Emerson Copeland XC643 User guide

Application Engineering

B U L L E T I N

AE8-1386 R1 October 2013

Application Guidelines for the

Emerson Closed Loop Digital Controller (XC643)

Table of Contents

Safety

Safety Instructions....................................................2 How to See and Modify the Set Points..................... 11

Safety Icon Explanation............................................2 How to Modify the Set Point of Compressors

Instruction Pertaining to Risk of Electrical Shock, and/or Fans.........................................................12

Fire, or Injury to Persons...........................................3 The Info Menu.........................................................12

Safety Statements ....................................................3 How to Enter the “Pr1” Parameter List .....................12

How to Enter in Parameters List “Pr2” .....................12

Introduction How to Change Parameter Values..........................12

Overview ..................................................................4 Keyboard Locking....................................................13

Product Specifications ..............................................4 Parameters .............................................................13

Components.............................................................5 Compressor Regulation...........................................13

Digital Compressor Regulation................................14

Installation and Controller Operating Instructions Fan Regulation........................................................15

Wiring & Electrical Connections................................6 Use of the Programming "HOT KEY".......................15

Probes Connection...................................................6 Parameter Default Values and Descriptions ............16

Probe Wiring.............................................................6 Commissioning the XC643CX.................................17

Systems with Compressor Pumpdown Cycle............8 Commissioning the XC643 in the E2.....................17-21

Mounting & Installation..............................................8

Controller Display......................................................9

Controller Startup.....................................................10

First Installation......................................................10

How to Set the Kind of Refrigerant.........................10

How to Set the Kind of Probes............................... 11

Programming Procedure........................................ 11

Probe Errors.......................................................... 11

Printed in the U.S.A.

Application Engineering

B U L L E T I N

AE8-1386 R1

Safety Instructions

Copeland™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.

SafetyIconExplanation

DANGER

WARNING

CAUTION

NOTICE

CAUTION

Printed in the U.S.A.

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.

Application Engineering

B U L L E T I N

AE8-1386 R1

Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons

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.

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.

•install, commission and maintain this equipment.

•

•All valid standards and codes for installing, servicing, and maintaining electrical and

refrigeration equipment must be observed.

Printed in the U.S.A.

Application Engineering

B U L L E T I N

AE8-1386 R1

INTRODUCTION

The XC643CX is designed to manage one Copeland™

digital compressor on a single-compressor condensing

unit, or two compressors in parallel, with one digital

compressor in addition to a fixed-speed compressor.

The controller also manages condenser fans. Control

is based on the pressure or temperature sensed in the

low pressure suction (compressors) and high pressure

(condenser) circuits.

The front panel offers information on the system status,

the status of loads, and any alarm conditions. The

controller can be easily programmed through a hot key.

The controller can be connected to a monitoring system

via the serial TTL output, using the standard ModBus

RTU protocol.

Overview

On refrigeration applications where the load may vary

over a wide range, some means of capacity control is

often desirable for optimum system performance and

control. In addition, compressor capacity modulation

can reduce power and energy consumption, reduce

Table 1 - Modulation Ranges

Modulation Range

Compressor Family of Full Load

Capacity

Scroll Digital ZBD/ZRD/ZFD/ZPD 10-100%

3D Discus Digital 10-100%

4D Discus Digital 55-100%

6D Discus Digital 70-100%

compressor cycling, and decrease the starting

electrical load. In order to achieve these objectives,

Emerson Climate Technologies has developed the

Copeland Discus Digital™and Copeland Scroll Digital™

compressors.

The XC643 is one module (one part number) which

can support scroll and Discus digital (3D, 4D, 6D)

compressors. See Table 1 for specific modulation

ranges.

For more details on Copeland digital compressors refer

to the following Application Engineering guidelines

or contact your Emerson Climate Technologies

representative:

AE21-1319, Digital Capacity Control for Refrigeration

Scroll Compressors

AE21-1355, Digital Capacity Control for Copeland and

Intelligent Store Discus Refrigeration Compressors

AE4-1357, Upgrade Procedures for Parallel Applications

Using Digital Capacity Control for Copeland and

Intelligent Store Discus Refrigeration Compressors (for

3D Discus)

AE4-1373, Upgrade Procedures for Parallel Applications

Using Digital Capacity Control for Copeland and

Intelligent Store Discus Refrigeration Compressors (for

4D & 6D Discus)

The simplest way to apply the XC643 digital controller

is with one suction pressure transducer or evaporator

temperature sensor. The controller reads the suction

pressure and modulates the digital compressor as

Table 2 - Product Specifications

Housing: Self extinguishing ABS.

Case: Front panel 32x74 mm (1.26x2.91 inch), depth 70mm (2.76 inch)

Mounting: “CX”format panel mounting in a 29x71 mm panel cut-out (1.14x2.80 inch)

Protection: IP20

Frontal protection: IP65

Connections: Removable terminal block 6 and 14 wires

Power supply: 24Vac/dc * 10%, 50-60Hz.

Power absorption: 5VA max

Display: 4 digits red led and 4 digit orange led.

Serial output : TTL standard Communication protocol: ModBus - RTU

Operating temperature: -28 to +60°C (-20 to +140F); Storage temperature: -25-60°C (-13-140F)

Relative humidity: 20-85% (no condensing)

Printed in the U.S.A.

O16,6

Application Engineering

B U L L E T I N

AE8-1386 R1

needed. If condenser fan control is also needed, a

second pressure transducer or condenser temperature

sensor can be added to read the high side pressure at

the exit of the condenser (reading liquid pressure or

liquid temperature).

This digital controller will also work with temperature

sensors rather than pressure transducers. The two

different types of sensors (temperature and pressure)

cannot be mixed. For example, you cannot use a

pressure transducer for suction and a temperature

sensor for condensing in an application.

Pressure transducers and NTC temperature sensors

are available with the controller kit. If you want to use a

different pressure transducer, consult your Application

Engineer.

Table 3 - Components

Part Number

998-0189-00

943-0017-00

929-0005-00

939-0007-00

939-0008-00

939-0009-00

943-0018-00

943-0019-00

962-0007-00

Description

Complete kit with controller, wire harnesses, pressure and NTC temperature

transducers

Controller only

Wire harness only

Pressure transducer only, PP11 suction

Pressure transducer only, PP30 discharge

Temperature transducer only

TTL/ RS485 Serial Converter

Hot key

Optional terminal box

PP11 - PP30 - Bar

7/16”-20UNF

18,5 12,5 17

Figure 1 - XC643CX 14 and 6 Pin Connectors

The XC643CX is provided with 2 socket connectors with

14 and 6 pins. These cable harnesses must be used.

Printed in the U.S.A.

Figure 2 - Standard Pressure Transducer

PP11 -0.5 to 7 bar (-7 to 100 psig) suction, female

PP30 0 to 30 bar (0 to 435 psig) discharge, female

Note: Alternative pressure transducers may be used.

Refer to Table 7.

Application Engineering

B U L L E T I N

AE8-1386 R1

TTL/RS485 external converter: used to convert the

TTL output into a RS485 (+) and (-) signal for the

monitoring system MODBUS_RTU compatible.

(XWEB).

Note! When connecting to an E2 System controller for

supervisory control, the polarity from the XC643 should

be reversed from the polarity at the E2 communication

port. The XC643CX uses a 9600 baud rate.

Figure 3 - TTL / RS485 Serial Converter

INSTALLATION AND CONTROLLER OPERATING

INSTRUCTIONS

Wiring and Electrical Connections

Before connecting cables make sure the power supply

complies with the rated voltage requirements. Separate

the probe cables from the power supply cables, the

outputs and the power connections. Do not exceed

the maximum current allowed on each relay (3A

resistive). In case of heavier loads use a suitable

external relay or contactor. Always use a Class 2

transformer with minimum power 5VA.

The power supply for the controller is 19-28VAC,

48-62Hz. The maximum load is 5 VA. 24V power to

the module must be on any time the unit is on and

should not be interrupted by any control. Center tap

transformers are not to be used.

Probes Connection

If using terminal ends be sure there are no bare parts

which could cause short circuiting or introduce noise

disturbance at high frequencies. To minimize the

induced disturbances use shielded cables with the

shield connected to earth.

Pressure probe (4 - 20 mA): respect the polarity.

Pb1 is suction; Pb2 is condenser.

Temperature probe (NTC 10K): Temperature probes

should be insulated from direct air streams to correctly

measure the temperature.

Probe Wiring

The XC643CX is capable of regulating the compressors

and condenser fans on any of the following types of

pressure/temperature sensors. The user must use the

same type of sensor to control the compressors and

the fans.

- 4-20mA pressure transducers (refer to Figure 4a)

- 0.5-4.5V ratiometric pressure transducers (refer

to Figure 4b)

- NTC 10K temperature sensors (refer to Figure 4c)

Note! The 14-pin connector consists of low voltage

wires. Keep the cables away from the power cables.

Use shielded cable to lengthen the cables.

PIN 4 is the common line for the temperature probes PIN

6 gives a 12Vdc supply for the 4-20mA pressure

transducers

PIN 10 is the ground connection for ratiometric pressure

transducers

Digital Line O

Fan2 Fan1 Comp2 Comp ut

15 17 19

16 18 20

Pb1*Pb2*

1 5 7

Hot Key/TTL

2 4 6 8 10

Supply

24V

Printed in the U.S.A.

12V

40mA

Figure 4 - XC643 Module Connections

Pb1

Pb2

Application Engineering

B U L L E T I N

AE8-1386 R1

PP11, PP30, 4-20mA pressure transducers

respect the polarity. Pb1 Pb2

dEU= Pr4 5 7

Suction

Brown (+) to terminal 6 ; white (-) to terminal 5 4 6 8

Condenser

12V

Brown (+) to terminal 6 ; white (-) to terminal 7

40mA

Figure 4a - Wiring Diagram for 4-20 mA Pressure Transducer

Pb1 Pb2

Temperature probes (NTC 10K)

dEU= tPr

Suction: 4-5

Condenser: 4-7

5 7

4 6 8

Figure 4b - Wiring Diagram for NTC 10K Temperature Probes

Ratiometric transducers (0.5 -4.5Vdc)

dEU= Pr5 Gnd

Suction

In In

5 (control); 4(+); 10 (gnd) 1 5 7

Condenser 2 4 6 8 10

7 (control); 4(+); 10 (gnd) + Gnd

40mA

Figure 4c - Wiring for Ratiometric Pressure Transducers

Printed in the U.S.A.

•1.5”

Application Engineering

B U L L E T I N

AE8-1386 R1

Systems with Compressor Pumpdown Cycle Mounting and Installation

In systems that require a compressor pumpdown,

special attention should be paid to the control logic

for the digital unloader coil. Inherent to the digital

control, the compressor will effectively ramp down and

track the suction pressure by loading and unloading

to decreasing modulation rates. In order to avoid an

extended compressor pumpdown cycle, the digital

solenoid should be wired/controlled such that when a

pump down cycle is initiated the coil is de-energized.

This will force the compressor to run fully loaded (100%

capacity). Refer to AE-1182 and AE-1221 for more

details on pumpdown cycles.

Note: The Digital unloader solenoid is always energized

for 2 seconds upon start-up and at shut down of the

compressor.

PANEL

BRACKET

If this controlleris used outside,it should be enclosed in a

box with IP65 rating. Controllers should be mounted on

panel, in a 29x71 mm (1.14x2.80 inch) hole, and

fixed using the special brackets supplied. The controller

should not be mounted on the compressor nor in the

compressor terminal box.

The ambient operating temperature range is between

14-140 degrees F. (Can operate in ambients as low as

-40°F when applied with an enclosure.)

Ensure ventilation around the controller.

Note! For systems applied in low ambient conditions,

special attention should be paid to the digital

compressor's minimum allowable pressure differential

(Absolute Discharge Pressure - Absolute Suction

Pressure). Copeland Scroll compressors must maintain

at least a 75 PSID while the Copeland Discus must have

a 45 PSID to operate correctly.

(PUSH TO RELEASE)

•3.1”

•Front

•2.6”

•Back

•Side

Figure 5 - XC643 Dimensions and Mounting

Printed in the U.S.A.

Application Engineering

B U L L E T I N

AE8-1386 R1

Table 4 - Display Legend

UPPER DISPLAY LOWER DISPLAY ICONS

Suction temperature or Discharge temperature - Active loads

pressure or pressure - Measurement unit

Active Loads Suction

Pressure or

Temperature

Discharge

KPa

Temperature

or Pressure

Figure 6 - Controller Display

Table 5 - Icon Legend

LED FUNCTION MEANING

ON Celsius degrees

ON Fahrenheit degrees

bar ON bar displaying

PSI ON PSI displaying

kPa ON KPA displaying

ON Copeland Scroll Digital compressor on

Digital compressor is waiting to start (flash once per second) or

Flashing digital input alarm for DIGITAL COMPRESSOR (flash twice per

second) or DIGITAL COMPRESSOR in maintenance status.

ON Compressor 2 on

Flashing Compressor 2 is waiting to start (flash once per second)

ON Fan 1 on

Flashing Fan 1 is waiting to start (flash once per second)

ON Fan 2 on

Flashing Fan 2 is waiting to start (flash once per second)

ON The digital solenoid valve coil is energized

Printed in the U.S.A.

Application Engineering

B U L L E T I N

AE8-1386 R1

Keyboard

(SET)

Standard view: to see or modify the set point. In programming mode use SETP to

select a parameter or confirm an operation.

(UP)

In programming mode: used to browse the parameter codes or increase the displayed value.

With Hot key inserted: UP starts the Hot key programming procedure.

To access the INFO menu: push and release UP to access the INFO menu.

(DOWN)

In programming mode: used to browse the parameter codes or decrease the displayed value.

Not used Displays running hours for each load Not used

Key Combinations

+ Lock and unlock keyboard

+ Exit programming mode

+ Enter programming mode

Table 6 - Value Pre-Set According to the Kind of Refrigerant

R-404A R-22 R-410A R-507 R-134a R-407A R-407C

SETC (psig) 55 43 78 55 17 42 37

SETF (psig) 220 181 295 220 114 194 179

LSE (psig) 5 1 11 5 -7 -1 -1

HSE (psig) 114 93 155 114 51 99 95

LSF (psig) 170 131 245 169 63 143 130

HSF (psig) 270 231 345 269 163 243 230

Pbd 10 10 10 10 10 10 10

Pb 58 58 58 58 58 58 58

Controller Start-Up

First installation

At first installation:

1. Select the kind of refrigerant.

2. Select the kind of transducer

3. For systems with master controller

supervisory control, set the module node

address.

How to Set the Kind of Refrigerant

The controller has been programmed with several

refrigerants.

The pre-set refrigerant is: R-404A.

Printed in the U.S.A.

By modifying the refrigerant (FtyP), other defaults will

also change. Refer to Table 6.

If another refrigerant is used:

1. Enter the Programming mode by pressing the

Set and DOWN key for 3s.

2. Select the FtyP, kind of refrigerant,

parameter.

3. Press the “SET”key: the value of the

parameter will start blinking.

4. Use “UP”or “DOWN”to change the refrigerant

among the following:

r22(0) - 134(1) - 404(2) - 407A(3) - 407C(4) -

410(5) - 507(6)

This manual suits for next models

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