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AE4-1287 R8

Copeland Discus

™

Compressors with

Demand Cooling

™

System

AE4-1287 R8 March 2015

TABLE OF CONTENTS

Section Page Section Page

Safety

Safety Instructions ...................................................2

Safety Icon Explanation ...........................................2

Instructions Pertaining to Risk of Electrical

Shock, Fire, or Injury to Persons ...........................3

Safety Statements ...................................................3

Introduction ...............................................................4

Updated Discharge Temperature Guidelines ...........4

Operating Range .....................................................4

Demand Cooling System .........................................4

Demand Cooling System Design .............................5

Demand Cooling Compressors ...............................5

Condenser Sizing ....................................................5

Demand Cooling System Components ...................5

Demand Cooling with CoreSense

™

Protection ........6

System Information ..................................................6

Demand Cooling with Discus

™

Compressor

Unloading ..............................................................6

4D and 6D Unloading with Demand Cooling ...........7

3D Copeland Discus Digital

™

compressors with

Demand Cooling ...................................................7

Performance Adjustment Factors ............................7

Demand Cooling Speciﬁ cations ...............................7

Figures and Tables

Demand Cooling System .........................................7

Low Temperature Operating Envelopes With and

Without Demand Cooling....................................8

CoreSense™ Discharge Temperature Protection....8

Standard Location of CoreSense

Temperature Probe ............................................9

Low Temperature Operating Envelope for R-22 at

65°F Return Gas (with Head Fan) ...................9

Demand Cooling System Diagram ........................10

Demand Cooling Wiring Schematics ................11-13

Demand Cooling Operating Setpoints and

Control Actions ....................................................14

Demand Cooling Kit Part Numbers .......................14

Appendix - Demand Cooling Diagnostics ...... 15-18

Summary of content (18 pages)

PAGE 1
AE4-1287 R8 AE4-1287 R8 March 2015 Copeland Discus™ Compressors with Demand Cooling™ System TABLE OF CONTENTS Section Page Section Safety Figures and Tables Safety Instructions ...................................................2 Safety Icon Explanation ...........................................2 Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons ...........................3 Safety Statements ...................................................3 Demand Cooling System ..
PAGE 2
AE4-1287 R8 Safety Instructions Copeland Discus™ compressors are manufactured according to the latest U.S. and European Safety Standards. Particular emphasis has been placed on the user's safety. Safey icons are explained below and safety instructions applicable to the products in this bulletin are grouped on page 3. These instructions should be retained throughout the lifetime of the compressor. You are strongly advised to follow these safety instructions.
PAGE 3
AE4-1287 R8 Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons WARNING WARNING WARNING CAUTION ELECTRICAL SHOCK HAZARD • Disconnect and lock out power before servicing. • Discharge all capacitors before servicing. • Use compressor with grounded system only. • Molded electrical plug must be used when required. • Refer to original equipment wiring diagrams. • • Failure to follow these warnings could result in serious personal injury.
PAGE 4
AE4-1287 R8 Introduction than AHRI rating condition at 65°F return gas. Energy efficiency regulations drive continuous change in the availability of refrigerants to the marketplace. With the introduction of R-22 as a replacement for R-502, compressors began to experience internal discharge temperatures that exceed the safe operational limits for long term stability of refrigerant oil.
PAGE 5
AE4-1287 R8 Performance data for Demand Cooling compressors includes the effects of injection when it is required. The approximate conditions where injection occurs are shown in Figures 2, 3, and 6. At the conditions where Demand Cooling is operating, the performance values are time averages of the instantaneous values, since small fluctuations in suction and discharge conditions occur as the Demand Cooling injection valve cycles.
PAGE 6
AE4-1287 R8 C. The alarm signal for local or remote control. The alarm relay is energized, after a one minute delay, by a continuous, low or high TS temperature signal. An alarm signal can indicate the following: communicated to the CoreSense Protection module. See Figure 8E. System Information 1. Demand Cooling is designed to work on all Copeland Discus compressors equipped with injection ports. A different kit is required for each compressor body style and control voltage.
PAGE 7
AE4-1287 R8 Performance Adjustment Factors nomenclature beginning with -ADx (e.g. 4DKNF63KLTSK-AD0) Demand Cooling capability is built in. Performance values for R-407A, R-407C, R-407F, R-448A and R-449A are not provided in this bulletin. For actual performance values refer to Product Selection Software (PSS) or the Online Product Information (OPI) at EmersonClimate.com.
PAGE 8
AE4-1287 R8 Without Demand Cooling With Demand Cooling - Head fan required - CoreSense discharge temp protection required - Head fan optional Figure 2 – Low Temp Envelope without Demand Cooling Figure 3 – Low Temp Envelope with Demand Cooling Injection lines represent maximum operation point within discharge temperature limits of the compressor. For operating points below the line, Demand Cooling would not be active.
PAGE 9
AE4-1287 R8 Figure 5 – Standard Location of CoreSense Temperature Probe (for compressors without CoreSense Diagnostics) R-22 Low Temp Applications 140 130 Demand Cooling Required* 120 Condensing Te emperature (°F) 110 100 90 65°F Return Gas Demand Cooling Injec on Line 80 70 *If Liquid Injec on Is Not Installed, Recommend 265°F MAX Discharge Line Temp.
PAGE 10
AE4-1287 R8 M TO CONTROL CIRCUIT L A DEMAND-COOLING CONTROL S MODULE INJECTION VALVE ELECTRICAL CONTROL LINE REFRIGERANT INJECTION LINE MANUAL SHUTOFF VALVE DEMAND COOLING SENSOR AND SENSOR LINES CONDENSER INJECTION LINE FILTER RECEIVER LIQUID LINE FILTER DRIER COMPRESSOR INJECTION SOLENOID VALVE SUCTION LINE FILTER TXV EVAPORATOR ACCUMULATOR Figure 7 Demand Cooling System Diagram © 2015 Emerson Climate Technologies, Inc.
PAGE 11
AE4-1287 R8 Current Sensing (CS) Relay 240vac Compressor Contactor (CC) Compressor Motor L1 L2 L3 Sentronic NOTE: Compressors with internal overload protection MUST have some means, such as a current sensing relay, to deenergize the Demand Cooling Module and the Sentronic when the compressor is not running! Demand Cooling Module L M A S Control Temp.
PAGE 12
AE4-1287 R8 Compressor Contactor (CC) 240vac Compressor Motor L1 L2 L3 Sentronic Demand Cooling Module Controls NOTE: The control circuit must be arranged so that the Demand Cooling Module and the Sentronic are deenergized when the compressor is not running! L M A S Temp. Sensor 240 2 L M CC A Injection Solenoid Electronic Switch L2 L1 Figure 8C Demand Cooling Wiring Schematic with Sentronic Oil Pressure Control less Current Sensing Relay L2 L1 Injection Solenoid Temp.
PAGE 13
AE4-1287 R8 NOTE: The CoreSense module is dual rated for 120v / 240v. The Demand Cooling module must be matched to the line voltage. L1 * 120v or 240v L2 CoreSense Module Terminal Strip Demand Cooling Module L 120v 240v L M Current Sensor Connector 2 M CC A Control Temp. Sensor Current Sensor A S Injector Control Switch Injection Solenoid L1 Contactor L2 Figure 8E Coresense Protection with Copeland Demand Cooling © 2015 Emerson Climate Technologies, Inc.
PAGE 14
AE4-1287 R8 Table 1 Demand Cooling Operating Setpoints and Control Actions Table 2 Demand Cooling Kit Part Numbers Frequency 50HZ 60HZ Voltage 2D 3D 4D 6D 4D*X,4D*N¹ 6D*X,6D*N¹ 120V 998-1000-12 998-1001-13 998-1001-14 998-1001-16 998-2001-14 998-2001-16 240V 998-1000-22 998-1001-23 998-1001-24 998-1001-26 998-2001-24 998-2001-26 120V 998-1000-12 998-1000-13 998-1000-14 998-1000-16 998-2000-14 998-2000-16 240V 998-1000-22 998-1000-23 998-1000-24 998-1000-26 998-2000-24 998
PAGE 15
AE4-1287 R8 Appendix ® Copeland Demand Cooling® Diagnostics Demand Cooling Operating Characteristics 2. Place the wrapped probe-sensor inside an insulation shield to protect it from air currents. Use a material such as Permagum® or piping insulation such as ArmafleX®. The insulating material should be tightly wrapped around the taped-sensor and the wrap should be secured with wire or tiewraps if necessary. There should be no free air movement over the metal part of the taped-sensor.
PAGE 16
AE4-1287 R8 Bench Check of the Module and Injection Valve • A controlled voltage source the same as the rating of the module and the injection valve. • A multimeter. 6. After one minute, the module should trip. The run contact 'L' to 'M' should open, and the alarm contact 'L' to 'A' should close. Deenergize the module and disconnect the injection valve. The resistance should be zero ohms between 'L' and 'A', and between 'L' and 'M' there should be an open circuit.
PAGE 17
AE4-1287 R8 is closed. If correct control voltage is not present, replace the module. 2. Deenergize the system and disconnect the sensor from the module. Energize the system so the compressor is running. The frosting should stop. 3. If correct control voltage is present, make sure there is a full sight glass of liquid from the receiver at the injection valve. If there is not a full sight glass of liquid, the piping from the receiver should be checked before proceeding.
PAGE 18
AE4-1287 R8 be occasional Demand Cooling trips. If lowering system temperatures corrects the continuous problem, the test is ended, if not go to Step 5. 1) Measure the room temperature. 2) Connect the temperature sensor probe to the compressor discharge line 6” from the discharge valve. The probe must be tightly secured to the discharge line, and must be well insulated so that moving air will not produce a false reading (a poorly insulated probe may cause errors of more than 30°F!). 5.