Emerson Copeland Stream Digital 4MAD-22X, Application Manuallines

Page 1: ...Application Guidelines Copeland Stream Digital Semi Hermetic Compressors 4MFD 13X to 4MKD 35X 6MMD 30X to 6MKD 50X ...

Page 2: ...al control 7 2 6 4 Recommended application settings for modulation on Stream Digital compressors 7 2 6 5 Digital solenoid valve Gaskets 7 2 6 6 Compressor cooling 7 2 6 7 Unloaded start 7 2 6 8 Oil pumps 8 2 6 9 Oil pressure 8 2 6 10 Oil circulation 8 2 6 11 Oil level 8 2 6 12 Multiple compressor application 9 3 Installation 10 3 1 Compressor handling 10 3 1 1 Delivery 10 3 1 2 Transport and stora...

Page 3: ...r protection 19 4 6 2 Oil pressure control 19 4 7 Crankcase heater 21 5 Starting up operation 22 5 1 Leak test 22 5 2 System evacuation 22 5 3 Preliminary checks Pre starting 22 5 4 Charging procedure 22 5 5 Initial start up 23 5 6 Minimum run time 23 5 7 Pump down 23 6 Maintenance repair 24 6 1 Exchanging the refrigerant 24 6 2 Replacing a compressor 24 6 3 Lubrication and oil removal 24 6 4 Oil ...

Page 4: ...on indicates operations with a danger of explosion 1 2 Safety statements Refrigerant compressors must be employed only for their intended use Only qualified and authorized HVAC or refrigeration personnel are permitted to install commission and maintain this equipment Electrical connections must be made by qualified electrical personnel All valid standards for connecting electrical and refrigeratio...

Page 5: ...ctive equipment gloves eye protection etc must be used at all times POE must not come into contact with any surface or material that it might damage including without limitation certain polymers eg PVC CPVC and polycarbonate IMPORTANT Transit damage Compressor malfunction Use original packaging Avoid collisions and tilting ...

Page 6: ...0 381 x 305 Cooling capacity kW COP Medium temperature 1 Low temperature 2 Model Nominal horsepower hp Displacement m3 h Net weight kg Footprint mm 1 R404A evaporating 10 C condensing 45 C suction gas temperature 20 C subcooling 0K R134a evaporating 10 C condensing 45 C superheat 20K subcooling 0K 2 R404A evaporating 35 C condensing 40 C suction gas temperature 0 C subcooling 0K Table 1 Stream Dig...

Page 7: ...at pumps pumpdown is recommended the use of a crankcase heater is mandatory retrofit to R450A and R513A is only allowed for compressors which are approved for these refrigerants Contact Application Engineering for any further information IMPORTANT It is essential that the glide of refrigerant blends primarily R407C is carefully considered when adjusting pressure and superheat controls Oil recharge...

Page 8: ...gure 2 Exploded view of the Digital mechanism Factory delivered 4M D and 6M D compressors include as standard configuration one standard bank one Digital modulated bank one capacity controlled bank blocked suction std only for 6M D NOTE To upgrade 6M compressors to 6M D Emerson Climate Technologies recommends to use the central cylinder bank 2 6 2 Digital theory of operation Digital technology is ...

Page 9: ...low Loaded Valve de energized 100 capacity Unloaded Valve energized 0 capacity 1 Solenoid valve 2 Cylinder head 3 Valve plate 4 5 Unloading piston Figure 5 Cutaway view of the Digital cylinder head loaded and unloaded 1 Gas enters the compressor 2 passes through the body 3 into the valve plate 4 Compressed gas 5 exits the compressor Bolts studs Solenoid valve Solenoid valve gasket Cylinder head 1 ...

Page 10: ...ssor configuration The compressor can also operate at a 100 load for the full modulation sequence 2 6 5 Digital solenoid valve Gaskets Due to the high life cycle requirements in a hot gas environment a special valve has been developed Due to reliability requirements only Emerson solenoid valves may be used All compressor warranties are null and void if the Emerson valve is not used Solenoid coils ...

Page 11: ...irculation Oil returns with the suction gases through a suction strainer and separates in the motor chamber reaching the crankcase by way of oil return relief valve in the partition between motor housing and crankcase This relief valve closes on compressor start up due to the pressure difference arising between motor side and crankcase thus slowing down pressure decrease in the crankcase over a ce...

Page 12: ... the smallest capacity to cover all the gaps between steps to ensure the most efficient system control For example a 4M D has a continuous capacity from 50 to 100 Therefore when a 4M D Stream Digital compressor is selected the associated fixed capacity compressor should have 50 to 100 of the full load of the Stream Digital compressor NOTE For best results the Stream Digital compressor must be the l...

Page 13: ... equipment according to weight Keep in the upright position Do not stack pallets on top of each other Keep the packaging dry at all times Figure 8 Compressors are delivered on pallets Cooling fans are delivered in separate boxes Accessories may be mounted or delivered loose Solenoid valves are never mounted except the Digital head solenoid valve 3 1 3 Positioning and securing IMPORTANT Handling da...

Page 14: ...k and or the compressor bottom plate feet Excessive unevenness can result in too high mechanical stress to the system and could damage the compressor or rack Therefore the flatness of the mounting location is essential In addition both vibration shock and mechanical stress to compressor can be avoided by using rubber mounting parts If the installation requires a very high level of vibration absorp...

Page 15: ... and tube outer diameter are 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 b...

Page 16: ...re internally connected in star and operated in parallel You cannot change the voltage by changing the electrical connections as these motors are only suitable for one voltage The first part winding ie the 2 3 winding on terminals 1 2 3 can be used for part winding start remove the bridges After a time delay of 1 0 1 seconds the second part winding ie the 1 3 winding on terminals 7 8 9 must be bro...

Page 17: ...rt Y Y Part winding start First start step 1 2 3 Y Y 4 3 1 1 Compressors with CoreSense Diagnostics module Legend A4 Sensor module K1 Contactor M1 A5 Compressor terminal box K4 Contactor M1 for second part winding CCH Crankcase heater M21 Fan motor condenser F6 Fuse for control circuit R2 Crankcase heater F7 Fuse for control circuit Y21 Solenoid valve capacity control 1 F8 Fuse for control circuit...

Page 18: ...2 Crankcase heater F6 Fuse for control circuit Y7 Solenoid valve Digital F7 Fuse for control circuit Y21 Solenoid valve capacity control 1 F8 Fuse for control circuit Y22 Solenoid valve capacity control 2 F10 Thermal protection switch M21 Y3 Solenoid valve unloaded start K1 Contactor M1 Figure 14 Safety instructions Product description Installation Electrical connection Starting up operation Maint...

Page 19: ...on line start Y Star Delta start Y 4 3 2 1 Compressors with CoreSense Diagnostics module Legend A4 Sensor module K1 Contactor M1 A5 Compressor terminal box K2 Contactor M1 Y connection CCH Crankcase heater K3 Contactor 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 Y21 Solenoid valve capacity control 1...

Page 20: ...4 4 Protection devices Independently from the internal motor protection fuses must be installed before compressor start up The selection of fuses has to be carried out according to VDE 0635 DIN 57635 IEC 269 1 or EN 60 269 1 4 5 CoreSense Diagnostics CoreSense Diagnostics can be used for all 4M D and 6M D Stream Digital compressors It combines oil and motor protection into one module replacing OPS...

Page 21: ...gure 17 CoreSense Diagnostics module For the electrical connection of the CoreSense Diagnostics module please refer to the wiring diagram below Figure 18 CoreSense Diagnostics module wiring diagram Discharge temperature Sensor Oil Pressure Sensor Motor Temperature Sensor PTC CoreSense Control Module Current Sensor Sensor Module ...

Page 22: ... 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 Control circuit wiring Figure 19 Control circuit wiring diagram 4 6 2 Oil pressure control The oil pressure switch breaks the control circuit when the pressure difference between the oil pump outlet and the crankcase is too low The switch must be pro...

Page 23: ...Orange OG Output changeover contact linked to compressor contactor Pink PK Output changeover contact linked to alarm Blue BU Power supply output Figure 20 NOTE Where a 5 or 7 wire cable is stated a 4 or 6 wire cable is required In some countries only a 5 or 7 wire cable is available See more information about OPS2 in Technical Information D7 8 3 DWM Copeland Semi hermetic Compressor Oil Pressure D...

Page 24: ...ds Heaters for 4M D and 6M D compressors are screwed into a sleeve see Figure 22 The crankcase heater is available in 120V 230V and 480V The operation of 120V and 230V crankcase heaters is controlled by the CoreSense Diagnostics module this is not possible with 480V heaters Figure 22 100 Watt crankcase heater element Safety instructions Product description Installation Electrical connection Starti...

Page 25: ... Due to the factory holding charge of dry air the compressor is under pressure about 1 to 2 5 bar this is to indicate the compressor does not leak When removing plugs from the compressor in order to connect a pressure gauge or to fill in oil the plugs 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 possi...

Page 26: ...lication range For application envelopes please refer to Copeland brand products Select software available at www emersonclimate eu NOTE To avoid motor damage the compressor MUST NOT be started nor may high potential testing be carried out under vacuum 5 6 Minimum run time Emerson Climate Technologies recommends a maximum of 10 starts per hour The most critical consideration is the minimum run tim...

Page 27: ...t be removed after 72 hours It is highly recommended that the suction accumulator be replaced if the system contains one This is because the accumulator oil return orifice or screen may be plugged with debris or may become plugged shortly after a compressor failure This will result in starvation of power usage When a compressor is exchanged in the field a major portion of the oil may remain in the...

Page 28: ...ant low and high temperatures and materials commonly found in refrigeration systems is complex and difficult to evaluate without rigorously controlled chemical laboratory testing The use of additives without adequate testing may result in malfunction or premature failure of components in the system and in specific cases in voiding the warranty on the components 6 5 Unbrazing system components WARN...

Page 29: ...e mountings Ø 25 5 mm 5 Crankcase heater 2 Magnetic plug 1 16 UN 6 Plug oil charge 1 4 3 Oil sight glass 1 4 20 UNC 7 Plug high pressure connection 1 8 4 Plug low pressure connection 1 8 6M D 6MMD 30X 6MTD 35X 6MUD 40X 6MID 40X 6MJD 45X 6MKD 50X SL Suction line size sweat 6MMD 30X 6MTD 35X 6MID 40X 6MJD 45X Ø 2 1 8 DL Discharge line size sweat 6MTD 35X 6MUD 40X 6MJD 45X 6MKD 50X Ø 1 5 8 SL Suction...

Page 30: ...e piston con rod assemblies clean the Torx screws and apply Loctite 2701 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 Disclaimer 1 The contents of this publication are presented for informational purpos...

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