Emerson Copeland 2D Series, Application Manuallines

Page 1: ...Application Guidelines Semi Hermetic Compressors Discus K L S Series ...

Page 2: ...its 6 2 6 Design features 7 2 6 1 Construction 7 2 6 2 Compressor cooling 8 2 6 3 Unloaded start 8 2 6 4 Capacity control 9 2 6 5 Demand Cooling 9 2 6 6 Discharge Temperature Control valve DTC 9 2 6 7 Running gear lubrication 9 2 6 8 Oil pumps Suction gas cooled compressors 10 2 6 9 Oil pressure 10 2 6 10 Oil circulation 10 2 6 11 Oil level 11 2 6 12 Oil separation management for booster applicati...

Page 3: ...thermal protection switch for single phase motors System A 18 4 5 2 Thermistor protection System W 18 4 6 Discharge temperature protection 19 4 7 Demand Cooling 20 4 8 Oil pressure control 20 4 8 1 Oil pressure switch OPS2 20 4 8 2 SENTRONIC Oil pressure control 21 4 8 3 Oil pressure switch ALCO FD 113 ZU A22 057 21 4 8 4 Crankcase heaters 22 5 Starting up operation 23 5 1 Leak test 23 5 2 System ...

Page 4: ...perheat 27 7 5 Acid formation 28 7 6 Inadequate compressor cooling 28 7 7 High discharge temperatures 28 7 8 Motor burnout due to undersized contactors 28 7 9 Motor burnout due to by passed or disconnected protectors 28 8 Dismantling disposal 28 Appendix 1 Compressor connections 29 Standard compressor connections 29 Discus compressor connections 35 Appendix 2 Tightening torques Nm 38 Disclaimer 39...

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Page 6: ...icon indicates operations with a danger of electric shock IMPORTANT This icon indicates instructions to avoid malfunction of the compressor Danger of burning or frostbite This icon indicates operations with a danger of burning or frostbite NOTE This word indicates a recommendation for easier operation Explosion hazard This icon indicates operations with a danger of explosion 1 2 Safety statements ...

Page 7: ...nly approved refrigerants and refrigeration oils must be used WARNING High shell temperature Burning Do not touch the compressor until it has cooled down Ensure that other materials in the area of the compressor do not get in touch with it Lock and mark accessible sections CAUTION Overheating Bearing damage Do not operate compressors without refrigerant charge or without being connected to the sys...

Page 8: ...orm of single compressors condensing units or as multi compressor equipment The compressor is only one component which must be combined with many others to build a functional and efficient refrigeration system Therefore the information in this manual relates to all semi hermetic compressors with standard equipment and accessories only 2 2 About these guidelines These guidelines are intended to ena...

Page 9: ...4 D6 3 4 0715 0716 E DWM Copeland designation old models 2 3 2 Suction gas cooled compressors Copeland brand designation present models ...

Page 10: ...e date of production consists of the year and week of production In addition the year and month of production are shown as part of the serial number Jan A Feb B Dec L The mutual nameplate on TWIN compressors only indicates the model and the year of manufacturing All other details should be taken from the individual compressor nameplates 2 4 1 DWM Copeland designation old models DK DL D2S D4S D4D D...

Page 11: ...m Copeland brand products Select software available at www emersonclimate eu Qualified refrigerants R134a R404A R407A R407C R407F R448A R449A R450A R507 R22 R22 Copeland brand products standard oils Emkarate RL 32 3MAF Suniso 3 GS Servicing oils Emkarate RL 32 3MAF Mobil EAL Arctic 22 CC Shell 22 12 Suniso 3 GS Fuchs Reniso KM 32 Capella WF 32 Only valid for compressors 2D 3D and 8D Table 1 Qualif...

Page 12: ...ssors using mineral oil or semi synthetic oil and R22 HCFC are equipped with a centrifuge lubrication system K L compressors using ester oil for chlorine free HFC refrigerants like R404A are equipped with an internal oil pump The LHA compressor has an external oil pump Refrigerant cooled compressors from D4S upwards are also available as TWIN Tandem ie two compressors of the same type coupled toge...

Page 13: ...through a water coil wound round the motor section Usually the water coil is connected before the water cooled condenser With mains water a single coil W is used and with cooling tower connection a split coil W2 is used To improve heat transmission the water coil is embedded into thermocement on motors 0 75 HP but smaller than 4 HP If cylinder head cooling is also required an additional fan must b...

Page 14: ...ompressors are equipped with a plugged injection port on the side of the compressor wall close to the base of the cylinder block The injection port can be retro fitted with the DTC valve The temperature sensing element with 12 NPT thread fits on the D4SL T D6SL T and D6SU compressor body close to the discharge shut off valve Please note that DTC is needed only in systems with R22 refrigerant The v...

Page 15: ... plug on the compressor crankcase or the suction service valve During irregular operating conditions eg a blockage of the suction filter the pressure measured at the suction shut off valve of the compressor may differ widely from that measured at the crankcase therefore pressure drops have to be avoided 2 6 10 Oil circulation Oil returns with the suction gases through a suction strainer and separa...

Page 16: ...stalled in the discharge line of the high stage compressor It will separate the oil from the discharge gas and pass it to an oil reservoir The oil will then pass from the oil reservoir through the oil management system to each individual compressor ensuring full lubrication and extended compressor life and reliability 2 6 13 R22 Low temperature applications using D2SA 450 X Air D2SC 550 X Air comp...

Page 17: ...g to weight Keep in the upright position Stack pallets on top of each other when not exceeding 300 kg Stacking higher than the recommended maximum can cause accidents Do not stack single boxes on top of each other Keep the packaging dry at all times Compressors are individually packed and may be delivered on pallets depending on quantity and size Cooling fans are delivered in separate cartons Acce...

Page 18: ... for semi hermetic compressors A compressor may be rigidly mounted ie without springs In this case more shock and vibration loading will be transmitted to the frame If the installation requires a very high level of vibration absorption additional vibration absorbers available on the market can be fitted between the rails and the foundation To ensure proper lubrication of moving parts the compresso...

Page 19: ...rotect the installation against dangerous system pressures Before operating the compressors the pressure switches and other safety devices must be installed correctly Maximum allowable pressures must not be exceeded For connecting a high pressure switch there is a tapped hole with plug in 1 8 27 NPTF on each cylinder head Figure 9 Figure 10 3 2 4 Oil pressure switch The oil pressure switch breaks ...

Page 20: ...e clean prior to assembly Using a double tipped torch apply heat in area 1 As the tube approaches brazing temperature move the torch flame to area 2 Heat area 2 until braze temperature is attained moving the torch up and down and rotating around the tube as necessary to heat the tube evenly Add braze material to the joint while moving the torch around the joint to flow braze material around the ci...

Page 21: ...ide diameter mm 1 20 6 M20 x 1 5 20 2 32 5 M32 x 1 5 32 3 50 5 M50 x 1 5 50 4 63 5 M63 x 1 5 63 Table 2 Characteristics of the holes for cable bushings Figure 13 Position of the holes for cable bushings top view of a 6 cylinder compressor The protection class of each terminal box according to IEC 60529 is given in Table 3 hereunder Old models Present models Class Option DK DL D2D D2S K L 2D IP54 D...

Page 22: ...e identical the star connection motor can also be used for starting remove bridges 4 2 5 Part winding motor YY Y Code A PWS motors contain two separate windings 2 3 1 3 which are internally connected in star and operated in parallel You cannot change the voltage by changing the electrical connections The motor is only suitable for one voltage range The first part winding the 2 3 winding on termina...

Page 23: ...rs each on 4 6 and 8 cylinder compressors connected in series are embedded in the motor windings in such a manner that the temperature of the thermistors can follow with little inertia An electronic release module is required which switches a control relay depending on the thermistor resistance The release module INT69 2 for one thermistor chain or two chains with a 5 minute time delay INT69TM 2 f...

Page 24: ... lamp fault N Neutral connection T PTC sensor resistance of one thermistor 1 2 Sensor connection at 20 C is between 30Ω 250Ω measuring 12 Alarm connection voltage 3V maximum 14 Control circuit X Additional terminal box 11 Control voltage connection A8 Release module for discharge temperature S2 Reset button protection Figure 17 Protection class IP55 Safety instructions Product description Installa...

Page 25: ...e electrical control cabinet and the compressor terminal box should be used Wiring diagrams for both the OPS1 and OPS2 are shown in Technical Information D7 8 3 DWM Copeland Semi hermetic Compressor Oil Pressure Differential Switch OPS2 available at www emersonclimate eu The wiring diagram relates to an option using a 7 wire cable Wiring Brown BN Power supply input Violet VIO Running signal from t...

Page 26: ...witch Figure 20 Protection class IP31 4 8 3 Oil pressure switch ALCO FD 113 ZU A22 057 Legend 11 Voltage connection A5 Compressor terminal box 21 Control voltage connection R Relay 22 Control circuit N Neutral connection 24 Alarm connection t Time delay A2 Oil pressure switch Figure 21 Protection class IP30 Safety instructions Product description Installation Electrical connection Starting up oper...

Page 27: ...ors is a self regulating 27 Watt PTC heater see Fig 22 70 Watt and 100 Watt heater element The 70 Watt heater for L 2D and D2 compressors is screwed into a pocket Heaters for D3 3D D4 and D6 compressors are screwed into a sleeve see Fig 22 Figure 22 Crankcase heater 27W 70W and 100W 200 Watt heater element In compressors that are equipped with a deep oil sump the heater element is inserted into a ...

Page 28: ...ssure approximately 1 to 2 5 bar this is to indicate the compressor does not leak When plugs are removed from the compressor in order to connect a pressure gauge or to fill in oil the plug may pop out under pressure and oil can spurt out 5 3 Preliminary checks Pre starting Discuss details of the installation with the installer If possible obtain drawings wiring diagrams etc It is ideal to use a ch...

Page 29: ...askets should be oiled before fitting O rings should also be oiled NOTE A compressor should never be operated beyond its approved application range Check by consulting the appropriate data sheet To avoid motor damage the compressor must neither be started nor may high potential testing be carried out under vacuum 5 6 Minimum run time Emerson Climate Technologies recommends a maximum of 10 starts p...

Page 30: ...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 suc...

Page 31: ...l of POE would be higher than the sight glass indicates This is due to the high hygroscopicity of the POE oil To determine the actual moisture content of the lubricant samples have to be taken from the system and analysed 6 6 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 additiv...

Page 32: ...l to be properly lubricated 7 2 Oil dilution During the off cycle a certain refrigerant concentration is always present in the compressor oil This depends on the compressor temperature and crankcase pressure The rapid reduction of pressure on start up causes the refrigerant to evaporate from the oil This causes oil foaming which can be seen in the compressor oil sight glass The oil pump draws in m...

Page 33: ...ischarge line a few centimetres from the service valve Symptoms of high discharge temperatures are cutting out on the high pressure switch dirty condenser oil carbonisation black oil and acid formation Inadequate lubrication is the result The condenser should be cleaned regularly The evaporating temperature should not be allowed to fall below the application limit of the compressor 7 8 Motor burno...

Page 34: ...sure connection 1 8 27 NPTF 2 Pocket for heater with plug M25 x 1 5 7 Plug high pressure connection 1 8 27 NPTF 3 Magnetic plug 1 8 27 NPTF 8 Plug oil charge 1 8 27 NPTF DL L DLE 20 LE 20 DLJ 20 LJ 20 DLL 40 LL 40 DLF 20 LF 20 DLJ 30 LJ 30 DLSG 40 LSG 40 DLF 30 LF 30 DLL 30 LL 30 SL Suction line sweat Ø 1 2 DL Discharge line sweat Ø 1 2 1 Base mountings Ø 14 mm 7 Plug low pressure connection 1 8 2...

Page 35: ...il pressure connection Schraeder 1 4 6 mm 6 Plug low pressure connection 1 8 27 NPTF 13 Sensor connection OPS 7 Plug high pressure connection 1 8 27 NPTF SL Suction line sweat Ø 1 1 8 DL Discharge line sweat Ø 7 8 1 Base mountings Ø 12 mm 7 Plug high pressure connection 1 8 27 NPTF 3 Magnetic plug 3 8 18 NPTF 8 Plug oil charge 1 4 18 NPTF 4 Plug oil pressure control LP 1 4 18 NPTF 9 Pocket for hea...

Page 36: ... 27 NPTF 20 DTC valve plug connection 1 8 27 NPTF D4S D4SA 100 D4SF 100 D4SH 150 D4SJ 200 D4SL 150 D4ST 200 D4SA 200 D4SH 250 D4SJ 300 SL Suction line sweat D4SF 100 D4SL 150 D4SA 100 D4SA 200 D4SH 150 Ø 1 5 8 DL Discharge line sweat D4SF 100 D4SL 150 D4SA 100 D4SH 150 D4SA 200 D4SH 250 Ø 1 1 8 SL Suction line sweat D4ST 200 D4SJ 200 D4SH 250 D4SJ 300 Ø 2 1 8 DL Discharge line sweat D4ST 200 D4SJ ...

Page 37: ...nkcase heater 1 2 14 NPSL 7 Plug high pressure connection 1 8 27 NPTF 16 Plug high pressure connection 1 4 18 NPTF D6SJ D6SJ 300 D6SJ 400 SL Suction line sweat Ø 2 1 8 DL Discharge line sweat Ø 1 3 8 1 Base mountings Ø 18 mm 11 Oil screen built in 3 Magnetic plug 1 16 UN 12 Oil pressure connection Schraeder 1 4 6 mm 4 Plug oil pressure control LP 1 4 18 NPTF 13 Sensor connection OPS 5 Connection o...

Page 38: ...8SH 400 D8SH 500 D8SJ 450 D8SJ 500 D8SJ 600 D8SK 600 D8SK 700 SL Suction line sweat D8SH 370 D8SH 400 D8SH 500 Ø 2 5 8 DL Discharge line sweat D8SH 370 D8SH 400 D8SH 500 D8SJ 450 D8SJ 500 D8SJ 600 Ø 1 5 8 SL Suction line sweat D8SJ 450 D8SJ 500 D8SJ 600 D8SK 600 D8SK 700 Ø 3 1 8 DL Discharge line sweat D8SK 600 D8SK 700 Ø 2 1 8 1 Base mountings Ø 18 mm 8 Plug oil charge 1 4 18 NPTF 3 Magnetic plug...

Page 39: ...Plug high pressure connection 1 8 27 NPTF 23 Plug intermediate pressure connection 1 4 18 NPTF 8 Plug oil charge 1 4 18 NPTF D6TJ 6TJ D6TJ 250 6TJ 250 SL Suction line sweat Ø 1 5 8 DL Discharge line sweat Ø 1 3 8 EV De superheating expansion valve 11 Oil screen built in 1 Base mountings Ø 18 mm 12 Oil pressure connection Schraeder 1 4 6 mm 3 Magnetic plug 1 16 UN 13 Sensor connection OPS 4 Plug oi...

Page 40: ...ow pressure connection 1 2 14 NPTF 7 Plug high pressure connection 1 8 27 NPTF D3D 3D D3DA 50 3DA 50 D3DC 75 3DC 75 D3DS 100 3DS 100 D3DA 75 3DA 75 D3DC 100 3DC 100 D3DS 150 3DS 150 SL Suction line size sweat D3DA 50 D3DA 75 D3DC 75 D3DC 100 D3DS 100 Ø 1 3 8 DL Discharge line size sweat D3DA 50 Ø 7 8 SL Suction line size sweat D3DS 150 Ø 1 5 8 DL Discharge line size sweat D3DA 75 D3DC 75 D3DC 100 ...

Page 41: ...aeder 7 16 UNF 5 Connection oil pressure control HP 1 4 6 mm 13 Sensor connection OPS 6 Plug low pressure connection 1 8 27 NPTF 15 Sleeve crankcase heater 1 2 14 NPSL 7 Plug high pressure connection 1 8 27 NPTF 17 Plug low pressure connection 3 8 18 NPTF D6D D6DH 200 D6DL 270 D6DH 350 SL Suction line size sweat Ø 2 1 8 DL Discharge line size sweat Ø 1 3 8 1 Base mountings Ø 18 mm 8 Plug oil charg...

Page 42: ...ion 1 8 27 NPTF 19 Bore crankcase heater Ø 1 2 8 Plug oil charge 1 4 18 NPTF D8D 8D D8DL 370 8DL 370 D8DH 500 8DH 500 D8DT 450 8DT 450 D8DJ 600 8DJ 600 SL Suction line size sweat D8DL 370 D8DH 500 Ø 2 5 8 SL Suction line size sweat D8DT 450 D8DJ 600 Ø 3 1 8 DL Discharge line size sweat Ø 15 8 8 Plug oil charge 1 4 18 NPTF 1 Base mountings Ø 18 mm 11 Oil screen built in 3 Magnetic plug 1 16 UN 12 O...

Page 43: ...SW 12 7 Plug 4 8 16 1 4 18 NPTF 1 4 18 NPTF 1 4 18 NPTF 27 50 Nm SW 17 5 27 50 Nm 27 50 Nm SW 17 5 SW 17 5 Plug 17 1 2 14 NPTF 57 80 Nm SW 27 0 3 8 18 NPTF 33 66 Nm SW 27 0 Plug 18 crankcase heater 1 2 14 NPTF 45 57 Nm SW 17 5 Oil sight glass 1 1 8 12 UNF 1 1 8 12 UNF 1 4 20 UNC 4 5 6 Nm SW 11 4 5 6 Nm 4 5 6 Nm SW 11 Blind flange for oil screen 5 16 18 UNC 26 32 Nm SW 12 7 Blind flange for oil sig...

Page 44: ...W 9 10 32 UNF 3 4 4 Nm SW 9 Bolt for the connecting rod 3 1 4 28 UNF 1 4 28 UNF 15 18 Nm 15 18 Nm Torx screw Torx screw 2 On LH compressors 3 8 18 NPTF 22 25 Nm SW 12 7 3 In case of replacement of the piston con rod assemblies clean the Torx screws and apply Loctite 2701 The ranges of torque values given in this specification are assembly torque Torque after joint relaxation must be within 15 of t...

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