Emerson Copeland 4MSL-03, Application Manuallines

Page 1: ...Copeland Stream CO2 Semi Hermetic Compressors for Transcritical Subcritical Applications 4MTL 05_ to 4MTL 50_ Application Guidelines 4MSL 03_ to 4MSL 15_ ...

Page 2: ...mpressor construction 7 2 5 2 Compressor cooling 7 2 5 3 Lubrication 7 2 5 4 Oil level 8 3 Installation 11 3 1 Compressor handling 11 3 1 1 Delivery 11 3 1 2 Transport and storage 11 3 1 3 Positioning and securing 11 3 1 4 Installation location 12 3 1 5 Mounting parts 12 3 2 Pressure safety controls 13 3 2 1 Safety relief valves 13 3 2 2 Maximum allowable pressures PS 14 3 2 3 Maximum operating pr...

Page 3: ...stics until December 2019 included 28 4 8 Crankcase heater 29 5 Start up operation 31 5 1 Leak test 31 5 2 System evacuation 31 5 3 Preliminary checks Pre starting 31 5 4 Charging procedure 32 5 5 Initial start up 32 5 6 Minimum run time 32 5 7 Inverter operation 33 5 7 1 Maximum Operating Current Models 4MTL 35 to 4MTL 50 33 5 7 2 Recommendations for use with an inverter 33 6 Maintenance repair 3...

Page 4: ...efer to the Manufacturer s Declaration available at www climate emerson com en gb These instructions should be retained throughout the lifetime of the compressor You are strongly advised to follow these safety instructions 1 1 Icon explanation WARNING This icon indicates instructions to avoid personal injury and material damage CAUTION This icon indicates instructions to avoid property damage and ...

Page 5: ... and colourless so it cannot be perceived directly in case of emission 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 compressor without refrigerant charge or without it being connected...

Page 6: ..._ 9 5 16 302 3 80 170 4MSL 12_ 12 5 20 702 3 90 4MSL 15_ 17 9 31 502 3 90 1 Evaporating 10 C gas cooler outlet temp 35 C high pressure 90 bar superheat 10 K subcooling 0 K 2 Evaporating 35 C condensing 5 C superheat 10 K subcooling 0 K Table 1 Stream CO2 compressors range and performance at full load 100 Table 2 shows the key pressure values that are relevant to the use of Stream CO2 compressors C...

Page 7: ...hermetic compressors for CO2 transcritical and subcritical applications with standard equipment and accessories only 2 2 Nomenclature The model designation contains the following technical information about Stream CO2 compressors Figure 1 Nomenclature The oil type is indicated on the nameplate see Chapter 2 3 Nameplate information Several oils are qualified see Chapter 2 5 1 Qualified refrigerant ...

Page 8: ...t and oils factory oil charges To recharge When the compressor is completely empty of oil the amount of oil to be recharged is typically 0 12 litre less than the original oil charge oil will already be present in the system To top up During commissioning planned maintenance or servicing add oil so that the compressor oil level is between min and max of side sight glasses and full in the housing co...

Page 9: ...o secure maximum protection of the compressor In general higher superheat on the suction inlet of a compressor provides higher safety but the limits for the maximum allowable discharge temperature have to be considered as well superheat has a direct impact on the discharge temperature Particular attention should be paid to the following points Measuring the suction superheat becomes more critical ...

Page 10: ...s The cylinder heads and the discharge plenum are designed to minimize the heat transfer to suction side Each cylinder head has a plugged 1 8 27 NPTF tapped hole on the high pressure Figure 6 Compressor external view 2 5 2 Compressor cooling Compressor motor cooling must be ensured in all circumstances All Stream CO2 compressors are suction gas cooled With suction gas cooled compressors the motor ...

Page 11: ...essors are delivered with sufficient oil for normal operation see Table 3 The optimum oil level should be checked by operating the compressor until the system is stable and then comparing the sight glass reading with the corresponding diagram below The oil level should be min and max of the side sight glasses and full in the housing cover sight glass The housing cover sight glass serves only as a ...

Page 12: ...verts the magnetic field changes into an equivalent signal which is used by the internal integrated electronics to evaluate the oil level The OM5 TraxOil provides both an oil level monitoring function and an oil level balancing function for active oil level management systems especially in CO2 applications The OM5 TraxOil has been developed and specially optimized for CO2 systems where maximum wor...

Page 13: ... OW5 generates an alarm signal and the alarm contact SPDT changes into alarm state The alarm contact may be used to shut down the compressor The alarm will be reset when the oil level goes back to normal More information about this product can be found at www climate emerson com en gb ...

Page 14: ...d if needed take action to ensure the stability of the stacked loads Keep the packaging dry at all times Respect the maximum number of identical packages which may be stacked on one another where n is the limiting number Transport n 1 Storage n 1 Figure 13 Maximum stacking loads for transport and storage NOTE The compressor is pre charged with dry air to avoid any moisture contamination Compressor...

Page 15: ...ng parts In this case more shock and vibration loading will be transmitted to the frame Use only the compressor foot for fixation and avoid direct contact of other parts of the compressor housing with bordering components or base frame Unevenness in the mounting surface will have to be compensated by the rack and or the compressor bottom plate feet Excessive unevenness can result in too high mecha...

Page 16: ...de Typically the suction side of the system is anyhow protected by an additional pressure relief valve This system pressure relief valve is also acceptable for compressor protection The pressure relief valve does not replace pressure switches or additional safety valves in the system High pressure side HP 135 bar Usually after a blow off pressure relief valves are never perfectly tight It is there...

Page 17: ...m CO2 compressors For the low pressure cut out connection port 6 is recommended it is located on the right hand side of the compressor ie the side where the electrical box is installed above the oil level NOTE The compressor operating range may be restricted for various reasons Check the application range limitations in Copeland brand products Select software at www climate emerson com en gb 3 3 S...

Page 18: ...le in Appendix 2 Tightening torques in Nm The spindle is front seated close to piping system when the compressor is delivered 3 3 2 Explanation of supplier description W 13 5 ODS 3 8 Outer diameter tube for brazing Brazing Outer diameter tube for welding Welding 3 3 3 Additional information about shut off valves CAUTION High operating pressures Risk of leakage High operating pressures must be take...

Page 19: ... tightness of the compressor during transport For Stream CO2 compressors Emerson also offers variations for connection sizes see Tables 9 10 below for details Additionally a compression fitting can be used for the discharge part of the compressors Compressors can be ordered with variation discharge shut off valve with Hy Lok fitting at the discharge part The tube diameter for the discharge line mu...

Page 20: ...70 70 x 70 52 x 52 1 W35 ODS 1 7 8 W30 ODS 7 8 4MTL 40 26 80 4MTL 50 32 00 Table 10 Variations with smaller tube connections 3 4 Screens CAUTION Screen blocking Compressor breakdown Use screens with at least 0 6 mm openings The use of screens finer than 30 x 30 meshes 0 6 mm openings anywhere in the system should be avoided with these compressors Field experience has shown that finer mesh screens ...

Page 21: ...g ie the 1 3 winding on terminals 7 8 9 must be brought on line 4 2 2 Part winding motors YY Y Code F Part winding motors contain two separate windings Code F motors always split by 1 2 1 2 which are internally connected in star and operated in parallel The voltage cannot be modified by changing the electrical connections as the motor is only suitable for one voltage The first part winding ie the ...

Page 22: ...3 Recommended isolator packed in T Box Figure 22 Terminal box isolators jumpers position for part winding motors NOTE The isolators are not factory mounted they are packed and shipped loose in the terminal box NOTE Assembly instructions with an exploded view are provided in Appendix 3 4 2 4 2 Star Delta motors EW Star Delta motors can be connected Direct On Line or Star Delta start Star Delta moto...

Page 23: ...9Y in diagrams below must be considered The position of the terminals in large models 4MTL 35 to 4MTL 50 is inverted and corresponds to the black positions The factory delivery is correct DO NOT reverse the connections 4 3 1 1 Wiring diagram 1st part for part winding motors AW FW Figure 24 Wiring diagram Part winding motors AW FW 4 3 1 2 Wiring diagram 1st part for Star Delta motors EW Figure 25 W...

Page 24: ...rol oil heater F1 F2 F3 Compressor fuses PTC Motor thermal protection F4 F5 Fan fuses PM Phase monitoring F6 CoreSense and heater fuse PS Power supply F7 Control circuit fuse H1 Diagnosis LED K11 Time relay for part winding if used M2 Fan motor Q11 Compressor contactor Q15 Fan contactor Q12 Compressor contactor Y if Y Δ start Q13 Compressor contactor Δ if Y Δ start Q14 Compressor contactor 2nd par...

Page 25: ...nal box compressor K4 Contactor M1 for 2nd part winding F6 Fuse for control circuit M21 Fan motor condenser F7 Fuse for control circuit R2 Crankcase heater F8 Fuse for control circuit S1 Thermistor chain motor temperature F10 Thermal protection switch M21 S2 Thermistor chain motor temperature Y3 Solenoid valve unloaded start Figure 27 Wiring diagram Part winding motors AW FW with CoreSense Protect...

Page 26: ...tactor M1 Δ connection F6 Fuse for control circuit M21 Fan motor condenser F7 Fuse for control circuit R2 Crankcase heater F8 Fuse for control circuit S1 Thermistor chain motor temperature F10 Thermal protection switch M21 S2 Thermistor chain motor temperature K1 Contactor M1 Y3 Solenoid valve unloaded start Figure 28 Wiring diagram Direct On Line EW motors with CoreSense Protection ...

Page 27: ...H Crankcase heater L1 Current transducer CoreSense F6 Fuse for control circuit M21 Fan motor condenser F7 Fuse for control circuit R2 Crankcase heater F8 Fuse for control circuit S1 Thermistor chain motor temperature F10 Thermal protection switch M21 S2 Thermistor chain motor temperature Figure 29 Wiring diagram Part winding motors AW FW with CoreSense Diagnostics NOTE The sensor module inside the...

Page 28: ...ntrol circuit Y7 Solenoid valve pumpdown F8 Fuse for control circuit Y21 Solenoid valve F10 Thermal protection switch M21 Y22 Solenoid valve K1 Contactor M1 S1 Thermistor chain motor temperature K2 Contactor M1 Y connection S2 Thermistor chain motor temperature K3 Contactor M1 Δ connection Figure 30 Wiring diagram Direct On Line EW motors with CoreSense Diagnostics NOTE The sensor module inside th...

Page 29: ...cked rotor single missing phase voltage imbalance low voltage etc An external overload protection is not necessary The module is capable of communication via Modbus and Bluetooth optional protocol Figure 31 Next Gen CoreSense module Figure 32 Next Gen CoreSense inside the terminal box 4 5 1 Next Gen CoreSense specifications The Next Gen CoreSense module is located and prewired in the terminal box ...

Page 30: ... Guide TI_Stream_NGCS_05 Next Generation CoreSense for Copeland Stream Compressors Guide for the Replacement of CoreSense Diagnostics 4 6 CoreSense Protection 4 6 1 Motor protection IMPORTANT Different sources for power supply and contact 11 14 Module malfunction Use the same potential for the power supply L and the switch contact of the control loop 11 14 Stream compressors with P at the end of t...

Page 31: ...l pressure protection only for 4MTL 35 to 4MTL 50 locked rotor single missing phase voltage imbalance and low voltage The module is capable of communication via Modbus protocol An external overload protection is not necessary Figure 35 Compressor internal view with sensors and CoreSense Diagnostics module For the electrical connection of the CoreSense Diagnostics module refer to the wiring diagram...

Page 32: ...er available in 115 V or 230 V The crankcase heater is delivered as a kit together with the compressor This easy to install kit consists of 3 parts 1 crankcase heater 1 heat conductive paste tube 1 mounting ring The operation of 115 V and 230 V crankcase heaters can be controlled by the Next Generation CoreSense module Figure 37 100 Watt crankcase heater element Figure 38 Crankcase heater kit The ...

Page 33: ...in the hole The mounting ring preassembled on the heater before insertion has to be pressed into the hole The crankcase heater is secured into position It is also possible to secure the heater more firmly by using a rubber hammer on the flat surface Table 13 Crankcase heater installation procedure ...

Page 34: ...em separately 5 2 System evacuation Before commissioning 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 evacuate...

Page 35: ...ge should be placed in the high side of the system to prevent bearing washout during first time start 5 5 Initial start up CAUTION Oil dilution Bearing malfunction 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 CAUTION High discharge pressure operation Compressor damage Do not use compressor to t...

Page 36: ... frequency drives Table 15 below shows the values for both types of operation Compressor MOC A MOCVS A 4MTL 35 59 6 67 1 4MTL 40 67 4 75 8 4MTL 50 82 7 90 6 Table 15 Maximum operating current for large Stream CO2 compressor 5 7 2 Recommendations for use with an inverter Running the Stream CO2 compressor with an inverter is a reliable application Nevertheless resonances might occur in the lower fre...

Page 37: ...34 AGL_Stream_ST_4MTL_4MSL_E_Rev01 NOTE Performance data and envelopes are published in Copeland brand products Select software at www climate emerson com en gb ...

Page 38: ...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 6 3 Lubrication and oil removal CAUTION Chemical reaction Compressor destruction Do not mix up ester oils with...

Page 39: ...ation systems is complex and difficult to evaluate without rigorously controlled chemical laboratory testing The use of additives without adequate testing may result in malfunction or premature failure of components in the system and in specific cases in voiding the warranty on the components 6 5 Unbrazing system components WARNING Explosive flame Fire hazard Oil refrigerant mixtures are highly fl...

Page 40: ...TL 09 ID 1 2 Tube OD 12 85 mm SL Suction line size sweat 4MSL 08 4MSL 12 4MSL 15 4MTL 12 4MTL 15 4MTL 30 ID 7 8 Tube OD 22 40 mm DL Discharge line size sweat 4MSL 08 4MSL 12 4MSL 15 4MTL 12 4MTL 15 4MTL 30 ID 5 8 Tube OD 16 15 mm SL Suction line size sweat 4MTL 35 4MTL 40 4MTL 50 ID 1 3 8 Tube OD 35 25 mm DL Discharge line size sweat 4MTL 35 4MTL 40 4MTL 50 ID 1 1 8 Tube OD 28 75 mm 1 Base mountin...

Page 41: ...m Discharge temperature sensor 1 8 27 NPTF 30 35 Nm Terminal studs M5 8 5 9 6 Nm SW 8 Mounting plate for terminals 3 8 16 UNC 36 44 Nm SA 3 16 Mounting plate for terminals 3 8 16 UNC 70 75 Nm Stator cover 1 2 13 UNC 119 159 Nm SW 19 mm Housing cover 1 2 13 UNC 119 159 Nm SW 19 mm Screws for oil pump cover 3 8 16 UNC 2A 52 64 Nm SW 9 16 Schraeder valve in oil pump cover 1 8 27 NPTF 11 13 5 Nm SW 11...

Page 42: ...en Inbus hexagon heads Wrench The ranges of torque values given in this specification are assembly torques Torque after joint relaxation must be within 15 of the minimum assembly torque unless re torque is called for and must not be above 10 of the maximum assembly torque ...

Page 43: ...40 AGL_Stream_ST_4MTL_4MSL_E_Rev01 Appendix 3 Correct T plate isolators depending on motor version power supply ...

Page 44: ...e Technologies GmbH and or its affiliates collectively Emerson as applicable reserve the right to modify the design or specifications of such products at any time without notice 3 Emerson does not assume responsibility for the selection use or maintenance of any product Responsibility for proper selection use and maintenance of any Emerson product remains solely with the purchaser or end user 4 Em...

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