visograph Oil switch load input activation ▪ The corresponding (the input is configured as compressor is turned off DIC = 1 Oil pressostat Compressor (with step compressors all Automatically as soon as the input is compressor Circuit 1) (for each (for each...
- Page 59 Generic alarms Name on Code Description Cause Action Reset Visograph Probe failure Automatically as soon as the probe Probe 1 failure Only signalling alarm restarts working Probe failure Automatically as soon as the probe Probe 2 failure Only signalling alarm restarts working Probe failure Automatically as soon as the probe...
- Page 60 Generic alarms Name on Code Description Cause Action Reset Visograph If value of gas leak detector 1 [2- When value of gas leak detector 1 [2-3- GLeak1 3-4] probe > GLD1 [GLD6- 4] probe ≤ GLD1 – GLD3 PRGLK1 Gas leak pre- Relay set in GLD4 [GLD9- [2-3-4]- GLD11-GLD16] and gas leak...
- Page 61 Compressor with inverter alarms Name on Code Description Cause Action Reset Visograph INVO Oil switch load input activation ▪ The corresponding INVO Inverter safety (for (the input is configured as Automatically as soon as the input is inverter is turned off. (for suction alarm for oil suction...
- Page 62 Gas cooler alarms Name on Code Description Cause Action Reset Visograph (Priority on probe failure alarms) The % of the valve updates every second in order to reach the correct percentage. If the receiver pressure value High pressure on Automatically as soon as the HP REC is between the values GC29 and GC28 –...
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Page 63: Appendix 2: Temperature / Resistance Curve For Ntc
Appendix 2: Temperature / resistance curve for NTC Temp Resistance Temp Resistance Temp Resistance Temp Resistance Temp Resistance Temp Resistance [Ω] [Ω] [Ω] [Ω] [Ω] [°C] [°C] [°C] [Ω] [°C] [°C] [°C] 329500 67770 17960 5827 2228 973.1 -49.5 320200 -19.5 66170 10.5... - Page 64 Temp Resistance Temp Resistance Temp Resistance Temp Resistance Temp Resistance Temp Resistance [Ω] [Ω] [Ω] [Ω] [Ω] [Ω] [°C] [°C] [°C] [°C] [°C] [°C] -32.5 126550 -2.5 30390 27.5 9112.5 57.5 3266.5 87.5 1354.5 123300 29730 8944 3215 1336 -31.5 120200 -1.5 29105...
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Page 65: Appendix 3: Temperature / Resistance Curve For Ptc
Appendix 3: Temperature / resistance curve for PTC Temp Resistance Temp Resistance Temp Resistance Temp Resistance Temp Resistance Temp Resistance Temp Resistance [Ω] [Ω] [Ω] [Ω] [Ω] [Ω] [Ω] [°C] [°C] [°C] [°C] [°C] [°C] [°C] 420.6 772.8 1240.5 1524.5 1841 -64.5 423.57... - Page 66 Temp Resistance Temp Resistance Temp Resistance Temp Resistance Temp Resistance Temp Resistance Temp Resistance [Ω] [Ω] [Ω] [Ω] [Ω] [Ω] [Ω] [°C] [°C] [°C] [°C] [°C] [°C] [°C] -47.5 522.35 -17.5 692.2 12.5 895.4 42.5 1132.05 72.5 1402.1 102.5 1705.75 132.5 2028 524.9...
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Page 67: Appendix 4: Ecodesign Overview Tables According To Regulation 2015/1095/Eu
Appendix 4: Ecodesign overview tables according to Regulation 2015/1095/EU C6.1.11/0718-0619/E... - Page 68 C6.1.11/0718-0619/E...
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Page 69: Appendix 5: List Of Tables And Figures
Appendix 5: List of tables and figures Tables Table 1: CO unit technical data ........................4 Table 2: CO unit features ..........................4 Table 3: Qualified refrigerant and oil ......................6 Table 4: Fan specifications ........................... 9 Table 5: Fan technical data .......................... 9 Table 6: Legend of the P&I diagram for CO units .................. - Page 70 Figure 32: Switching from transcritical to subcritical mode ................ 25 Figure 33: Controller logic for the pumpdown function ................26 Figure 34: Sensoring in subcritical mode ....................27 Figure 35: iPro Alarm flashing symbol ......................27 Figure 36: iPro "Alarm" key ........................28 Figure 37: Active alarms screen .........................
- Page 71 The Emerson logo is a trademark and service mark of Emerson Electric Co. Emerson Climate Technologies Inc. is a subsidiary of Emerson Electric Co. Copeland is a registered trademark and Copeland Scroll is a trademark of Emerson Climate Technologies Inc.. All other trademarks are property of their respective owners.