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Emerson AE4-1287 R7 User Manual

Emerson AE4-1287 R7
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1
© 2012 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
AE4-1287 R7
Application Engineering
BULLETIN
Copeland Discus
Demand Cooling
AE4-1287 R7 December 2013
Application Engineering
BULLETIN
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
Operating Range .....................................................4
Demand Cooling System Design .............................4
Demand Cooling™ Compressors ............................5
Condenser Sizing ....................................................5
Demand Cooling System Components ...................5
System Information ..................................................6
Demand Cooling with Discus Compressor
Unloading ..............................................................6
4D and 6D Unloading with Demand Cooling ...........6
3D Copeland Discus Digital™ with Demand
Cooling ..................................................................6
Performance Adjustment Factors ............................7
Demand Cooling Speci cations ...............................7
Figures and Tables
Demand Cooling System .........................................7
Low Temperature Operating Envelope with
Demand Cooling for R-407A, R-407C and
R-407F..................................................................8
Low Temperature Operating Envelope for R-22 at
65°F Return Gas (with Head Fan) .........................8
Demand Cooling System Diagram ..........................9
Demand Cooling Wiring Schematics ............... 10-12
Demand Cooling Operating Setpoints and
Control Actions ....................................................13
Demand Cooling Kit Part Numbers .......................13
Demand Cooling Evaporator Capacity Adjustment
Factors for HCFC-22 ...........................................14
Demand Cooling Evaporator Mass Flow
Adjustment Factors for HCFC-22 ........................14
Appendix - Demand Cooling Diagnostics ...... 15-18
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Emerson AE4-1287 R7 Specifications

General IconGeneral
BrandEmerson
ModelAE4-1287 R7
CategoryRefrigerator
ColorBlack
Energy Star CertifiedNo
Voltage115V
RefrigerantR600a
Frequency60 Hz
ApplicationHome, Office, Dorm

Summary

Safety Instructions

Safety Icon Explanation

Explains the meaning of safety icons like DANGER, WARNING, CAUTION, NOTICE.

Safety Instructions: Hazards

Electrical Shock Hazard

Details precautions for electrical hazards during servicing.

Pressurized System Hazard

Outlines risks associated with pressurized systems containing refrigerant and oil.

Burn Hazard

Warns about potential burns from hot compressor components and brazing.

Safety Instructions: Handling and General

Compressor Handling

Provides guidance on safely handling compressors using appropriate lifting devices.

General Safety Statements

General statements regarding safe installation, commissioning, and maintenance.

Introduction to Demand Cooling

HCFC-22 and Low-Temperature Use

Introduces HCFC-22 as a low-temperature refrigerant alternative and its challenges.

POE Lubricant Handling

Advises on careful handling of POE lubricant and protective equipment.

Demand Cooling System Operation

Explains how the system uses electronics to monitor and control discharge temperature via refrigerant injection.

Operating Range and Design

Describes protection temperature ranges and system design for minimizing injection impact.

Demand Cooling System Components

Temperature Sensor (TS)

Describes the NTC thermistor used to sense temperature and provide signals to the module.

Control Module (CM)

Explains the CM's functions: input comparison, output control, and alarm signaling.

Injection Valve (IV)

Details how the IV meters refrigerant flow into the compressor for cooling.

Compressor Modifications and Sizing

Demand Cooling Compressors

Details modifications to existing Discus compressors for Demand Cooling use.

Condenser Sizing

States that Demand Cooling has virtually no effect on system heat of rejection for condenser sizing.

System Information and Requirements

System Cleanliness and Filters

Emphasizes system cleanliness and the use of specific filter dryers.

Refrigerant Supply Line and Head Fan

Details requirements for the liquid refrigerant supply line and head fan usage.

Return Gas Temperature and Defrost

Specifies the return gas temperature limit and defrost scheme considerations.

Demand Cooling with Compressor Unloading

Unloading Compatibility

Discusses Demand Cooling approval with specific compressor unloading types like 4D, 6D.

Demand Cooling Performance and Specifications

3D Copeland Discus Digital™ with Demand Cooling

Describes using Demand Cooling with 3D Discus digital compressors and sensor replacement.

Performance Adjustment Factors

Explains how return gas temperature affects injection and performance factors.

Demand Cooling Specifications

Refers to figures and tables for operating envelopes and setpoints.

Demand Cooling Operating Envelopes

Figure 2 - Operating Envelope for R-407A/C/F

Graph showing operating limits for specific refrigerants with Demand Cooling.

Figure 3 - Operating Envelope for R-22

Graph showing operating limits for R-22 with Demand Cooling at 65°F return gas.

Demand Cooling System Diagram

Figure 4 - System Diagram

Illustrates the components and flow of the Demand Cooling system.

Demand Cooling Wiring Schematics

Figure 5A - With Sentronic and Current Sensing Relay

Wiring diagram for Demand Cooling with Sentronic oil pressure and current sensing relays.

Figure 5B - Less Sentronic Oil Pressure Control

Wiring diagram for Demand Cooling without Sentronic oil pressure control.

Demand Cooling Wiring Schematics

Figure 5C - With Sentronic Less Current Sensing Relay

Wiring diagram for Demand Cooling with Sentronic oil pressure control but without current sensing.

Figure 5D - With Isolated Control Contacts

Wiring diagram showing Demand Cooling with isolated control contacts.

Demand Cooling Wiring Schematics

Figure 5E - CoreSense Protection Integration

Wiring diagram illustrating CoreSense Protection integration with Demand Cooling.

Demand Cooling Setpoints and Parts

Table 1 - Operating Setpoints and Control Actions

Lists setpoints and actions for the Demand Cooling module based on temperature.

Table 2 - Kit Part Numbers

Provides part numbers for Demand Cooling kits and related components.

Kit Contents and Accessories

Lists items included in kits and optional mounting brackets/sensors.

Demand Cooling Adjustment Factors

Table 3A - Evaporator Capacity Factors for HCFC-22

Table of factors to adjust evaporator capacity based on operating conditions.

Table 3B - Mass Flow Factors for HCFC-22

Table of factors to adjust mass flow based on operating conditions.

Appendix: Demand Cooling Diagnostics

Demand Cooling Operating Characteristics

Explains how the NTC thermistor and module monitor discharge temperature.

Bench Testing Components

Details how to bench test the sensor and control module for proper function.

Appendix Table 1 - Sensor Resistance Values

Table of calculated sensor resistance values for various temperatures.

Bench Testing Module and Injection Valve

Module and Injection Valve Test

Steps to bench test the Demand Cooling module and injection valve for proper operation.

Installed System Checks

Injection Valve Not Injecting Troubleshooting

Troubleshooting steps for diagnosing issues when the injection valve fails to inject.

Troubleshooting Injection Valve Issues

Injection Valve Continually Injecting Troubleshooting

Troubleshooting steps for diagnosing continuous injection by the valve.

Diagnosing Suction Pressure Issues

Diagnostic steps for identifying issues related to suction pressure related to injection.

Troubleshooting Cycling Injection Valve

Cycling Injection Valve Diagnosis

Troubleshooting steps for when the injection valve cycles on and off.

Appendix Table 2 - Discharge Temperature Data

Table showing expected discharge temperatures for various operating conditions.

Appendix Figure 1 - Injection Areas

Graph showing Demand Cooling injection zones based on operating conditions.

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