Stream Digital User Manual Application Guide
Contents
1. pur o 5 2 6 11 Oil level z All compressors are delivered with sufficient oil for normal operation The optimum oil level S should be checked by operating the compressor until the system is stable and then comparing the sight glass reading with the appropriate diagram below Oil level should be min 7s and max Ya of sight glass For service compressors when an oil regulator is used the oil level should be min 7s and max Ya of sight glass The level can also be checked within 10 seconds of compressor shut down For 4M D and 6M D compressors a higher oil level may be accepted when an oil regulator is in use because the oil separator will reduce excessive oil circulation pU Os Q N Stream 5 Oc g T ne E Q Figure 7 4M D and 6M D compressors E 2 6 12Application limits 4MAD1 22X 4MHD1 25xX 4MID1 30X 4MJD1 30X2 4MKD1 32X 0 6MID1 40X 6MJD1 45X 6MKD1 50X 60 DT TY TT Full Capacity 100 m Suction gas temperature 0 C Full Capacity 100 Suction gas temperature 25 C 40 Maintenance amp repair an Digital Fan Envelope n3 c Digital without fan Envelope Condensing Temperature Dismantling amp disposal 5 Ge I T T T T T T lI Y T EN __1_ T Lus L 02. __ ________ E 8 PAE L KAA EA IE M 8 SA CN pta ae EIS L NRI T 8 2 6 13 Multiple compressor EG 9 3 AA see uaecedeuseexnaseus 10 SU 10 10 Mans porn and STONGE NEIN o 10 Positioning ne 10 EUR Nice Pet Tm 10 CEP n 11 ol 11 32 1 High pressure 810 AA AA 11 Re low ON 11 3 2 3 ee LS NNI 11 OG TO 12 Le a Nese ets nate 12 A Electrical CONMMECUION e 13 A Ke I Ime URN omm 13 pde ec ricum E TOT me 13 SN ITI PIGS MOO NNI m 13 ac Dela motns Code Esri _ _ _6_ RIAM UE 13 4 2 3 Part winding motors YY Y COGO AC use eceniaeesi tdeo tipa pit RA war asia Getae PAURA ER UU DG 13 LAN NU MA NUNC EEEO IE EARE EI 13 4341 Wiring diagram Jor part winding moto
3. 50 45 40 35 30 25 20 15 10 5 0 5 10 Evaporating Temperature C Figure 8 Application envelopes for High and Medium temperature compressors used with R404A 8 C6 3 2 1211 E 4MFD1 13X AMLD1 15X 4MMD1 20X AMTD1 22X 4MUD1 25xX 6MMD1 30X 6 1 35 6MUD1 40X 50 55 50 Full Capacity 100 m Superheat 20K l Full Capacity 100 Suction gas temperature 25 C 40 35 30 25 Digital Fan envelope limit 20 45 Digital without fan envelope limit Condensing Temperature 10 5 0 55 50 45 40 35 30 25 20 15 10 5 0 Evaporating Temperature Figure 9 Application envelopes for Medium and Low temperature compressors used with R404A NOTE Application envelopes with other refrigerants are available on request 2 6 13 Multiple compressor application To ensure smooth and continuous modulation selection of the digital and non digital compressors capacities can be made according to the following rule Rule For optimum suction pressure control the following guideline is recommended in the selection of fixed capacity and Digital compressors per suction header D gt F1 F2 lt D F1 F3 lt D F1 F2 FN lt D F1 2 FN 1 where D Capacity of the Stream Digital compressor F1 FN Capacity of the standard Stream compressor The compressor selected should be the smallest compressor capacity that still covers all the gaps between steps to ensure t
4. description Installation 2 42 Maintenance amp Starting up amp Dismantling amp connection repair operation disposal 5 Starting up amp operation WARNING A Diesel effect Compressor destruction The mixture of air and oil at high temperature can lead to an explosion Avoid operating with air 5 1 Leak test The suction shut off valve and discharge shut off valve on the compressor must remain closed during pressure testing to prevent air and moisture from entering the compressor The test pressure dried nitrogen must not exceed 20 5 bar provided no other system component s pressure is lower In this case the lower pressure is the test pressure 5 2 System evacuation Before the installation is put into commission remove the holding charge then evacuate with a vacuum pump Proper evacuation reduces residual moisture to 50 ppm The installation of adequately sized access valves at the furthest point from the compressor in the suction and liquid lines is advisable To achieve undisturbed operation the compressor valves are closed and the system is evacuated down to 0 3 mbar 0 225 Torr Pressure must be measured using a vacuum pressure Torr gauge on the access valves and not on the vacuum pump this serves to avoid incorrect measurements resulting from the pressure gradient along the connecting lines to the pump Then the compressor must be evacuated Due to the factory holding charge of d
5. Q O C 65 Maintenance amp Dismantling amp Q repair disposal 6 Maintenance amp repair 6 1 Exchanging the refrigerant Qualified refrigerants and oils are given in Chapter 2 5 1 It is not necessary to replace the refrigerant with new unless contamination due to an error such as topping up the system with an incorrect refrigerant is suspected To verify correct refrigerant composition a sample can be taken for chemical analysis A check can be made during shut down by comparing the refrigerant temperature and pressure using precision measurements at a location in the system where liquid and vapour phases are present and when the temperatures have stabilised In the event that the refrigerant needs replacing the charge should be recovered using a suitable recovery unit In the event that R22 in a system with mineral oil is to be replaced with RA07C or R404A the oil must also be changed Please refer to Technical Information C7 26 1 Refrigerant Changeover from HCFC to HFC Refrigerants 6 2 Replacing a compressor CAUTION Inadequate lubrication Bearing destruction Exchange the accumulator fij 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 bur
6. Exploded view of Digital mechanism Factory delivered 4M D and 6M D compressors include as standard configuration One standard bank Digital modulated bank capacity controlled bank blocked suction std only for 6M D 2 6 2 Digital theory of operation Digital technology is now available on the 4M D and 6M D Stream compressors Applied to one bank on a 4M D compressor it provides 50 to 10096 capacity modulation When combined with a blocked suction bank on a 6M D compressor it provides 33 to 100 Digital capacity control is achieved by using a proven internal unloading method based on blocking gas to the valve plate suction area Capacity control can be achieved by varying the percentage of duty cycle when the compressor is loaded and unloaded The unloader piston mechanism that controls the flow of suction gas into the cylinders is driven by a solenoid valve Bolts studs sl oolenoid valve oolenoid valve gasket 7 Cylinder head gt 2 3 Figure 3 Digital modulation components C6 3 2 1211 E Starting up amp Electrical Installation Product Safety connection instructions Maintenance 4 Dismantling amp c prar Q x o repair operation disposal Loaded Unloaded Gas enters compressors Passes through body Passes through body Into valve plate Unloader mechanism blocks gas Compressed gas before entering valve plate Exits comp
7. brand products with CO Discharge Sensor Module Current Sensor Temp Sensor i 4 yi f A i p CoreSense M 4 Control Module Oil Pressure Sensor Motor Temp Sensor PTC Figure 156 CoreSense Diagnostics module 16 C6 3 2 1211 E For the electrical connection of the CoreSense Diagnostics module please refer to the wiring diagram below L4 420v N LP Alarm Indicator CoreSense Terminal Strip Figure 167 CoreSense wiring diagram NOTE For more information please refer to Technical Information D7 8 4 CoreSense Diagnostics for Stream refrigeration compressors 4 6 Crankcase heaters IMPORTANT dilution Bearing malfunction the crankcase heater on 12 hours before starting compressor A crankcase heater is used to prevent refrigerant migrating into the shell during standstill periods Heaters for 4M and 6M compressors are screwed into a sleeve see Figure 18 The crankcase heater is available in 120V 230V and 480V The operation of 120V 230V crankcase heater is controlled by the 1 Diagnostics module this is not possible with the 480V heater SENE ane sae aa a 666 272 Figure 178 100 Watt crankcase heater element C6 3 2 1211 E 17 Safety instructions Product
8. 4 2 1 Three phase motors All compressors can be started direct on line The necessary position of bridges for direct on line start depending on type of motor and or mains voltage is shown in Chapter 4 3 Wiring diagrams 4 2 2 Star Delta motors Y Code E With the help of bridges this motor is interchangeable for star Y or delta operation It is suitable for two voltages eg 230V in delta 400V in star connection If the supply voltage and the nominal voltage of the motor in A connection are identical the star connection motor can also be used for starting remove the bridges 4 2 3 Part winding motors YY Y Code A PWS motors contain two separate windings 2 3 1 3 which are internally connected in star and operated in parallel You cannot change the voltage by changing the electrical connections as the motor is only suitable for one voltage The first part winding ie the 2 3 winding on terminals 1 2 3 can be used for part winding start remove the bridges After a time delay of 1 0 1 seconds the second part winding ie the 1 3 winding on terminals 7 8 9 must be brought on line 4 3 Wiring diagrams The position of the jumpers in the terminal box and the recommended wiring diagrams are shown in Figures 13 and 14 C6 3 2 1211 E 13 Safety instructions Product description Installation rw E amp Starting up amp Dismantling amp c
9. starting operation and maintenance of Digital semi hermetic compressors This guideline is not intended to replace the system expertise available from system manufacturers Maintenance amp repair Dismantling amp disposal C6 3 2 1211 E 3 2 3 Nomenclature The model designation contains the following technical information about Stream Digital compressors Number of Cylinders Bore denomination Motor version D CoreSence Diagnostics 25 AWM D 0000 Motor size 25 25hp Oil type Ester oil X Mineral ail 0 2 4 Nameplate information All important information for identification of the compressor is printed on the nameplate located below the compressor oil pump The type of refrigerant used should be stamped on the nameplate by the installer The date of production consists of the year and week of production The year and month of production are also part of the serial number Jan A Feb B Dec L 4MUD 25X AWM D SERAL CD2 52 54 MaxOperPressHil 28 225 3 50 Ihz v 994 SE 1 VOLTAGE 380 420 YYIY 180 199 440 480 YYY 3 200 Made in Czech Republic by Emerson Glimale Technolgies 5 4 41 3 itx Ni _ teza eae semean CE Figure 1 Nameplate position 2 5 Application range 2 5 1 Qualified refrigerants and oils IMPORTANT It is essential that the
10. 2 592 7883 Emerson Copeland PerformanceAlert and Copeland Scroll are trademarks of Emerson Electric Co or one of its affiliated companies 2012 Emerson Climate Technologies Inc All rights reserved Malaysia Emerson Electric Malaysia Sdn Bhd Level M2 Blk A Menara 5 Jalan Yong Shook Lin 46050 Petaling Jaya Selangor Malaysia Tel 60 3 7949 9222 Fax 60 3 7949 9333 Middle East amp Africa Emerson Climate Technologies PO Box 26382 South Jabel Ali Free Zone Dubai UAE Tel 971 4 811 8100 Fax 971 4 886 5465 Philippines Emerson Climate Technologies 4 Floor San Miguel Properties Centre 7 St Francis Street Ortigas Center Mandaluyong City Philippines Tel 632 689 7288 632 479 5200 Fax 632 479 5271 Taiwan Emerson Electric Taiwan Co Ltd 3F No 2 DunHua South Road Sec 1 Taipei 105 Taiwan Tel 886 2 8161 7688 Fax 886 2 81617614 Thailand Bangkok Emerson Electric Thailand Ltd 34th Floor Nation Tower 1858 133 Bangna Trad Bangkok 10260 Thailand Tel 66 2 716 4700 Fax 66 2 751 4240 4241 Vietnam Emerson Climate Technologies Vietnam Suite 307 308 123 Truong Dinh St Dist 3 Ho Chi Minh Vietnam Tel 84 8 3932 2044 Fax 84 8 3932 2055 kd EMERSON Climate Technologies EMERSON CONSIDER IT SOLVED
11. Copeland Application Guideline Semi Hermetic Stream Digital Compressors 4MFD 13Xto 6MKD 50X c PIG M 3 T Nx EMERSON Climate Technologies 1 M 1 IN Bae ca ________ aa 1 DEP a Erie DES EE E 1 Lo Gee Wall SEC DOM NE T 2 4 OU E TITO Tm 3 2 1 Common information about Copeland brand products semi hermetic Stream Digital 3 22 UMN tueur tetuer Ebenen rentre odi eodeni MKUKI 3 Be eye HT TNR 4 LAN i EET 4 uic tem 4 2 8 GST nez 4 Zi Decon eaU ES NETT Hm 5 2 0 EE em 5 eo ON 5 Ee O NN _________________ ___ ___________ 5 2 6 4 Recommended application settings for modulation on Stream Digital compressors essere 7 2 6 5 Digital solenoid valve EU a RR 7 2D OO 7 CEA E 7 PASEO E po A I M coerce 7 PA LD 7 PANIE
12. PUT Os 5 CURRENT E SENSOR TT MI L1 N AA S o _ a 242 gt Legend sensor module Y Contactor M1 amp Terminal box compressor KI oco A Contactor M1 o CCH Crankcase heater MZ Fan motor condenser Fuse for control circuit M21 Fan motor condenser o m Fuse for control circuit Y7 Solenoid valve digital discus head a Fuse for control circuit Y21 Solenoid valve capacity control 1 Thermal protection switch M2 oolenoid valve capacity control 2 loss Contactor M1 Figure 145 C6 3 2 1211 E 15 4 4 Protection devices Independently from the internal motor protection fuses must be installed before the compressor The selection of fuses has to be carried out according to VDE 0635 DIN 57635 IEC 269 1 or EN 60 269 1 4 5 CoreSense Diagnostics CoreSense Diagnostics for all 4M D and 6M D semi hermetic Stream compressors combines oil and motor protection into one module replacing OPS1 2 and the electronic module INT69TM In addition to diagnostics it provides advanced protection against faults such as high discharge temperature locked rotor single missing phase voltage imbalance low voltage The module is capable of communication via Modbus protocol An external overload protection is not necessary Copeland
13. The semi hermetic reciprocating compressor family consists of different ranges The Stream Digital series of 4M D and 6M D models range from 13 hp to 50 hp Nominal Medium temperature Low temperature Displacement _ Horsepower B Cooling Cooling m h Capacity COP Capacity hp en KW KW 2 2 4 Product c Q o o 6 2 7 78 88 190 187 18 7 186 4 108 SESS 4 381 305 Installation 202 120 215 219 MTD 32X 135 221 MUD 40X MKD 50X D j Sed 23 256 d 29 1 R404A Evaporating 10 C Condensing 45 C Suction Gas Temperature 20 Subcooling 2 R404A Evaporating 35 C Condensing 40 C Suction Gas Temperature 20 C Subcooling Electrical connection Table 1 Stream Digital compressors range and performance for full load 100 oemi hermetic Stream Digital compressors are suitable for a wide range of applications in the oj form of either single compressors condensing units or as multi compressor equipment E S The compressor is only one component which must be combined with many others to build a functional and efficient refrigeration system 3 So Therefore the information in this manual relates to all semi hermetic Stream Digital 0 compressors with standard equipment and accessories only 2 2 About this guideline This guideline is intended to enable users to ensure the safe installation
14. bly line 18 C6 3 2 1211 E 5 5 Initial start up CAUTION fi Oil dilution Bearing malfunction is important to ensure that new compressors are not subjected to liquid abuse Turn the crankcase heater on 12 hours before starting the compressor CAUTION fij High discharge pressure operation Compressor damage Do not use compressor to test opening set point of high pressure cut out The compressor must be equipped according to our technical documentation considering the application intended Make sure of this before start up For brazing connections where dissimilar or ferric metals are joined a silver alloy rod with a minimum of 30 silver shall be used being either flux coated or with a separate flux Bolt torque settings are listed in Appendix With the exception of rubber coated metallic gaskets Wolverine all gaskets should be oiled before fitting O rings should also be oiled A compressor should never be operated beyond its approved application range Check by consulting the appropriate data sheet To avoid motor damage the compressor MUST NOT be started nor may high potential testing be carried out under vacuum 5 6 Minimum run time Emerson Climate Technologies recommends a maximum of 10 starts per hour The most critical consideration is the minimum run time required to return oil to the compressor after start up C6 3 2 1211 E Safety instructions Installation Product description Electrical connection
15. by Emerson Climate Technologies contain oil with low moisture content and it may rise during the system assembling process Therefore it is recommended that a properly sized filter drier is installed in all POE systems This will maintain the moisture level in the oil to less than 50 ppm If oil is charged into a system it is recommended to use POE with a moisture content no higher than 50 ppm 20 C6 3 2 1211 E The diagram below compares the hygroscopic characteristics of POE oil with mineral oil moisture absorption in PPM at 25 and 50 relative humidity ppm 1500 Safety instructions KT1 0 0593 50 100 150 200 250 300 h Figure 189 Absorption of moisture in ester oil in comparison to mineral oil in ppm by weight at 25 and 50 relative humidity h hours Product description If the moisture content of the oil in a refrigeration system reaches unacceptably high levels corrosion and copper plating may occur The system should be evacuated down to 0 3 mbar or lower If there is uncertainty as to the moisture content in the system an oil sample should be taken and tested for moisture Sight glass moisture indicators currently available can be used with the HFC refrigerants and lubricants however the moisture indicator will just show the moisture content of the refrigerant The actual moisture level of POE would be higher than the sight glass indicates This is due to the high hygroscopicity of the POE oil To determine t
16. e moving the torch around the joint to flow braze material around the circumference After the braze material flows around the joint move the torch to heat area 3 This will draw the braze material down into the joint The time spent heating area 3 should be minimal As with any brazed joint overheating may be detrimental to the final result To disconnect Heat joint areas 2 and 3 slowly and uniformly until the braze material softens and the tube can be pulled out of the fitting To reconnect Recommended brazing materials Silfos with minimum 5 silver or silver braze used on other compressors 3 4 Screens CAUTION fij Screen blocking Compressor breakdown Use screens with at least 0 6 mm openings The use of screens finer than 30 x 30 mesh 0 6 mm openings anywhere in the system should be avoided with these compressors Field experience has shown that finer mesh screens used to protect thermal expansion valves capillary tubes or accumulators can become temporarily or permanently plugged with normal system debris and block the flow of either oil or refrigerant to the compressor Such blockage can result in compressor failure 12 C6 3 2 1211 E 4 Electrical connection 4 1 General recommendations The compressor terminal box has a wiring diagram on the inside of its cover Before connecting the compressor ensure the supply voltage the phases and the frequency match the nameplate data 4 2 Electrical installation
17. ed Unloaded Figure 6 The digital signal from the controller activates the unloading The load and unload times will give the compressor an operating range during a 20 second cycle Minimum percent capacity would be 50 for 4M D and 33 or 67 for 6M D depending on compressor configuration The compressor can also operate at a 100 load for the full modulation sequence 2 6 5 Digital solenoid valve Gaskets Due to the high life cycle requirements in a hot gas environment a special valve has been developed Due to reliability requirements only Emerson solenoid valves may be used All compressor warranties are null and void if the Emerson valve is not used Solenoid coils will be sold separately for all Stream Digital compressors The solenoid coil is available for several voltages 24V 120V and 240V Stream Digital compressors use special head and valve plate gaskets which have modifications to ensure gas flow for proper digital modulation Only Emerson gaskets may be used All compressor warranties are null and void if the Emerson gaskets are not used 2 6 6 Compressor cooling Compressor motors must always be cooled and cylinder head cooling may also be needed at certain operating conditions All Stream Digital compressors are suction gas cooled With suction gas cooled compressors the motor is cooled by refrigerant gas that is led over the motor An additional fan may be required depending upon the operation conditions see Cope
18. glide of refrigerant blends primarily R407C is carefully considered when adjusting pressure and superheat controls Oil recharge values can be taken from Copeland brand products Selection Software www emersonclimate eu Table 2 Qualified refrigerants and oils for recharging and topping up 4 C6 3 2 1211 E To recharge When the compressor is completely empty of oil the amount of oil to be recharged is typically 0 12 litre less than the original oil charge oil will already be around the system To top up During commissioning planned maintenance or servicing add oil so that the compressor oil level is correct 2 6 Design features 2 6 1 Compressor construction All compressors are fitted with Discus valve plates which cannot be dismantled To maintain the high capacity of these compressors the correct valve plate to body gasket must always be selected in case of exchange The 4M and 6M Digital head is fitted on the terminal box side cylinder bank 6MID1 40X 6MJD1 45X 6MKD1 50X compressors equipped with a capacity control on the central cylinder bank Each oylinder head has a plugged 1 8 27 NPTF tapped hole for connecting high pressure switches These high pressure switches must be calibrated and tested before putting the compressor into service They must stop the compressor if the allowable pressure is exceeded The complete cylinder head is under discharge pressure Figure 2
19. he actual moisture content of the lubricant samples have to be taken from the system and analysed Installation 6 4 Oil additives Although Emerson Climate Technologies cannot comment on any specific product from our own testing and past experience we do not recommend the use of any additives to reduce compressor bearing losses or for any other purpose Furthermore the long term chemical stability of any additive in the presence of refrigerant low and high temperatures and materials commonly found in refrigeration systems is complex and difficult to evaluate without rigorously controlled chemical laboratory testing The use of additives without adequate testing may result in malfunction or premature failure of components in the system and in specific cases in voiding the warranty on the component Electrical connection 6 5 Unbrazing system components WARNING Explosive flame Burning Oil refrigerant mixtures are highly flammable Remove all refrigerant before opening the system Avoid working with an unshielded flame in a refrigerant charged system Starting up amp operation Before opening up a system it is important to remove all refrigerant from both the high and low sides of the system If the refrigerant charge is removed from a scroll equipped unit from the high side only it is possible for the scrolls to seal preventing pressure equalization through the compressor This may leave the low side shell and suction li
20. he most efficient system control Example A 4M D has a continuous capacity from 50 to 100 therefore when a 4M D Stream Digital compressor is selected the fixed capacity compressor beside it should have 50 to 100 of the full load of the digital compressor NOTE For best results the digital compressor needs to be the lead compressor It must be the first compressor On and last compressor Off in multiple compressor applications C6 3 2 1211 E 3 Installation WARNING IN High pressure Injury to skin and eyes possible Be careful when opening connections on a pressurized item 3 1 Compressor handling 3 1 1 Delivery Please check whether the delivery is correct and complete Any deficiency should be reported immediately in writing Standard delivery Suction and discharge shut off valves Oil charge oil sight glass Mounting kit CoreSense Diagnostics module Holding charge up to 2 5 bar g dry air Digital Solenoid valve delivered mounted 3 1 2 Transport and storage WARNING Risk of collapse Personal injuries Move compressors only with A appropriate mechanical or handling equipment according to weight Keep in the upright position Stack pallets on top of each other when not exceeding 300 kg Do not stack single boxes on top of each other Keep the packaging dry at all times Figure 109 Compressors are individually packed and may be delivered on pallets depending on quantity and s
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22. ipment must be observed _ 4 Use personal safety equipment Safety goggles gloves v protective clothing safety boots and hard hats should be worn where necessary C6 3 2 1211 E Starting up amp Electrical Installation Product connection description Maintenance amp Dismantling amp c repair operation disposal 1 3 General instructions A 5 d 4 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 approved refrigerants and refrigeration oils must be used WARNING High shell temperature Burning Do not touch the compressor until it has cooled down Ensure that other materials in the area of the compressor do not get in touch with it Lock and mark accessible sections CAUTION Overheating Bearing damage Do not operate compressors without refrigerant charge or without being connected to the system IMPORTANT Transit damage Compressor malfunction Use original packaging Avoid collisions and tilting C6 3 2 1211 E 2 Product description 2 1 Common information about Copeland amp brand products semi hermetic Stream Digital compressors Safety instructions This manual covers semi hermetic Stream Digital compressors
23. ize Cooling fans are delivered in separate cartons Accessories may be mounted or delivered loose Solenoid valves are never mounted except the Digital head one 3 1 3 Positioning and securing IMPORTANT Handling damage Compressor malfunction Only use the lifting eyes E whenever the compressor requires positioning Using discharge or suction connections for lifting may cause damage or leaks If possible the compressor should be kept vertical during handling For safety reasons two lifting eyes should be fitted before moving a compressor 72 13 UNC Refer to drawings on Figure 11 to see how to apply other lifting methods In order to avoid refrigerant leaks or other damage the compressors should not be lifted by the service valves or other accessories 10 C6 3 2 1211 E 4M D 6M D max 220 kg max 260 kg Figure 101 3 1 4 Installation location Ensure the compressors are installed on a solid level base 3 1 5 Mounting parts To minimize vibration and start stop impulses flexible mounting should be used For this purpose one set of spring mounting parts for each of the Stream models is delivered with each 4M and 6M compressor Due to differences in weight cylinder motor side different springs have to be used on both sides Springs have different colours for easier identification violet on motor side and orange on cylinder side Transport clamp Transport position Operational position Figure 112 When Strea
24. land brand products Selection Software on www emersonclimate eu 2 6 7 Unloaded start With direct starting the motor of a compressor is switched directly into the mains by means of a switch The resulting breakaway starting current amounts to multiple times the rated motor current operating maximum without consideration being given to transient phenomena In the case of high powered motors the breakaway starting currents become so large that they lead to disruptive voltage dips in the mains The compressors that are subject to current limitation must therefore by all means be equipped with starting load reduction to guarantee perfect starting even when the voltages amount to less than approximately 85 of the voltage on the nameplate 2 6 8 Oil pumps The oil pumps used for Stream Digital compressors are independent of their rotating direction Stream Digital compressors are delivered with CoreSense Diagnostics The oil pump integrates the electronic switch for integrating oil pressure safety functionality 2 6 9 Oil pressure Normal oil pressure is between 1 05 and 4 2 bar higher than crankcase pressure Net oil pressure can be read by connecting two pressure gauges to the compressor and comparing the readings One gauge should be connected to the oil pump The second gauge should be C6 3 2 1211 E Starting up amp Electrical Installation Product Safety connection instructions Maintenance 4 Dismantling 4
25. m Digital compressors are mounted in racks rubber mounting parts should be used A compressor may be rigidly mounted ie without springs In this case more shock and vibration loading will be transmitted to the frame If the installation requires a very high level of vibration absorption additional vibration absorbers available on the market can be fitted between the rails and the foundation 3 2 Pressure safety controls 3 2 1 High pressure control A high pressure control with a maximum cut out setting of 28 bar g is required The high pressure cut out should have a manual reset feature for the highest level of system protection 3 2 2 Low pressure control The normal minimum cut out setting is 0 1 bar g for R404A The low pressure cut out should have a manual reset feature for the highest level of system protection C6 3 2 1211 E Safety instructions Product description c S 65 P Starting up amp Electrical connection Maintenance amp Dismantling amp repair operation disposal 3 2 8 Maximum operating pressures Maximum operating pressures according to EN 12693 shown on the compressor nameplate are obligatory and must not be exceeded High pressure side HP 28 0 bar low pressure side LP 22 5 bar NOTE The compressor operating range may be restricted for various reasons Check the application range limitations in Copeland amp brand products Selection Software on w
26. ne tubing pressurized If a brazing torch is then applied to the low side while the low side shell and suction line contain pressure the pressurized refrigerant and oil mixture could ignite when it escapes and contacts the brazing flame To prevent this occurrence it is important to check both the high and low sides with manifold gauges before unbrazing Instructions should be provided in appropriate product literature and assembly line repair areas If compressor removal is required the compressor should be cut out of system rather than unbrazed Oo E disposal 7 Dismantling amp disposal Dismantling amp Removing oil and refrigerant Do not disperse in the environment Use the correct equipment and method of removal Dispose of oil and refrigerant properly Dispose of compressor properly C6 3 2 1211 E 21 Contact List Emerson Climate Technologies Asia Pacific Headquarters 10 F Pioneer Building 213 Wai Yip Street Kwun Tong Kowloon Hong Kong Tel 852 2866 3108 Fax 852 2520 6227 Australia Emerson Climate Technologies Australia Pty Ltd Unit R7 391 Park Road Regents Park NSW 2143 Australia Tel 61 2 9795 2800 Fax 61 2 9738 1699 China Beijing Emerson Climate Technologies Suzhou Co Ltd Beijing Branch Room 1017 Canway Building 66 Nan Lishi Road XiCheng District Beijing 100045 PRC Tel 86 10 5763 0488 Fax 86 10 5763 0499 Ch
27. nout the majority of contaminated oil will be removed with the compressor The rest of the oil is cleaned through the use of suction and liquid line filter driers A 100 activated alumna suction line filter drier is recommended but must be removed after 72 hours It is highly recommended that the suction accumulator be replaced if the system contains one This is because the accumulator oil return orifice or screen may be plugged with debris or may become plugged shortly after a compressor failure This will result in starvation of power usage 6 3 Lubrication and oil removal CAUTION fij Chemical reaction Compressor destruction Do not mix up ester oils with mineral oil and or alkyl benzene when used with chlorine free refrigerants The compressor is supplied with an initial oil charge The standard oil charge for use with refrigerants R404A R407A R407C RAO7F R134a is a polyolester POE lubricant Emkarate RL 32 3MAF In the field the oil level could be topped up with Mobil EAL Arctic 22 CC if 3MAF is not available The standard mineral oil for R22 is Suniso 3GS One disadvantage of POE is that it is far more hygroscopic than mineral oil see Figure 19 Only brief exposure to ambient air is needed for POE to absorb sufficient moisture to make it unacceptable for use in a refrigeration system Since POE holds moisture more readily than mineral oil it is more difficult to remove it through the use of vacuum Compressors supplied
28. onnection repair operation disposal 4 3 1 Wiring diagram for part winding motors AW Part winding motors can be connected direct on line or part winding start Part winding start ud Stan First start step 1 2 3 Y Y Part winding motor Y Y Code A COMPRESSOR M21 210 Y7 Y22 Min AS In T 5 tete L1 L2 L3 F7 CURRENT SENSOR Legend AA Sensor module K1 Contactor M1 5 Terminal box compressor KA Contactor M1 for second part winding CCH Crankcase heater M2 Fan motor condenser ic Fuse for control circuit M21 Fan motor condenser IT Fuse for control circuit p solenoid valve digital discus head E Fuse for control circuit YAI aos Solenoid valve capacity control 1 PO ose Thermal protection switch M2 Solenoid valve capacity control 2 Figure 134 14 C6 3 2 1211 E 4 3 2 Wiring diagram for Star Delta motors EW Star Delta motors can be connected direct on line or Star Delta start Direct on line start Direct on line start Star Delta start Y Safety instructions Star Delta motor Y A Code E Product description COMPRESSOR WIRING HARNESS c amp Ph o c L1 L2 L3 rr a 23 y MODULE COMM 24 VAC O IN
29. pe repair operation disposal connected to the crankcase T fitting instead of plug on the compressor crankcase or the suction service valve During irregular operating conditions eg a blockage of the suction filter the pressure measured at the suction shut off valve of the compressor may differ widely from that measured at the crankcase therefore pressure drops have to be avoided 2 6 10 Oil circulation Cil returns with the suction gases through a suction strainer and separates in the motor chamber reaching the crankcase by way of an oil return relief valve in the partition between motor housing and crankcase This relief valve closes on compressor start up due to the pressure difference arising between motor side and crankcase thus slowing down pressure decrease in the crankcase over a certain period of time It reduces the foaming of the oil refrigerant mixture that would occur if the pressure decreased rapidly The valve does not reopen until the pressure has been equalized by means of a crankcase ventilating valve This second valve connects the crankcase and suction side cylinder head It reduces the pressure difference by means of a very small bore in the plate of the valve so slowly that oil foams less and only limited oil refrigerant foam is transferred to the oil pump Compressors with four and six cylinders have one crankcase ventilating valve on the left cylinder bank Safety instructions Product c
30. ressor Gas enters compressors IS pe m It Figure 4 Gas flow Loaded Unloaded 1 Solenoid valve 2 Cylinder head 3 Valve plate 4 5 Unloading piston Figure 5 Cutaway view of the Digital cylinder head loaded and unloaded 2 6 3 Digital control Capacity modulation is achieved by energizing and de energizing the solenoid valve When the solenoid valve is de energized the digital bank capacity is 100 When the solenoid valve is energized the digital bank capacity is zero Therefore the capacity achieved is the time average capacity Example 20 second cycle if the solenoid is de energized for 16 seconds and then energized for 4 seconds the resulting capacity will be approximately 8096 For 4M D Stream compressors one bank of the compressor remains loaded 100 while the digital bank will modulate O to 10096 to provide the additional capacity The capacity is 50 to 100 as one bank is modulating On a 6M D with blocked suction the blocked suction bank will unload when demand capacity is less than 67 and load when the demand capacity is higher than 67 The digital bank will continue to load and unload providing continuous capacity across the 33 to 10096 range 6 C6 3 2 1211 E 2 6 4 Recommended application settings for modulation on Stream Digital compressors The digital modulation recommended cycle time is 20 seconds For other values check with Application Engineering 5095 Modulation 40 Modulation Load
31. rs AWA Eu eiu p bri resin 14 4 3 2 Winng diggram Tor Star Delta motors EW EEE 15 24 IPROESCEDDLEIGNMIEBS 16 IAA m 16 AE Te Nc RET T E 17 LAUNGUA ODA 18 CSE E E 18 e Ya scudo nee desde ub MER OMNE MIN MM 18 5 3 Preliminary checks Dam a 18 ETIAIN 18 19 E _____________________ _____ 19 6 MAINTENANCE e 20 cas eee Ce UFU dU 20 G2 Replacing a COMPI ____ on 20 ANON INOW AN NR 20 21 systemi ______ ______ __ _ 2 e 7 7 eee M M gt 21 1 Safety instructions Copeland brand products semi hermetic compressors are manufactured according to the latest European safety standards Particular emphasis has been placed on the user s safety These compres
32. ry air the compressor is under pressure about 1 to 2 5 bar this is to indicate the compressor does not leak When plugs are removed from the compressor in order to connect a pressure gauge or to fill in oil the plug may pop out under pressure and oil can spurt out 5 3 Preliminary checks Pre starting Discuss details of the installation with the installer If possible obtain drawings wiring diagrams etc It is ideal to use a check list but always check the following Visual check of the electrics wiring fuses etc Visual check of the plant for leaks loose fittings such as TXV bulbs etc Compressor oil level Calibration of HP amp LP switches and any pressure actuated valves Check setting and operation of all safety features and protection devices All valves in the correct running position Pressure and compound gauges fitted Correctly charged with refrigerant Compressor electrical isolator location amp position 5 4 Charging procedure CAUTION fi Low suction pressure operation Compressor Damage Do not operate with a restricted suction Do not operate with the low pressure cut out bridged The system should be liquid charged through the liquid receiver shut off valve or through a valve in the liquid line The use of a filter drier in the charging line is highly recommended The majority of the charge should be placed in the high side of the system to prevent bearing washout during first time start on the assem
33. sors are intended for installation in systems according to the EC Machines directive They may be put to service only if they have been installed in these systems according to instructions and conform to the corresponding provisions of legislation For relevant standards please refer to Manufacturers Declaration available on request These instructions should be retained throughout the lifetime of the compressor You are strongly advised to follow these safety instructions 11 lcon explanation WARNING CAUTION This icon indicates instructions to This icon indicates instructions to avoid personal injury and material avoid property damage and possible damage personal injury High voltage IMPORTANT This icon indicates operations with a his icon indicates instructions to danger of electric shock avoid malfunction of the compressor Danger of burning or frostbite This word indicates a This icon indicates operations with a NOTE recommendation for easier operation danger of burning or frostbite Explosion hazard This icon indicates operations with a danger of explosion 1 2 Safety statements Refrigerant compressors must be employed only for their intended use Only qualified and authorized HVAC or refrigeration personnel are permitted to install commission and maintain this equipment Electrical connections must be made by qualified electrical personnel valid standards for connecting electrical and refrigeration equ
34. ww emersonclimate eu 3 3 Brazing procedure IMPORTANT Blockage Compressor breakdown Maintain a flow of oxygen free nitrogen through the system at very low pressure during brazing Nitrogen displaces the air and prevents the formation of copper oxides in the system If allowed to form the copper oxide material can later 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 OUL Figure 12 shows the proper procedures for brazing the suction and discharge lines The copper coated steel tubes on Stream Digital compressors can be brazed in approximately the 3 2 1 same manner as any copper tube poem a Recommended brazing materials any silfos material is recommended preferably with a minimum of 5 silver However 0 silver is acceptable Be sure tube fitting inner diameter and tube outer diameter are clean prior to assembly Using a double tipped torch apply heat in area 1 Figure 12 Suction tube brazing the tube approaches brazing temperature move the torch flame to area 2 Heat area 2 until braze temperature is attained moving the torch up and down and rotating around the tube as necessary to heat the tube evenly Add braze material to the joint whil
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