Fusion User Manual - Emerson Climate Technologies
Contents
1. Copeland Scroll About Emerson Climate Technologies Emerson Climate Technologies a business seqment of Emerson is the world s leading provider of heating air conditioning and refrigeration solutions for residential industrial and commercial applications It combines best in class technology with proven engineering design distribution educational and monitoring services to provide customized integrated climate control solutions for customers worldwide Emerson Climate Technologies innovative solutions which include industry leading brand Copeland Scroll improve human comfort safeguard food and protect the environment For more information visit EmersonClimateAsia com Leading Innovation in Scroll Semi Hermetic Technology Emerson realized an increasing need for a versatile reliable quiet lightweight serviceable compressor for the Cold Room market and set out to develop a solution for this need In the development process the company brought together 70 years of semi hermetic compressor expertise and 25 years of leadership in scroll technology What came out of this endeavor is the newly designed Copeland Scroll Fusion compressor which combines Emerson s revolutionary scroll technology along with the serviceability of a traditional semi hermetic compressor Our Vision Emerson Climate Technologies With Our Partners Will Provide Global Solutions To Improve Human Comfort Safeguard Food And Protect The Environment2. Table of Contents Safety Information Features and Benefits Nomenclature Operating Envelopes Technical Data Dimensional Drawings Wiring Diagram Contact Lists LA Safety Information Copeland brand products semi hermetic compressors are manufactured according to international safety standards Particular emphasis has been placed on the user s safety This user manual should be retained throughout the lifetime of the compressor Safety instructions must be followed by all users before compressor operation Only qualified and authorized personnel are permitted to do installation commissioning and repairing of this compressor Electrical connections must be made by qualified electrical personnel ICON DEFINITION CAUTION This icon indicates instructions to avoid property damage and WARNING This icon indicates instructions to avoid personal injury and ELECTRICAL SHOCK This icon indicates operations with a danger of electric shock possible personal injury A Caution e Make sure that the compressor is upright and there are no collisions or tilting during transit e Use only refrigerants and oils approved by Emerson e Make sure that the supply power voltage frequency and phase are exactly as per the specifications on the compressor nameplate e The dry air inside the compressor should be evacuated before installation The compressor comes charged with dry air at a pressure of 2 0 bar
3. restart will be attempted when the windings have cooled and the timer has timed out The compressor will not be locked out but the cause of overheat must be investigated to prevent long term compressor damage Motor overheat can be caused by a mechanical problem which if not rectified quickly could cause complete compressor failure and system contamination Common mechanical problems that lead to motor trips include worn bearings or worn scroll sets as a result of overheating Checking Thermistors and Sensors Table 2 provides resistance values of the thermistors at several useful temperatures A Caution Use a voltage no higher than 3 VDC when testing An ice bath can be used at 0 C and boiling water can be used at 100 C Temperature Location 0 C 25 C 100 C eran eni 11 28KOhm 10KOhm 9500hm kom TTT 5 Table 2 For the motor thermistor chain the trip resistance is gt 4 5 K Ohms and the reset resistance is lt 2 75 K Ohms Resistance at room temperature should be lt 500 Ohms If the oil level switch is not functioning correctly the optical part can be easily changed without breaking into the system Malfunction is also possible if the lens M25 5 Sensors 3xM16 Reser de i Remove Terminal Box Cover for Customer Wiring Figure 13 Terminal Box Location For Wiring is coated by system contaminants The lens vvill need to be removed and cleaned to restore correct operation The
4. ATddNS YAMOd YOLOW YOSSAYdNOD 40 N M M MOSHO L HOSNAS dWAL 1404 39UVHOSIA Z MOLOVLNO 1911 MOSHO AVTAY 1100 YOLIOVINOI YOSSAYdWOD 999 UYOSSIYANOO H T naviy L1 NMOd NMOd diNNd ON CNOILdO LNOILdO CH UNING MOSS3MdiNO TARA ZH09 0S M34Od YOLOW 3 TX 2 022 zi efe N orario EN 999 ELICLILL 3ATVA V NOlSNVdX4 FA VINOYLIITI FUSE 1A 250VAC R HOLMS D ZEISS 034 al YOSNAS 13 37 122 110 IVOILdO Yyov a i INPUT 220V 240VAC OUTPUT 16VAC IVNINYI L YOSNAS HOLIMS 1 YOLOW 440 NO DI asusossnvat 1 FINFHOASNVUL wp Bui N __Aopesxagprepuelg 000000 R Buum wayshS popuewwosey Figure 10 Wiring Diagram 14 1 Weg ko hu H L d ES ei hk Koch LI i iL li Ti u lil ME 8 1 R zi B Ft i a 4 uk hl bis im 1 K L Figure 11 CoreSense Wiring and Joints Step 1 Connect Compressor Motor Wires Step 2 Connect PWR Terminal Wires Step 3 Connect Demand Terminal Wires Figure 12 CoreSense Recommended Wiring Sequence Gland Waterproof Number Gland 1 For PWR and Demand Connector s Wires Wires Gland Description One jacket line with four wires goes through the joint joint A Red and B Blue Controller Power Supply Input 220 240VAC
5. Do Not e Use the compressor to de pressurize to evacuate a refrigeration system e Start the compressor when it is under vacuum e Conduct a test without connecting the compressor to a system e Start the compressor without a refrigerant charge e Operate a compressor beyond its approved application envelope e Touch the compressor or pipes when the compressor is running High low temperature may cause burns frostbite e Release refrigerant into the environment without using appropriate refrigerant recovery unit and methods when removing refrigerant from the system A Warning e When operating the compressor or checking a refrigeration system leakage do not exceed operating pressures out of the application envelope material damage Do not run the compressor with air When operating with air the diesel effect may occur i e the air sucked in may mix with oil and gas Such a mixture could explode due to high temperature in the scroll discharge port and thereby destroy the compressor and cause injury or death Open the discharge and suction shut off valve before starting the compressor It is of vital importance that the discharge shut off valve is fully opened before the compressor is started If the discharge valve is closed or partly closed an unacceptable pressure accompanied by a proportionately high temperature will develop e All local safety regulations must be observed A Electrical Shock
6. Taman Tekno 8 JI Tekno Widya Blok H10 No 2 amp 3 Tangerang Selatan 15314 Indonesia Tel 6221 2666244 Fax 6221 2666245 Japan Emerson Japan Ltd Shin yokohama Tosho Building No 3 9 5 Shin Yokohama Kohoku ku Yokohama 222 0033 Japan Tel 8145 475 6371 Fax 8145 475 3565 Malaysia Emerson Electric Malaysia Sdn Bhd Level M2 Blk A Menara PKNS PI Jalan Yong Shook Lin 46050 Petaling Jaya Selangor Malaysia Tel 603 7949 9222 Fax 603 7949 9333 Emerson CoreSense Diagnostics and Copeland Scroll Fusion are trademarks of Emerson Electric Co or one of its affiliated companies 2013 Emerson Climate Technologies Inc All rights reserved EMERSON CONSIDER Middle East amp Africa Emerson Climate Technologies PO Box 26382 Jebel Ali Free Zone South Dubai UAE Tel 9714 811 8100 Fax 9714 886 5465 Philippines Emerson Climate Technologies 10 F SM Cyber West Avenue EDSA cor West Avenue Barangay Bungad Diliman Quezon City 1105 Philippines Tel 632 689 7200 South Korea Emerson Electric Korea Ltd 3F POBA Gangnam Tower 343 Hakdong ro Gangnam gu Seoul 135 820 Republic of Korea Tel 822 3483 1500 Fax 822 592 7883 Taiwan Emerson Electric Taiwan Co Ltd 3F No 2 DunHua South Road Sec 1 Taipei 105 Taiwan Tel 8862 8161 7688 Fax 8862 81617614 Thailand Bangkok Emerson Electric Thailand Ltd 34th Floor TCIF Tower 1858 133 Bangna Trad Bangk
7. e Turn off electrical supply and power before servicing e Use this equipment only in a grounded system e Refer to the applicable system wiring diagram as shown in this manual 0000 Use Personal Safety Equipment e The new compressor contains oil and dry air under a pressure of 2 0 bar While releasing pressure before installation the oil drain plug may pop out under pressure and oil could spurt out e Safety gloves protective clothing safety boots and protective eyewear should be worn where necessary Product Description Copeland Scroll Fusion was crafted specifically to adhere to the refrigeration industry s need for field serviceable solutions In addition it is specially designed for medium and low temperature refrigeration with the ability to handle various refrigerants Features and Benefits e Emerson s Copeland Scroll technology e Serviceability in the field e CoreSense Diagnostics e Integrated vapor injection technology e Wide range envelope and efficient operation e Ability to handle various refrigerants Nomenclature Type of Oil Code Description E POE Blank Mineral Oil Family Q Copeland Scroll Fusion Intelligence and Motor Protection Code Type W CoreSense Scroll Displacement cc rev OF185AE TWD 202 Model Variation Motor Types Code Phase T 3 Application Range Code Application Approved Refrigerants F Full Range R22 R404A Low Med High Typical Ele
8. on the thermostat The solenoid should be installed close to the expansion valve to keep the main volume of the liquid line on the high side of the system during off periods All solenoid valves leak slightly and may not be 100 effective in keeping liquid in the high side during extended shutdown periods which can occur in cold rooms used for storing seasonal products In most cases opening and closing the solenoid valve when the compressor starts and stops provides adequate protection from liquid migration to the compressor crankcase Liquid Line Insulation Copeland Scroll Fusion compressors have many characteristics found on two stage piston compressors among them a cold liquid line after the heat exchanger The cold liquid is very important for improving the system capacity and efficiency and any increase in liquid line temperature after the heat exchanger is a system loss The liquid line should therefore be insulated with tightly fitted closed cell foam The wall thickness of the insulation should be at least 10 mm for medium temperature applications and gt 15 mm for low temperature applications In some low temperature applications an uninsulated liquid line could even cause ice formation and in humid environments condensation will occur The line connecting the receiver to the inlet of the heat exchanger does not require insulation Pumpdown Cycle Pumpdown cycles are widely applied in systems with reciprocating compress
9. shutdown and automatic reset failure after 3 min delay Alternate Less oil level still OK but ori Show alarming and continue running Give display soon dangerous precaution Aaa Fault When power on 1 st time if any sensor except ols dps is wrong immediately locked The 4th low oil level in 1 hour compressor Fault shutdown and locked manual reset cut off power Number Low differential oil pressure Fault The 4th low differential pressure in 1 hour FLASH on require manual reset compressor shutdown and locked e Fault diagnostic code is visible through a transparent window on the cover 2 FLASH FLASH 1 FLASH 2 FLASH 3 FLASH 4 5 FLASH FLASH 7 FLASH FLASH 3andF Number nr Code Number Low oil level Require FLASH on manual reset The code and description can be found inside of the cover 21 Tool List 16 17 1 2 3 4 5 6 13 14 9 10 11 J 15 118 o Item No Tool Tool Tool Torque Value Components on Page 11 N Table o N m Pressure Differential Sensor i Three phase Terminal Plate o e 1 28 12 15 Oil Charge Fitting Plug Lower Cover 2 29 32 42 Oil Drain Oil Fitting Plug 2 42 Metric Hexagon 3 Lower Cover Bolts Torque Wrench 16 mm 57 68 Check Valve Bolts Ta 2 90 100 Oil Drain Oil Fitting Plug Oil Charge Fitting Plug 22 Description Specification Item No Tool Tool Tool Torque Value M t OTO l No Description Specificati
10. 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 19 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 Unbrazing System Components ZA Warning Oil refrigerant mixtures are highly flammable Remove all refrigerant before opening the system Avoid working with an unshielded flame in a refrigerant charged system 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 line tubing pressurized If a brazing torch is applied to the low side while Mi nl 20 the lovv side shell and suction line contain pressure the pressurized refrigerant and oil mixture could ignite when it escapes and comes in contact with the brazing flame To prevent this occurrence it is important to check both the high and low s
11. to liquid abuse Turn the crankcase heater on 12 hours before starting the compressor Maintenance Refrigerant Exchange Qualified refrigerants and oils were indicated on page 8 It is not necessary to replace the refrigerant with a new one 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 vapor phases are present and when the temperatures have been stable In the event that the refrigerant needs replacing the charge should be recovered using a suitable recovery machine When R22 in a system with mineral oil is to be replaced with R407C or R404A the oil must also be changed Please refer to Technical Information Refrigerant changeover from HCFC to HFC Refrigerants Replacing Compressor A Warning Rotalock valves should be re torqued periodically to ensure that leak tightness is maintained All gaskets and fittings should be inspected for signs of leaks and repaired if necessary Electrical connections should be checked for tightness All wires should be clamped securely and routed away from hot surfaces to prevent damage from vibration and heat Some minor repairs like sensor replacement can be done while the c
12. 50 60Hz Wire Function C Black and D Yellow Compressor Start Stop Feedback Input 220 240VAC 50 60Hz Output Wires A and B PWR Green connectors Wire Connection MNF eee syd IDE Demand Blue connectors Gland 2 For CCC Connector s One jacket line with two wires goes through the E Brown and F Blue Compressor Diagnostic Protection Contact Wires E and F CCC Green connectors Gland 3 Gland 4 For Alarm Connector s Wires For Compressor Motor Power Supply Wires One jacket line with two One jacket PVC line wires goes through the with four wires goes joint through the joint I J K Compressor Motor Power Supply G Brown and H Blue Dry Contact Output For Alarm Devices L Earth Wire Wires E and F Alarm Orange connectors Gland Internal 5 10 mm 50am 5 10 mm iamm Diameter Range Internal wire size 18 20 AWG Recommended wire size 18 AWG Rated voltage 300V 500V Jacket Line Requirement Table 1 message will be displayed on the control board and a timer will be started Three more attempts will be made to start and if differential pressure is not established the compressor will be locked out The alarm contact will close and can be used by the installer to turn on a light sound a bell etc The alarm contact is voltage free allowing maximum flexibility with regard to the type of alarm device that can b
13. Visual check of the electrics wiring fuses etc e Visual check of the plant for leaks loose fittings such as TXV bulbs etc e Compressor oil level e Calibration of HP and LP switches and any pressure actuated valves e Check setting and operation of all safety features and protection devices e All valves in the correct running position e Pressure and compound gauges fitted e Correctly charged with refrigerant e Compressor electrical isolator location amp position ZA Warning 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 securely electrically locking out the system This will prevent unauthorized personnel from accidentally operating the system and potentially ruining the compressor by operating with no refrigerant flow 18 ZA Warning Do not start the compressor while the system is in a vacuum Refrigerant Charging PC Board should be powered to close EXV before charging 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 Because scrolls have discharge check valves systems should be liquid charged on both the high and low sides simultaneously to ensure that a positive refrigerant pressure is present in the compressor before it runs Charging quantity can be determined by referring to system d
14. ctrical Codes Code 60 Hz 50 Hz D 460 3 380 420 3 5 200 230 3 200 220 3 7 380 3 Note QF205 has low temperature model only LUOOY pjod snzes dw WNIP N Do OSPIMOUS ainjeladwia WNIP N DoZ L lt gt BEIER WOO Di aJnzesaduIa MO 263 407 DSZ WU TO L 0 5 DI duz TO o S Lu Evaporating Temperature C A ASPIMOUYS ASPIMOYS Tree De niro aJnzeJdadUIa MO 2oZ R404 R22 LA 00 p La O LA N La OQ e LA li O LA N LL LA y p Li Note 20 C Return Gas Temperature Fan Cooling Note 20 C Return Gas Temperature No Fan Cooling N o Ln mM N N Jo Dulsu puo Io aNJeJadwWie D lsu puo Operating Envelopes R22 R404A R22 R404A Nameplate Information MODEL QF2054 TWD 203 SERIAL NO 12F00152Y L CA OIL scs 27 L R 9 MAXOPER PRESS STE 3 Ph 60 Hz 2900 RPM 36 91 M3 H Hz Ph VOLTAGE V MRA A LRA A 50 3 380 420vY 25 95 105 60 3 460 Y 30 95 105 4360 9927 1508 7227 Figure 1 Nameplate and nameplate location Technical Data QF185A QF205A Model Displacement 50 Hz TWD 50 Hz Motor Speed 50 Hz Power Crankcase Heater Voltage Initial Oil Charge Recharge QF185AE QF205AE p lt Discharge L
15. differential pressure svvitch is normally open vvhen the compressor is off and pressure has equalised It can be checked for continuity using an ohmmeter When the compressor starts the resistance should change from infinity to 0 Ohms The reed switch which is enclosed in plastic can also be closed by holding it close to a magnet Crankcase Heaters Differential Oil Pressure Sensor Vapor Out Discharge Port Temp Sensor Temp Sensor Vapor In Temp Optical Oil Level Sensor Sensor Figure 14 Sensor Location Crankcase heaters are very effective in keeping liquid out of the compressor and are recommended for all installations The heater should be on when the compressor is stopped A Caution At the time of initial startup or after any extended pe riod without power the heater should be energized 12 hours before starting the compressor Long off periods are common in cold stores holding seasonal products so it is particularly important to turn on power to the unit 12 hours before restarting after a long idle period A 220 V 60 W heater is supplied as standard equipment Startup and Operation Leak Pressure Testing The compressor has been pressure tested in the factory It is not necessary for the system manufacturer or installer to pressure test or leak test the compressor again although the compressor will normally be exposed to the pressure used as part of system testing Consider personal safety requirements and
16. e connected The alarm relay contact is rated at 250 VAC 1A and 30 VDC 1A A warning High discharge temperatures often occur when the system is short of refrigerant suction temperature rises bubbles form in the liquid line and there is insufficient liquid to feed the injection EXV properly The control module will stop the compressor display a fault code and 16 Internal wire seize 8 AWG or above 4 wires in total Rated voltage 600V 1000V close the alarm relay After a time delay the compressor will restart High discharge temperature alarms indicate a serious system problem and corrective action must be taken to avoid long term compressor damage and possible product loss Oil level is monitored by an optical sensor in the high side oil sump If the level falls to the minimum allowable a timer will start and the compressor will be stopped if sufficient oil has not returned to the sump in one minute Two restarts will be attempted after short delays and if the oil level does not recover the compressor will be stopped and locked out An alarm message will be displayed and the alarm relay will close Motor overheat may occur when the suction gas temperature is abnormally high mass flow is low and discharge pressure is also high Four thermistors are embedded in the windings and monitored by the control module If the module senses that the winding temperature is high it will stop the compressor and start a timer A
17. ength Dimensions Width Height Length Base Mounting Width Bolt Net Weight Gross Notes 1 MOC Maximum Operating Current 2 LRA Locked Rotor Current 3 QF205AF has low temperature model only Maximum Operating Pressures ution 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 The low pressure cut out should be set as high as possible in all applications For medium temperature applications the normal minimum is 2 5 bar g which corresponds to 10 C for R22 and 16 C for R404A For low temperature applications the minimum cut out setting should not be lower than 0 3 bar g for a compressor using R404A and should not be lower than 0 1 bar g for a compressor using R22 The cut out point of the LP switch must be calibrated using an accurate suction pressure gauge rather than the scale on the switch which is provided for rough setting only A Caution The Copeland Scroll Fusion compressor should NEVER be allowed to run in a vacuum The low pressure cut out should have a manual reset feature for the highest level of system protection AA warning The maximum pressure for leak testing should be no higher than 22 5 bar g Approved Refrigerants and Oil Refrigerants R404A and R22 are approved for use with Copeland Scroll Fusion Application with other refrigerants may be p
18. h low moisture content and this may rise during the system assembling process POE oil should not be exposed to the atmosphere for longer than 15 minutes A filter drier is installed to help maintain moisture level in the oil 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 Mineral Oil Figure 2 Absorption of moisture in ester oil in comparison to mineral oil in ppm by weight at 25 C and 50 relative humidity Installation Compressor Handling Delivery Please check carefully for unforeseen damage Any shortage or damage should be reported to the delivering carrier Heavy equipment should be left on its shipping base until it is moved to the final location The packing list included with each shipment should be carefully checked to determine if all parts and equipment have been received Deficiencies should be immediately reported in writing to your local Emerson Sales Office Standard delivery e Suction and discharge shut off valves e Oil charge oil sight glass e Oil level switch e Differential oil pressure sensor e Plate heat exchanger e Electronic expansion valve e Crankcase heater e CoreSense Diagnostics e Holding charge of up to 2 0 bar dry air e For other accessories please check the packing list Packaging All compressors are individually packed Accessories may be mounted or delivered loose Please pay attention to stac
19. ides 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 instead of unbrazing Dismantling and Disposal Removing oil and refrigerant e Do not disperse in the environment e Use the correct equipment and method of removal Dispose of oil and refrigerant properly e Dispose of compressor properly i se E ity LES oe jis Appendix Fault Diagnostic Code Description Status Compressor Action Normal compressor operation Normal Normal compressor operation Normal compressor off Normal Normal compressor standby db 0 Fault EXV vvill not vvork so compressor must stop follow Emerson Wiring Diagram Fault Compressor shutdown and automatic reset after 10 min delay i EE Fault Compressor shutdown and automatic reset after 10 min delay I Compressor shutdown and automatic reset Low oil level Fault after 5 min delay FLASH Low differential oil pressure Fault Compressor shutdown and automatic reset HP LP after 3 min delay h i Fault Compressor shutdown and automatic reset after 3 min delay Compressor shutdown and automatic reset Scroll temperature sensor failure Fault after 3 min delay PHE inlet temperature sensor Fault Compressor shutdown and automatic reset failure after 3 min delay PHE outet temperature sensor Fault Compressor
20. ischarge and suction pressures Another very useful parameter is the liquid line temperature which has been listed in the Fusion Catalogue At a measured condensing temperature and an evaporating temperature the liquid line temperature should be around Emerson s recommendation value within 5 tolerance ZA Warning 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 assembly line or on site Do not operate with a restricted suction Do not operate with the low pressure cut out bridged Do not operate compressor without enough system charge to maintain at least 0 3 bar suction pressure Allowing pressure to drop below 0 3 bar for more than a few seconds may overheat scrolls and cause early drive bearing damage If the suction pressure is low on startup and top up of the refrigerant charge is required it is preferable to bleed liquid slowly into the suction line of a running compressor than to risk overheating by vapour charging 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 assembly line Initial Startup ZA Warning It is important to ensure that new compressors are not subjected
21. king layers Stacking in transit should not be more than two layers and stacking in store should not be more than three layers The packaging must be kept dry and without damage at all times Transport Compressors should be moved only with mechanical handling equipment appropriate for the weight involved For safety reasons one lifting eye should be fitted before moving a compressor M16x2 0 Please refer to the illustrations on Figure 3 to see how to lift the compressor Safely A Warning The compressors must not be lifted by the service valves or other accessories Otherwise damage or refrigerant leaks may occur M16x2 0 Thread Figure 3 Compressor lifting method Mounting Parts AN caution To minimize vibration and start stop impulses flexible mountings should be used Because Copeland Scroll Fusion has scroll hermetic compressor level of vibration grommets are delivered A compressor may be rigidly mounted i e without grommet in which case more shock and vibration will be transmitted to the frame To ensure proper lubrication of moving parts the compressor should be installed with four mountings in the same plane Mounting Nut ANG Compressor Mounting Foot Mounting Spacer Baseplate M10 Mounting Bolt Figure 4 Mounting kit Mounting Kit Part Code 027 0443 00 Piping Connection and Compressor Installation Brazing elt is important to flow nitrogen through the sy
22. l add to rotor drag and increase power usage Lubrication and Oil Removal Do not mix up ester oils with mineral oil and or alkyl benzene when used with chlorine free HFC refrigerants The compressor is supplied with an initial oil charge The standard oil charge for use with refrigerants R404A R407A R407C R407F 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 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 ZA Warning 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 what the sight glass indicates Oil Additives Although Emerson Climate Technologies cannot comment on any specific product from our own testing and past experience we do not recommend
23. metal valve spacer and O ring must be oiled prior to assembly Area Area Area 3 2 1 et Compressor Valve Connecting Tube Figure 5 Brazing All dimensions are in mm Figure 6 Compressor connection and ports For identification refer to the Table on the next page 10 Connection Port Size N 5 Port Size CI ore aA RENE NEES s MIS Connector DUTVNOoptel curo 0 ECT E N E N lu o Comectoroptoni 10 name MIG CCRN TE Iw s ove 80 17 Vaporintemperstuesensor 18 Optcatolevelsensor _ o z 20 oiivesimgss a crankeaseheater Tr 22 tupese 1 25 Dischargevave 1210 26 esst Notes SL Suction Line DL Discharge Line To disconnect e Reclaim refrigerant from both the high and low side of the system Cut tubing near compressor To reconnect e Recommended brazing material is one with minimum 45 silver or silver braze material with flux Insert tubing stubs into fitting and connect to the system with tubing connectors Follow instructions on Brazing 3 2 1 Piping Connections Recommended minimum straight length from discharge valve to first bending point is 200 mm minimum bending Copeland Scroll Fusion has very low vibration radius is 60 mm characteristics so discharge and suction vibration eliminators should not be necessary in the majority of For ease of service a minimum space of 500 mm between installatio
24. ns The suction discharge and liquid pipes top cap surface to casing wall is recommended Refer to should all have sections running close to the compressor Figure 7 body in parallel with the shaft to absorb any startup or shutdown torsion Vibration is much lower than those Vapor Injection and Liquid line found in equivalent piston compressors and discharge Temperatures pulsations are negligible due to the muffling effect of the discharge cover Copeland Scroll Fusion compressor package applies vapor injection technology to improve LT operational Min Distance efficiency and provides a reliable LT envelope Vapor SEKR injection subcools the main liquid line and compressor oil using the integrated plate heat exchanger economizer The subcooling of liquid line calls for these recommendations 1 Liquid line pipe connecting the economizer to the evaporator expansion valve has to be well insulated separately See Liquid Line Insulation for insulation thickness 2 The lower liquid line temperature can increase the evaporator expansion valve capacities Please follow valve manufacturers recommended liquid temperature correction factors for proper selection of evaporator expansion valve Refer to catalogue or contact your Figure 7 Piping guideline local Emerson sales office for liquid line temperatures 11 Liquid Solenoid Valve A liquid line solenoid valve is effective in keeping liquid out of the low side when the system cycles
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26. ompressor is still under pressure To replace components that are under pressure shut down the compressor wait 15 seconds and turn off all power Close the service valves recover the refrigerant and change the faulty component Evacuate the compressor only open the service valves and recharge the same quantity of refrigerant that was recovered A Warning Change the accumulator 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 burnout 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 alumina 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 oil to the replacement compressor and a second failure When a single compressor or tandem is exchanged in the field it is possible that a major portion of the oil may still be in the system While this may not affect the reliability of the replacement compressor the extra oil wil
27. on N m 1 Discharge vave Rotate 3 EES GE Tube 5 s bd Nut orOiln Tube 10 s Nuts of Tube Oil Pulsation EVI Rotalock Nut 1 22 mm 25 30 40 50 Opening Wrench 24 mm Pressure Differential Sensor 100 110 Mechanical Part Lower Cover Terminal Box Cover Screws H3 6 1 2 Cross Screwdriver Voltage Tester Metric Internal Hexagon Socket Torque Wrench Screw CoreSense Connect S to Terminal Box H3 6 1 2 CoreSense Terminal Connectors 3 lt 5 N A gt Ul N co 3 40 5 10 200 775 Transformer Bolts 3mm Thrust Plate Bolts Ch N co 4mm N co Oil Separator Bolts Bolt Terminal Box Connect to Body 5mm 3 40 5 10 00 N co N n en 80 90 Flat Chisel N A 11 12 13 0 Rubber Hammer N A Special Bolts M12 N A Special Socket Torque VVrench lz 2 Torque Wrench M10 2 Opening Wrench 13mm 2 2 2 3 2 Top Cap Bolts 10mm Top Cap and Lower Cover Z 2 Top Cap and Lower Cover 2 Top Cap 2 HVE Holder A 12 15 N A Scroll Set Screw Upper Counterweight For Torque VVrench For Socket For Socket For Torque VVrench 30 150 N A For Teardovvn Only ir N Ul Torque Wrench Extension Bars Offset Socket Screw Key Set 1 5 to 10 mm 2 3 7 6 4 IER 8 9 1 1 2 LA Contact Lists Asia Pacific Headquarters Emerson Climate Technologies S
28. ors Copeland Scroll Fusion compressors have inherently superior liquid handling capability so a pumpdown at each thermostat cycle is not recommended A pumpdown cycle before defrost will be helpful in reducing the defrost time Copeland Scroll Fusion compressors are fitted with a spring loaded low leak check valve under the discharge service valve so an external check valve should not be necessary When pumpdown finishes the compressor will stop and contain a very large volume of high pressure gas in the top cap area This refrigerant will quickly leak back to suction and will cause a significant pressure rise that could reset the low pressure switch The control circuit should not allow the compressor to restart restart should only occur when the thermostat closes 12 High Pressure and Low Pressure Cut out Settings 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 The low pressure cut out should be set as high as possible in all applications For medium temperature applications the normal minimum is 2 5 bar g which corresponds to 10 C with R22 and 16 C with R404A For low temperature applications the minimum cut out setting should not be lower than 0 3 bar g for a compressor using R404A and should not be lower than 0 1 bar g for a compressor using R22 The cut out point of the LP switch mus
29. ossible in special cases Please contact an Emerson Climate Technologies Application Engineer o I e D ken NO X AA lt o LY IN aN o 98 Mineral oils such as Suniso 3GS are approved for R22 application Operation with R404A and R507 requires Polyol Ester POE lubricants and POE oil models are filled with Emkarate RL 32 3MAF ex factory Emkarate RL 32 3MAF and Mobil EAL Arctic 22 CC are both approved for top up and servicing A ution Do not mix ester oils with mineral oil and or alkyl benzene when using chlorine free HFC refrigerants The compressor is supplied with an initial oil charge The standard oil charge for use with refrigerant R404A 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 See nameplate for original oil charge in litres A field recharge is from 50 100 ml less than the original charge BD caution Oil must be drained from both the high and low sides of the compressor whenever oil is changed One disadvantage of POE is that it is far more hygroscopic than mineral oil see Figure 2 Brief exposure to ambient air causes POE to absorb sufficient moisture to make it unfit 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 a vacuum Compressors supplied by Emerson Climate Technologies contain oil wit
30. refer to nameplate test pressures prior to testing 17 AA warning The maximum pressure for leak testing should be no higher than 22 5 bar g Use only dry nitrogen or dry air for system pressure testing DO NOT USE other industrial gases If using dry air do not include the compressor in the pressure test isolate it first Never add refrigerant to the test gas as leak indicator System Evacuation and Dehydration Before the installation is put into operation 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 dry air the compressor is under pressure about 1 2 5 bar this is to indicate the compressor does not leak Preliminary Check Discuss installation details with the installer If possible obtain drawings wiring diagrams etc It is ideal to use a checklist but always check the following e
31. rminal box monitors several sensors and protects the compressor from the following malfunctions e Reverse rotation by differential oil pressure sensor e Compressor not pumping by differential oil pressure sensor e High discharge temperature by discharge port temperature sensor e Low oil level by optical oil level sensor e Motor overheat by embedded four thermistors e High pressure cut out to be connected by system manufacturer or installer e Low pressure cut out to be connected by system manufacturer or installer ZA Warning High Pressure and Low Pressure switches must be fitted by the system manufacturer and connected to the pressure ports shown in the compressor outline drawing on Figure 6 HP and LP cut out switches must be electrically connected as shown in the wiring diagram on Figure 10 ZA Warning Reverse rotation and lack of pumping have the same symptoms the discharge pressure does not rise and the suction pressure does not fall If the control module senses that the differential pressure switch has not closed after a short time delay the compressor will stop an error 13 IVNINHAL UI JO ONIZIM 59 LV HLIM LOANNOO 1ITIVYWA TVNINYIL DUSuUSCL 40 N M M OH 7 TVN IS 8033 440 NO YOSSAYdNOO Puewsq TWNINYAL Jossesdwo5 40 M 3H YOSNAS dWAL LNO HOdvA z LI IVIIO INI 1Y TN IVNINYIL Mel 40 N M M MOSHO 2 YOSN3S dN31 NI MOdVA E SAVANE LINIVIO LO
32. stem while brazing all joints during the system assembly process Nitrogen displaces the air and prevents the formation of copper oxides in the system eRecommended brazing materials any material is recommended preferably with a minimum of 45 silver e Be sure valves LD and connecting tube O D are clean prior to assembly If oil film is present wipe with denatured alcohol Dichlorotrifluoroethane or other suitable solvent e Using a double tipped torch apply heat in Area 1 As tube approaches brazing temperature move torch flame to Area 2 eHeat Area 2 until braze temperature is attained moving torch up and down and rotating around tube as necessary to heat tube evenly Add braze material to the joint while moving torch around joint to flow braze material around circumference Dimensional Drawings e After brazing material flows around joint move torch to heat Area 3 e 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 results e When welding the discharge line connection pipe to the discharge service valve the O ring must be replaced with a new one Replacement O ring can be found on the accessory bag elf the suction and discharge shut off valve bolts or rotary valve joint are released while brazing the shut off valves replace the shut off valve spacer or O ring The non
33. t be set using an accurate suction pressure gauge rather than the scale on the switch which is provided for rough setting only AA warning Copeland Scroll Fusion compressor should NEVER be allowed to run in a vacuum The low pressure cut out should have a manual reset feature for the highest level of system protection Condenser Filter Drier min 100 mesh Economizer Plate Heat Exchanger Economizer Liquid Out Line must be insulated Sight Glass Evaporator E VI Vapor Injection EXV Electronic Expansion Valve TXV Thermostatic Expansion Valve Fusion Standard BOM Figure 8 Schematic Diagram Electrical Installation The compressor is supplied with a wiring diagram inside the terminal box cover as shown in Figure 10 Fuses and circuit breakers must be installed in accordance with local electrical regulations The terminal box has an IP54 rating A Electrical Shock Conductor Cables Electrical Shock Shut Off Power before High potential testing ZA Warning The compressor and accessories are tested for leakage to ground before shipping Disconnect the control board PWR and DEMAND connections to avoid any risk of damage during high potential testing Three phase Motors All compressors can be started direct on line only Control Board Connection The control board which is mounted in the terminal box monitors the compressor sensors protects the compressor drives the elec
34. tronic expansion valve and displays useful information in a seven segment display Three red LEDs indicate the status of the Alarm CCC compressor contactor coil and a spare relay which is connected to the black terminal block The board is powered via a transformer with a nominal output of 16 VAC When correctly wired and powered up the board goes through a self checking routine and displays a flashing 0 If the display is blank check the power supply on the PWR terminals the transformer output and the green fuse The green fuse 250 V 2A protects the transformer and other electronic components The white fuse 250 V 1A protects the system control circuit and the on board relays from external short circuits Wiring Diagram and Wiring Instruction The position of the 4 Bit Dip Switch in the terminal box and the recommended wiring diagrams are shown in Figures 9 and 10 Fusion Control Box Wiring Standard According to Figure 11 there are 4 joints at the bottom of the control box Each joint has dedicated wires to be assembled Table 1 explains the function requirement and connection method of each joint and wires inside Figure 12 on the other hand shows the recommended wiring sequence for the control box 4 Bit Dip Switch D d a yi D m di ii d Le ie wf h Figure 9 CoreSense Diagnostics Board CoreSense Diagnostics The CoreSense Diagnostics module in the te
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