Copeland Scroll™ Fusion Compressor
Contents
1. Pumpdown Cycle Pumpdown cycles are widely applied in systems with reciprocating compressors 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 11 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 n2. Terminal Wires ec L E ii dosi 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 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 Wilce C ndo 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 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 5 10 mm 5 10 mm iamm Diameter Range Internal wire size 18 20 AWG Recommended wire size 18 AWG Rated voltage 300V 500V Jacket Line Requirement Internal wire seize 8 AWG or above 4 wires in total Rat
3. nm x SIN Figure 9 CoreSense Diagnostics Board CoreSense Diagnostics The CoreSense Diagnostics module in the terminal box monitors several sensors and protects the compressor from the following malfunctions Reverse rotation by differential oil pressure sensor Compressor not pumping by differential oil pressure sensor High discharge temperature by discharge port temperature sensor Low oil level by optical oil level sensor Motor overheat by embedded four thermistors High pressure cut out to be connected by system manufacturer or installer 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 12 TVNINdd1 wely dO ONIZIM MOAHO S L9 HLIM LO3NNOO 13T1VuVd TVNIIA3J3 L pueuieg JO SNIHIM 493HO 7 TVN9SIS MOVE 334 440 NO HOSS3HdWOO pueueg TVNIW331 0sseduo2 40 ONIMIM YOIH YOSNAS dWAL LNO H
4. 5 200 230 3 200 220 3 Note QF205 has low temperature model only 7 380 3 Operating Envelopes R22 R404A QF115 QF125 QF145 QF175 QF185 R22 R404A QF205 Condensing Temperature C Condensing Temperature C O v t 3 o Q v 7 F x 5 5 U E To m mE SE ai ai Em Q Qu aE 23 EO Eo EO e EE qi oC o pu 3 KO 70 88 ES 2 56 A E R22 U U d I 60 ba IS 50 40 30 20 10 0 50 40 30 20 10 0 10 20 Evaporating Temperature C Note 20 C Return Gas Temperature No Fan Cooling g J m fU D ai Lv E C gj EG Eu oo CS ERE z 70 z 60 un aU U U o o N Ta 60 m PR i R22 R404A 50 40 30 20 10 0 10 20 Evaporating Temperature C Note 20 C Return Gas Temperature No Fan Cooling Nameplate Information Copeland MODEL QF1 75A TWD 203 Oll TT R SERIAL NO 12F00747Y MAX OPER PRESS e gp EET He 28 22 3 Ph 50 Hz 2900RPM V Ph VOLTAGE V MRA A LRA A 380 420 Y 32 95 105 4650 Y 33 e 8963 4611 8895 3593 with CoreSense Diagnostics Figure 1 Nameplate and nameplate location Technical Data QF115A QF125A QF145A QF175A QF185A QF205A Model Displacement 50 Hz R404A QF115AE QF125AE QF145AE QF175AE QF185AE QF205AE Power Crankcase Heater Voltage Initial Oil Charge Recharge lt 220 2 66 2 54 1 1 8 SW 1SW 675 355 389 350 200 M10 2 Discharge Length Dimensions Width Height Length Base Mountin
5. 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 Bangkok 10260 Thailand Tel 662 716 4700 Fax 662 751 4241 Vietnam Emerson Climate Technologies Vietnam Suite 307 308 123 Truong Dinh St Dist 3 Ho Chi Minh Vietnam Tel 84 908 009 189 EMERSON CONSIDER IT SOLVED
6. with CoreSense Diagnostics DAN Wa 3 Copeland Scroll EMERSON About Emerson Climate Technologies Emerson Climate Technologies a business segment 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 fora versatile reliable quiet lightweight serviceable compressorforthe 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 Co
7. Climate Technologies Application Engineer 5 I e D ken NO e X An lt oj DU Ln aN 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 AA caution 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 with low moisture content and this may rise during t
8. Ltd Japan Guangzhou Sales Office 508 509 R amp F Yinglong Plaza No 76 Huangpu Road West Emerson Japan Ltd Shin yokohama Tosho Building Guangzhou PRC No 3 9 5 Shin Yokohama Kohoku ku Tel 8620 2886 7668 Yokohama 222 0033 Japan Fax 8620 2886 7622 Tel 8145 475 6371 Fax 8145 475 3565 China Shanghai Emerson Climate Technologies South Korea Suzhou Co Ltd Shanghai Sales Office Emerson Electric Korea Ltd 1801 Building B New CaoHeJing 3F POBA Gangnam Tower 119 Nonhyun International Business Center Dong Gangnam Gu Seoul 135 010 Korea 391Guiping Rd Shanghai PRC Tel 822 3483 1500 Tel 8621 3418 3968 Fax 822 592 7883 EmersonClimateAsia com Asia 02 B04 10 ROO Issued 12 2013 GSCAA032 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 Malaysia Emerson Electric Malaysia Sdn Bhd Level M2 Blk A Menara PKNS P Jalan Yong Shook Lin 46050 Petaling Jaya Selangor Malaysia Tel 603 7949 9222 Fax 603 7949 9333 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 23rd Floor San Miguel Properties Centre St Francis Street Ortigas Center Mandaluyong City Philippines Tel 632 689 7200
9. 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 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 18 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 A 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 itis 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
10. tubing pressurized If a brazing torch is applied to the low side while 19 the low 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 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 instead of unbrazing Dismantling and Disposal 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 Appendix Fault Diagnostic Code Description Status Compressor Action Normal compressor operation Normal Normal compressor operation Normal compressor off Normal Normal compressor standby EN E Fault EXV will not work so compressor must stop follow Emerson Wiring Diagram h dotoroserheai Fault Compressor shutdown and automatic reset after 10 min delay T h i E E sa Fault Compressor shutdown and automatic reset after 10 min delay 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 Woo
11. Area 3 Installation This will draw the braze material down into the joint The time spent heating Area 3 should be minimal Brazing As with any brazed joint overheating may be detrimental to the final results 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 e Ifthe 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 metal valve spacer and O ring must be oiled prior to assembly e Itis important to flow nitrogen through the system while brazing all joints during the system assembly process Nitrogen displaces the air and prevents the formation of copper oxides in the system e Recommended brazing materials any material is recommended preferably with a minimum of 45 silver 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 Area Area Area approaches brazing temperature move torch flame to Area 2 iii eHeat Area 2 until braze temperature is attained moving torch up and down and rotating around tube Compressor as necessary to heat tube evenly Add braze material to Valve Connecting the joint wh
12. OdvA F LI Ir INI 1Y TN IVNINYIL Mel 40 SNIHIAA MOSHO Z NOSN3S dial NI HOdVA E SAVANE LInoio LO A1ddNS H3AAOd YOLOW HOSS3HdWOO JO SNIHIM 423H9 L HOSN3S dWal LYOd 39UVHOSIA 7 MOLOVINOO 1SI1 MOSHO AVTAY 1100 YOLIOVINOI HOSS3HdlWO2 222 UYOSSIYANOO Lol Le Wii d NMOG NMOG diNNd ON diNNd CNOILdO LNOILdO YOLON W UNING VYOSSIYdINOI ER ZH09 0S M3MOd YOLOW 3 eg TX OWA0VZ 0ZZ Se N NEN ea st set MEME a O 999 8 d TIET I l us ANWA nS NoIsnvaxa Qe OINOULO313 lt i Ai l l l HOLIMS al B EEE Sp aaNSSIYd CEN Q O ala HOSNIS 13131 2g Iesu To TvOl1dO I es Xov18 I ST i E S c Q2 TVNIWS3L EE YOSNIS HOLIMS Tue d YOLOW JJO NO hs l I I A HINHOHSNYAHL I C DI BULA pe 5 L _ Mojerxa piepues 5 I LL sol 4 BuulM uu9 s S pepueuiuoo2e Figure 10 Wiring Diagram 13 Ven hs Tut AAB53345 EATER TAS ig ERRE AY E Di i EE dei S S LR UR UZ Page Wa 9 iii ce was oa 15 ia ob A 4 ve Bie L a A s lBolouup l Seu e NOS gt fy lt Figure 11 CoreSense Wiring and Joints Step 1 Connect Compressor Motor Wires Step 2 Connect PWR Terminal Wires Step 3 Connect Demand Terminal Wires Step 4 Connect CCC Terminal Wires Step 5 Connect Alarm
13. Three phase Terminal Plate M38 12 15 Oil Charge Fitting Plug Oil Drain Oil Fitting Plug 2 42 Lower Covey Metric Hexagon gt Lower Cover Bolts To bum d 57 68 Check Valve Bolts 7 23 30 100 Oil Drain Oil Fitting Plug Oil Charge Fitting Plug 21 Description Specification N m 2 81 Item No Tool Tool Tool Torque Value EE A B No Description Specification N m Oitevelsensor B Discharge vave Rotate 25 RotalockNutforOiloutTube 5 9 RotalockNutforOilinTube 10 9 Nuts of Tube Oil Pulsation EVI Rotalock Nut 1 22 mm 25 30 Opening Wrench 3 24 mm 40 50 Pressure Differential Sensor 72 81 Mechanical Part Lower Cover Terminal Box Cover Screws EXE H3 6 1 2 Screw CoreSense Connect Cross Screwdriver i to Terminal Box H3 6 i CoreSense Terminal 3 votada pet M N A Connectors Sie deer Transformer Bolts 15 28 3 mm Thrust Plate Bolts 16 28 4mm 5 65 7 75 Metric Internal SS l Oil Separator Bolts 17 28 Hexagon Socket 5 6 Bolt Terminal Box Connect 18 28 Torque Wrench 3 4 to Body Top Cap Bolts 19 29 10mm 80 90 22 FltChisel N A Top Cap and Lower Cover Rubber Hammer N A Top Cap 2 Special Bolts M12 N A Special Socket li Torque Wrench Lei Torque Wrench M10 Opening Wrench 13 mm IER Torque Wrench Extension Bars Offset Socket Screw Key Set 1 5to 10 mm HVE Holder Ul N 3 s uid A 12 15 N A Scroll Set Screw Upper Co
14. before installation The compressor comes charged with dry air at a pressure of 2 0 bar Do Not Use the compressor to de pressurize to evacuate a refrigeration system Start the compressor when it is under vacuum Conduct a test without connecting the compressor to a System Start the compressor without a refrigerant charge Operate a compressor beyond its approved application envelope Touch the compressor or pipes when the compressor is running High low temperature may cause burns frostbite Releaserefrigerant 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
15. cuated 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 Visual check of the electrics wiring fuses etc e 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 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 17 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 T
16. d line solenoid valve is effective in keeping liquid out of the low side when the system cycles 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
17. d 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 will 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 filteRdrier is installed in all POE systems This will maintain the moisture level in the oil to less than 50 ppm A 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
18. e 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 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 09C 25 C 100 C Rene aan 28KOhm 10KOhm 9500hm ZEN 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 cha
19. ed voltage 600V 1000V 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 be connected The alarm relay contact is rated at 250 VAC 1A and 30 VDC 1A Aad 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 15 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 b
20. g Width Bolt Net 130 Weight Gross 140 Notes 1 MOC Maximum Operating Current 2 LRA Locked Rotor Current 3 QF205A E has only low temperature model Maximum Operating Pressures A caution 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 set 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 y 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 possible in special cases Please contact an Emerson
21. ghtness 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 compressor 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 ZA 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 plugge
22. h 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 to liquid abuse Turn the crankcase heater on 12 hours before starting the compressor Maintenance Refrigerant Exchange Qualified refrigerants and oils were indicated in Chapter 2 5 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 tem perature 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 ZA Warning Rotalock valves should be re torqued periodically to ensure that leak ti
23. he system assembling process POE oil should not be exposed to the atmosphere for longer than 15 minutes It is therefore recommended to install a correctly sized filteRdrier 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 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 Suction and discharge shut off valves Oil charge oil sight glass Oil level switch Differential oil pressure sensor Plate heat exchanger Electronic expansion valve Crankcase heater CoreSense Diagnostics 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 pa
24. he 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 discharge 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 5K 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 throug
25. ile moving torch around joint to flow braze Tube material around circumference Figure 5 Brazing Dimensional Drawings L1 IT LJ hi j TT CH P 2 All dimensions are in mm Figure 6 Compressor connection and ports For identification refer to the Table on the next page D Connection Port Size N SM Ee Port Size L5 meeieftg MIS 6 Comector DUTVNOptel Cros I Oman 8 meme MS 9 Comectoroptoni 1 name MIG warma Cas neen Im 6 ver 17 Veporintemperaturesensor 18 Optcatolevelsensor Eau _ 71 Buiktinoiiscien Ju 20 Oleeisgtges r Lm Ledesch 2 tewpreswepot as Dischargevave 25710 26 esst Notes SL Suction Line DL Discharge Line To disconnect 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 Copeland Scroll Fusion has very low vibration For ease of service a minimum space of 500 mm between characteristics so discharge and suction vibration top cap surface to casing wall is recommended Refer to eliminators should not be nece
26. ion 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 refer to nameplate test pressures prior to testing 16 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 eva
27. mfort Safequard Food And Protect The Environment Table of Contents About Emerson Climate Technologies Table of Contents Features and Benefits Nomenclature Operating Envelopes Technical Data Dimensional Drawings Wiring Diagram Contact Lists 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 Make sure that the compressor is upright and there are no collisions ortilting during transit Useonly refrigerants and oils approved by Emerson Make sure that the supply power voltage frequency and phase are exactly as per the specifications on the compressor nameplate The dry air inside the compressor should be evacuated
28. nged without breaking into the system Malfunction is also possible if the lens M25 5 Sensors 3xM16 Reserved for A Remove Terminal Box Cover for Customer Wiring Figure 13 Terminal Box Location For Wiring is coated by system contaminants The lens will need to be removed and cleaned to restore correct operation The differential pressure switch is normally open when 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 Temp Sensor Discharge Port 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 arecommonin 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 Operat
29. ot be lower than 0 1 bar g for a compressor using R22 The cut out point of the LP switch must be set using an accurate suction pressure gauge rather than the scale on the switch which is provided for rough setting only Au 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 an ik He D ee Filter Drier Sch d d Fett min 100 mesh Economizer Plate Heat Exchanger Economizer Liquid Out Line must be insulated Sight Glass VI Vapor Injection EXV Electronic Expansion Valve TXV Thermostatic Expansion Valve Fusion Standard BOM Figure 8 Schematic Diagram Flectricallnstallation 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 AN 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
30. r thenien aine 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 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 ASSE 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 Fault diagnostic code is visible through a transparent window on the cover e The code and description can be found inside of the cover O Z CY ES D FLASH FLASH FLASH 2 FLASH 3 FLASH 4 5 FLASH FLASH 7 FLASH FLASH 3 and F Number S ance Number Low oil level Require FLASH on manual reset or r I 2J l 20 Tool List 16 17 1 2 3 4 5 6 13 14 9 10 11 J 15 18 Item No Tool Tool Tool Torque Value Components on Page N Table O Pressure Differential Sensor 1 g 29 1 7 Mechanical Part Lower Cover
31. ssary in the majority of Figure 7 installations The suction discharge and liquid pipes should all have sections running close to the compressor Vapor Injection and Liquid Line Temperatures body in parallel with the shaft to absorb any startup or shutdown torsion Vibration is much lower than those Copeland Scroll Fusion compressor package applies found in equivalent piston compressors and discharge vapor injection technology to improve LT operational pulsations are negligible due to the muffling effect of the efficiency and provides a reliable LT envelope Vapor discharge cover injection subcools the main liquid line and compressor oil using the integrated plate heat exchanger economizer The Recommended minimum straight length from discharge subcooling of liquid line calls for these recommendations valve to first bending point is 200 mm minimum bending ads nas s 1 Liquid line pipe connecting the economizer to the evaporator expansion valve has to be well insulated Min Distance separately See 3 2 6 forliquid line insulation thickness 500 mm 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 local Emerson sales office for liquid line temperatures Figure 7 Piping guideline 10 Liquid Solenoid Valve A liqui
32. the terminal box monitors the compressor sensors protects the compressor drives the electronic 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 Vode D t a n gt H k i n a i B I m gt e ep x V O z
33. unterweight a NJ greens Ul For Torque Wrench For Socket For Socket For Torque Wrench 30 150 N A For Teardown 11 Le 13 0 2 2 2 2 2 3 2 Only 2 3 7 6 4 0 9 Top Cap and Lower Cover a 2 2 N Contact Lists Asia Pacific Headquarters India Mumbai Emerson Climate Technologies Emerson Climate Technologies India Ltd Suite No 2503 8 25 F Unit No 4 5 6 amp 7 Bhaveshwar Arcade Exchange Tower 33 Wang Chiu Road Kowloon Bay Kowloon Hong Kong Tel 852 2866 3108 Fax 852 2520 6227 LBS Marg Opp Shreyas Cinema Ghatkopar West Mumbai 400 086 Maharashtra India Tel 9122 2500 6630 2500 6632 Australia Fax 9122 2500 6570 Emerson Climate Technologies Australia Pty Ltd India PUNE 356 Chisholm Road Auburn NSW 2144 Australia Tel 612 9795 2800 Fax 612 9738 1699 Emerson Climate Technologies India Ltd Plot No 23 Rajiv Gandhi Infotech Park Phase Il Hinjewadi Pune 411 057 Maharashtra India Tel 9120 2553 4988 China Beijing Emerson Climate Technologies Suzhou Fax 9120 2553 6350 Co Ltd Beijing Sales Office Indonesia Room 1017 JianWei Building eg l PT Emerson Indonesia 66 Nan Lishi Road XiCheng District Wisma 46 Kota BNI 16th Floor Suite 16 01 Beijing PRC Fax 861 0 5763 0499 Jakarta 10220 Indonesia Tel 6221 2513003 China Guangzhou Fax 6221 2510622 Emerson Climate Technologies Suzhou Co
34. will develop Alllocal safety regulations must be observed AN Electrical Shock Turn off electrical supply and power before servicing Use this equipment only in a grounded system Refertothe applicable system wiring diagram as shown in this manual 9000 Use Personal Safety Equipment 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 Safety gloves protective clothing safety boots and protective eyewear should be worn where necessary Product Description Copeland Scroll Fusion for refrigeration medium temperature and low temperature applications Features and Benefits e Emerson s Copeland Scroll technology Serviceability in the field CoreSense Diagnostics Integrated vapor injection technology e Wide range envelope and efficient operation 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 Bill of Material OF185AE TWD 203 Model Variation Motor Types Code Phase T 3 Application Range Code Application Approved Refrigerants Typical Electrical Codes F Full Range R22 R404A Code 60 Hz 50 Hz Low Med High D 460 3 380 420 3
35. y attention to stacking 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 AA warning The compressors must not be lifted by the service valves or other accessories Otherwise damage or refrigerant leaks may occur Lifting eye ero 6x2 0 Thread Figure 3 Compressor lifting method Mounting Parts A 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 horizontally on both axes Mounting Nut Compressor Mounting Foot Mounting Spacer Baseplate a M10 Mounting Bolt Figure 4 Mounting kit Mounting Kit Part Code 027 0443 00 Piping Connection and Compressor e After brazing material flows around joint move torch to heat
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