Safety instructions Copeland™ semi-hermetic compressors are manufactured according to the latest European safety standards. Particular emphasis has been placed on the user’s safety. These compressors are intended for installation in systems according to the Machinery Directive MD 2006/42/EC. They may be put to service only if they have been installed in these systems according to instructions and conform to the corresponding provisions of legislation.
General instructions WARNING System breakdown! Personal injuries! 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 electrically locking out the system. System breakdown! Personal injuries! Only approved refrigerants and refrigeration oils must be used.
Product description Common information about Copeland™ semi-hermetic compressors This manual covers all Copeland semi-hermetic compressors. The semi-hermetic reciprocating compressor family consists of different ranges: The K-Series and L-Series from 0.5 hp to 4 hp are available as air-cooled or water-cooled versions and use reed valve technology.
DWM Copeland designation (old models) NOTE: For more information, please refer to Technical Information D7.4.3 “Copeland™ semi-hermetic compressor model designation”. Nameplate information All important information for identification of the compressor is printed on the nameplate. The type of refrigerant used should be stamped on the nameplate by the installer. The date of production consists of the year and week of production.
2.4.2 Copeland brand designation (present models) K, L 6T, 8D 2D, 3D Application range 2.5.1 Qualified refrigerants and oils IMPORTANT It is essential that the glide of refrigerant blends (primarily R407C) is carefully considered when adjusting pressure and superheat controls. Oil recharge values can be taken from Copeland™...
Design features 2.6.1 Construction Standard Figure 1 All K-, L- and S-Series compressors are fitted with “Reed” valve plates. Depending on the number of cylinders, the motor cooling and the kind of application, there are three different compressor families: Air- or water-cooled single-stage compressors, models K, L with 2 cylinders and a displacement between 3.97 m³/hr and 22.5 m³/hr;...
Discus Figure 2 This family consists of refrigerant-cooled single-stage compressors, models 2D, 3D, D4D, D6D and 8D with 2, 3, 4, 6 and 8 cylinders and a displacement between 22.4 m³/hr and 181 m³/hr. All compressors are fitted with Discus valve plates which cannot be dismantled. To maintain the high capacity of these compressors the correct valve-plate-to-body gasket must always be selected in case of exchange.
perfect starting even when the voltages amount to less than approximately 85% of the voltage on the nameplate. Unloaded start is not available for Copeland brand 2-stage compressors and K/L. NOTE: For more information please refer to Technical Information D7.10.2 “Starting methods and unloaded start for semi-hermetic compressors”.
K & L compressor oil circulation The oil returning from the evaporator reaches the crankcase via an oil separator chamber behind the suction shut-off valve through a small connecting bore. Due to this connecting bore the crankcase pressure will be decreased slowly when the compressor starts. Thus the foaming of the oil and refrigerant mixture will be reduced.
To ensure each compressor has the correct amount of oil returned, Emerson Climate Technologies recommends the use of a highly efficient cyclone or coalescent type oil separator with an oil management system.
Installation WARNING High pressure! Injury to skin and eyes possible! Be careful when opening connections on a pressurized item. Compressor handling 3.1.1 Delivery Please check whether the delivery is correct and complete. Deficiencies should be reported immediately in writing. Standard delivery: ...
Pressure safety controls 3.2.1 High-pressure control A high-pressure control with a maximum cut-out setting of 28.8 bar(g) is required. The high-pressure cut-out should have a manual reset feature for the highest level of system protection. 3.2.2 Low-pressure control The normal minimum is 0.1 bar(g) for R404A. The low-pressure cut-out should have a manual reset feature for the highest level of system protection.
3.2.5 Maximum allowable pressures The maximum allowable pressures (according to EN 12693) shown on the compressor nameplate are obligatory and must not be exceeded. High pressure side (HP): 28.0 bar(g) (up to S/N 14K46143M & 14K031872M) 32.5 bar(g) (from S/N 14K46144M & 14K031873M onwards) ...
Electrical connection General recommendations The compressor terminal box has a wiring diagram on the inside of its cover. Before connecting the compressor, ensure the supply voltage, the phases and the frequency match the nameplate data. When the compressor is shipped the motor protector is mounted in the terminal box. The thermistors are factory connected.
and a potential relay, is needed for proper operation. Assembly must be in accordance with the position of the relay shown on the wiring diagram. 4.2.2 Three-phase motors All compressors can be started direct-on-line. The necessary position of bridges for direct-on-line start (depending on type of motor and/or mains voltage) is shown on the principle wiring in section 4.3.1.
Motor protection Each compressor has a motor protector. An external overload protection is not necessary. 4.5.1 Over-current thermal protection switch for single-phase motors – System A WARNING Compressor under voltage! Electrical shock! When the motor stops due to the over-current thermal protection switch, the compressor is still under voltage! This bimetal switch is installed in the terminal box.
Control circuit wiring: IMPORTANT Different sources for power supply and contact 11-14! Module malfunction! Use the same potential for the power supply and the switch contact of the control loop (11-14). Figure 16 Discharge temperature protection Legend H1 ..Signal lamp “fault” L ..
Demand Cooling Legend θ1 ..Temperature control device for A ..Alarm connection L ..Control voltage connection energising the injection valve θ2 ..Temperature control device for M ..Control circuit S ..Injection valve connection switching off the compressor L1 ..
4.8.4 Crankcase heaters IMPORTANT Oil dilution! Bearing malfunction! Turn the crankcase heater on 12 hours before starting the compressor. A crankcase heater is used to prevent refrigerant from migrating into the shell during standstill periods. 27-Watt heater element for K compressors ...
Starting up & operation WARNING Diesel effect! Compressor destruction! The mixture of air and oil at high temperature can lead to an explosion. Avoid operating with air. IMPORTANT Oil dilution! Bearing malfunction! Turn the crankcase heater on 12 hours before starting the compressor. Leak test The suction shut-off valve and discharge shut-off valve on the compressor must remain closed during pressure testing to prevent air and moisture from entering the compressor.
Minimum run time Emerson Climate Technologies recommends a maximum of 10 starts per hour. The most critical consideration is the minimum run time required to return oil to the compressor after start-up.
Maintenance & repair Exchanging the refrigerant Qualified refrigerants and oils are given in section 2.5.1. It is not necessary to replace the refrigerant with new 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.
Compressors supplied by Emerson Climate Technologies contain oil with low moisture content, and it may rise during the system assembling process. Therefore it is recommended that a properly sized filter-drier is installed in all POE systems.
Troubleshooting The prevention of failures is one of the primary responsibilities of the installer. Otherwise the user will not get the benefit of factory guaranteed quality. Lubrication problems Compressors are delivered with an initial oil charge. The correct oil level is shown in section 2.6.11.
Acid formation Acid forms in the presence of moisture, oxygen, metal salts and metal oxides, and/or high discharge temperatures. The chemical reactions are accelerated at higher temperatures. Oil and acid react with each other. Acid formation leads to damage of the moving parts and in extreme cases to motor burn-out.
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.
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