Emerson Copeland Discus Series Application Manuallines

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Table of Contents
Application Guidelines
Semi-Hermetic Compressors
Discus, K, L & S-Series

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  Summary of Contents for Emerson Copeland Discus Series

  • Page 1 Application Guidelines Semi-Hermetic Compressors Discus, K, L & S-Series...
  • Page 2: Table Of Contents

    Safety instructions .................... 1 1.1 Icon explanation ......................... 1 1.2 Safety statements ......................1 1.3 General instructions ......................2 Product description ..................3 2.1 Common information about Copeland™ semi-hermetic compressors ......3 2.2 About these guidelines ....................... 3 2.3 Nomenclature ........................3 2.3.1 Air- or water-cooled compressors ................
  • Page 3 3.2.2 Low-pressure control .................... 14 3.2.3 Internal pressure relief valve ................14 3.2.4 Oil pressure switch ....................14 3.2.5 Maximum allowable pressures ................15 3.3 Brazing procedure ......................15 3.4 Screens ..........................15 Electrical connection ..................16 4.1 General recommendations....................16 4.2 Electrical installation ......................
  • Page 4 6.6 Oil additives ........................26 6.7 Unbrazing system components ..................26 Troubleshooting ....................27 7.1 Lubrication problems ......................27 7.2 Oil dilution ........................27 7.3 Refrigerant migration ....................... 27 7.4 Inadequate suction superheat ..................27 7.5 Acid formation ........................28 7.6 Inadequate compressor cooling ..................
  • Page 6: Safety Instructions

    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.
  • Page 7: General Instructions

    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.
  • Page 8: Product Description

    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.
  • Page 9: Suction Gas-Cooled Compressors

    DWM Copeland designation (old models) 2.3.2 Suction gas-cooled compressors Copeland brand designation (present models) D6.3.4/0715-0716/E...
  • Page 10: Nameplate Information

    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.
  • Page 11: Copeland Brand Designation (Present Models)

    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™...
  • Page 12: Design Features

    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;...
  • Page 13: Compressor Cooling

    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.
  • Page 14: Capacity Control

    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”.
  • Page 15: Oil Pumps - Suction Gas-Cooled 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.
  • Page 16: Oil Level

    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.
  • Page 17: Installation

    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: ...
  • Page 18: Installation Location

    DK, K DL, L D2D, D2S, 2D D3D, D3S, 3D max. 45kg max. 90kg max. 140 kg max. 175 kg D4D, D4S D6D, D6S, D6T, 6T D8D, D8S, 8D Lifting eye ½” – 13 UNC max. 220kg max. 260kg max. 350 kg Figure 7 3.1.4 Installation location Ensure the compressors are installed on a solid level base.
  • Page 19: Pressure Safety Controls

    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.
  • Page 20: Maximum Allowable Pressures

    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) ...
  • Page 21: Electrical Connection

    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.
  • Page 22: Three-Phase Motors

    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.
  • Page 23: Motor Protection

    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.
  • Page 24: Discharge Temperature Protection

    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 ..
  • Page 25: Demand Cooling

    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 ..
  • Page 26: Sentronic Oil Pressure Control

    4.8.2 SENTRONIC Oil pressure control 2 & 3 cylinder models 4, 6 & 8 cylinder models Legend 2 ..Neutral connection L ..Control voltage connection A ..Alarm connection L1 ..Voltage connection A5 ..Compressor terminal box M ..Control circuit A2 ..
  • Page 27: Crankcase Heaters

    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 ...
  • Page 28: Starting Up & Operation

    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.
  • Page 29: Initial Start-Up

    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.
  • Page 30: Maintenance & Repair

    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.
  • Page 31: Oil Additives

    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.
  • Page 32: Troubleshooting

    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.
  • Page 33: Acid Formation

    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.
  • Page 34: Appendix 1 - Compressor Connections

    Appendix 1 – Compressor connections Standard compressor connections DK / K DKM-5* KM-5* DKJ-7* KJ-7* DKSJ-10* KSJ-10* DKSL-15* KSL-15* DKM-7* KM-7* DKJ-10* KJ-10* DKSJ-15* KSJ-15* DKSL-20* KSL-20* DKM-10* KM-10* DKJ-15* KJ-15* DKL-15* KL-15* DKL-20* KL-20* Suction line (sweat) Ø 1/2" Discharge line (sweat) Ø...
  • Page 35 DLH / LH DLHA-50* LHA-50* SL Suction line (sweat) Ø 1 1/8" Discharge line (sweat) Ø 7/8" Base mountings Ø 12 mm Plug high pressure connection 1/8" - 27 NPTF Magnetic plug 3/8" - 18 NPTF Plug oil charge 1/4" - 18 NPTF Plug oil pressure control LP 1/4"...
  • Page 36 D3SA-75* D3SC-75* D3SS-100* D3SC-100* D3SS-150* Suction line (sweat) Suction line (sweat) D3SA-75*, D3SC-75* Ø 1 3/8" Ø 1 5/8" D3SS-150* D3SC-100*, D3SS-100* Discharge line (sweat) Ø 1 1/8" Plug high pressure connection 1/2" - 14 NPTF Base mountings Ø 18 mm Plug oil charge 1/4"...
  • Page 37 D6SA-300* D6SF-200* D6SH-200* D6SL-250* D6ST-320* D6SH-350* SL Suction line (sweat) Ø 2 1/8" Discharge line (sweat) Ø 1 3/8" Base mountings Ø 18 mm Plug oil charge 1/4" - 18 NPTF Magnetic plug 1" - 16 UN Oil screen built-in Plug oil pressure control LP 1/4"...
  • Page 38 D6SK D6SK-400* D6SU-400* D6SK-500* Suction line (sweat) Ø 2 1/8" DL Discharge line (sweat) Ø 1 3/8" Base mountings Ø 18 mm Plug oil charge 1/4" - 18 NPTF Magnetic plug 1" - 16 UN Oil screen built-in Plug oil pressure control LP 1/4"...
  • Page 39 D6T / 6T D6TA-150* 6TA-150* D6TH-200* 6TH-200* 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 Base mountings Ø 18 mm 12 Oil pressure connection, Schraeder 1/4" - 6 mm Magnetic plug 1"...
  • Page 40: Discus Compressor Connections

    Discus compressor connections D2D / 2D D2DC-50* 2DC-50* D2DD-50* 2DD-50* D2DL-40* 2DL-40* D2DB-50* 2DB-50* D2DL75* 2DL75* D2DB-75* 2DB-75* Discharge line size (sweat) Discharge line size (sweat) D2DC-50*, D2DD-50*, Ø 7/8" Ø 1 1/2" D2DL-75*, D2DB-75* D2DL-40*, D2DB-50* SL Suction line size (sweat) Ø...
  • Page 41 D4DA-100* D4DF-100* D4DH-150* D4DJ-200* D4DL-150* D4DT-220* D4DA-200* D4DH-250* D4DJ-300* Suction line size (sweat) Discharge line size (sweat) D4DA-100*, D4DF-100*, D4DH-150*, Ø 1 5/8" D4DA-100*, D4DF-100*, D4DH-150*, Ø 1 1/8" D4DL-150*, D4DA-200* D4DL-150*, D4DA-200*, D4DH-250* Suction line size (sweat) Discharge line size (sweat) D4DH-250*, D4DJ-200*, Ø...
  • Page 42 D6DJ-300* D6DT-300* D6DJ-400* SL Suction line size (sweat) Ø 2 1/8" DL Discharge line size (sweat) Ø 1 3/8" Base mountings Ø 18 mm 11 Oil screen built-in Magnetic plug 1" - 16 UN 12 Oil pressure connection, Schraeder 7/16" - UNF Plug oil pressure control LP 1/4"...
  • Page 43: Appendix 2 - Tightening Torques (Nm)

    Appendix 2 - Tightening torques (Nm) DL, DLH D3S, D3D D4S, D6S, D6D D8S, D8D D8SK L, LH D6T, 6T 1/2"-13 UNC 53 - 84 Nm Suction 5/16"-18 UNC 1/2"-13 UNC 1/2"-13 UNC SW 19 5/8"-11 UNC 104 - 164 Nm shut-off valve 30 - 37 Nm 46 - 56 Nm...
  • Page 44: Disclaimer

    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.
  • Page 45 Tel. +49 (0) 2408 929 0 - Fax: +49 (0) 2408 929 570 - Internet: www.emersonclimate.eu The Emerson Climate Technologies logo is a trademark and service mark of Emerson Electric Co. Emerson Climate Technologies Inc. is a subsidiary of Emerson Electric Co.

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