Emerson Copeland 4MF-13X Application Manuallines
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Emerson Copeland 4MF-13X Application Manuallines

Stream semi-hermetic compressors
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Application Guidelines
Copeland
Stream
™
Semi-Hermetic Compressors
4MF-13X to 6MK-50X

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Summary of Contents for Emerson Copeland 4MF-13X

  • Page 1 Application Guidelines Copeland Stream ™ Semi-Hermetic Compressors 4MF-13X to 6MK-50X...

  • Page 2: Table Of Contents

    About these guidelines ....................1 Safety instructions ................... 1 1.1 Icon explanation ....................... 1 1.2 Safety statements ......................2 1.3 General instructions ......................2 Product description ..................3 2.1 Compressor range ......................3 2.2 Nomenclature ........................3 2.3 Nameplate information ..................... 4 2.4 Application range ......................
  • Page 3 3.5 Insulation material ......................15 Electrical connection ..................16 4.1 General recommendations..................... 16 4.2 Electrical installation ...................... 16 Part-winding motors (YY/Y) – Code A ..............17 4.2.1 Star / Delta motors (Y/∆) – Code E ..............17 4.2.2 4.2.3 Terminal box isolators and jumpers position ............17 4.3 Terminal box ........................

  • Page 4: About These Guidelines

    NOTE: Only dedicated compressors are allowed to be used with flammable refrigerants. Emerson marks all compressors that are qualified for flammable refrigerants with a sticker indicating the usage of such refrigerants. Systems using flammable refrigerants must be executed correctly while observing safety rules, as specified in corresponding safety standards such as, but not limited to EN 378.

  • Page 5: Safety Statements

    Safety statements ▪ Refrigerant compressors must be employed only for their intended use. The system has to be labelled according to the applicable standards and legislation. ▪ Only qualified and authorized RACHP (refrigeration, air conditioning and heat pump) personnel are permitted to install, commission and maintain this equipment. ▪...

  • Page 6: Product Description

    Product description Compressor range These application guidelines cover Copeland Stream semi-hermetic compressors. The semi- hermetic reciprocating compressor family consists of different ranges. The Stream series of 4M* and 6M* models ranges from 62 to 153 m³/h displacement. Cooling capacity (kW) Nominal Displa- Foot-...

  • Page 7: Nameplate Information

    Suniso 3 GS Servicing oils RL32 3MAF Mobil EAL Arctic 22 CC Fuchs Reniso KM 32 Capella WF 32 Table 2: Qualified refrigerants and oils for recharging and topping up recharge values taken from Copeland Select software available www.climate.emerson.com/en-gb. AGL_Stream_ST_A2L_A1_4M_6M_EN_Rev00...

  • Page 8: Application Limits

    Design features 2.5.1 Compressor construction All compressors are fitted with Stream valve plates. This is a unique Emerson valve plate design which is comparable to Discus™ valve plates. To maintain the high capacity of these compressors in case of exchange, make sure to always select the correct valve-plate-to-body gasket.

  • Page 9: Liquid Injection / Demand Cooling

    6MM-30X 6MT-35X 6MU-40X NOTE: For corresponding application envelopes, please see Select software available at www.climate.emerson.com/en-gb. 2.5.4 Unloaded start WARNING Ignition source in a potentially flammable atmosphere! Fire hazard! The solenoid valve of the unloaded start is not an ignition source during normal operation in an A2L-refrigerant system but could become one if not installed properly.

  • Page 10: Capacity Control

    Assembly Installation of the modified cylinder head and valve plate for unloaded start is only possible on certain positions on the compressor. Therefore all 4M* and 6M* compressor models have fixed cylinder head positions for unloaded start. Figure 4: Unloaded start position 4M* Figure 5: Unloaded start position 6M* NOTE: The operation of the unloaded start can also be controlled by the Copeland compressor electronics module (dedicated extension module D to be ordered).

  • Page 11: Oil Pumps

    2.5.6 Oil pumps All Stream compressors are equipped with an external oil pump. The oil pump will always work in the correct direction of rotation, regardless of the rotation direction of the compressor. Compressors delivered with Copeland™ compressor electronics (-N) or formerly with CoreSense™ Diagnostics (-D) include the oil pump and the electronic switch for the integrated oil pressure safety functionality.

  • Page 12: Dimensions Of Stream Compressors

    Once a new system design is set and assembled, a functional test is required. The functional test includes a qualification for the general system oil return. Systems with multiple compressors (two, three, or more) require additional oil balancing qualification between the parallel compressors. System engineers should review the system design and operation to identify the critical conditions and to check oil return and oil balancing.

  • Page 13: Models

    2.6.2 6M* models Figure 10: 6MI* and 6MM* compressors dimensions Figure 11: 6MJ*, 6MT*, 6MK* and 6MU* compressors dimensions Compressor (mm) (mm) (mm) (mm) 6MJ-45X 137.8 6MT-35X 6MK-50X 186.7 6MU-40X 169.8 Table 5: 6MJ*, 6MT*, 6MK* and 6MU* compressors dimensions AGL_Stream_ST_A2L_A1_4M_6M_EN_Rev00...

  • Page 14: 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. Any deficiency should be reported immediately in writing. Standard delivery: ▪...

  • Page 15: Installation Location

    In order to avoid refrigerant leaks or other damage the compressors should not be lifted by the service valves or other accessories. 3.1.4 Installation location Ensure the compressors are installed on a solid level base. For multiple compressor parallel configurations, the compressors must be positioned completely vertically on a totally horizontal surface or rail.

  • Page 16: Low-Pressure Protection

    Emerson requires without exception that all 4M* and 6M* compressors in A2L systems be fitted with a low-pressure control, with no service valve between the low pressure side and the pressure control.

  • Page 17: Brazing Procedure

    Brazing procedure WARNING Air/flammable refrigerant mixture! Creation of a potentially flammable atmosphere! Fire hazard! Remove all refrigerant before opening the system. When working on a refrigerant-filled system, make sure to follow the safety and working instructions given in Chapter 6 "Maintenance & repair". WARNING High temperature! Burning! Proceed with caution when brazing system components.

  • Page 18: Insulation Material

    Insulation material Insulation material is commonly used in a system to insulate the suction line, suction accumulator, expansion valve bulb or discharge line thermostat. When choosing the insulation material for A2L applications, particular attention shall be paid to its non-electrostatic properties, as it could be a potential ignition source.

  • Page 19: Electrical Connection

    The knockouts on the terminal box have to be removed before the electrical glands can be installed. First make sure that the terminal box is closed with the terminal box cover. Emerson recommends to use a subland twist driller to avoid any damage to the box while removing the knockouts.

  • Page 20: Part-Winding Motors (Yy/Y) - Code A

    NOTE: For the correct installation of the electrical fasteners on the terminal plate connections, a tightening torque of 8.5 to 9.6 Nm for the fixation of the nuts is required. NOTE: It is recommended to install a residual current device (RCD) in any electrical system associated with Stream 4M* and 6M* compressors and A2L flammable refrigerants such as R454C, R455A and R454A.

  • Page 21: Terminal Box

    Terminal box WARNING Ignition source in a potentially flammable atmosphere! Fire hazard! Particular attention must be paid in A2L refrigerant systems as any work on the energized terminals in the compressor terminal box could create an ignition. Do not touch the energized terminals with a tool or cable when the compressor is energized.
  • Page 22 Figure 20: Inside view of the Copeland compressor electronics module, with the modular boards Basic features Motor overheat protection High discharge temperature protection Oil level protection (in combination with Emerson Insufficient oil pressure protection TraxOil) Current protection Phase failure protection...
  • Page 23 Copeland compressor electronics – Electrical connections & wiring diagrams 4.5.1.3 The Copeland compressor electronics module is originally delivered with the basic modules preconnected. Figure 21: Basic module connections Figure 22: Wiring diagram – Part-winding motors (AW…) for part-winding start AGL_Stream_ST_A2L_A1_4M_6M_EN_Rev00...
  • Page 24 Figure 23: Wiring diagram – Part-winding motors (AW…) for direct-on-line start Figure 24: Wiring diagram – Star/Delta motors (EW…) AGL_Stream_ST_A2L_A1_4M_6M_EN_Rev00...
  • Page 25 Figure 25: Wiring diagram – Part-winding and Star/Delta motors (AW… & EW…) Legend Discharge gas sensor Discharge gas temperature monitoring Oil level watch (TraxOil) Digital oil level watch Oil differential pressure switch (OPS) Oil differential pressure protection High-pressure switch Alarm relay Low-pressure switch Run/control signal CTR2 DP Gateway...

  • Page 26: Compressors With Coresense Diagnostics

    4.5.2 Compressors with CoreSense Diagnostics WARNING Ignition source in a potentially flammable atmosphere! Fire hazard! The electrical switch of the CoreSense Diagnostics module is not an ignition source during normal operation in an A2L-refrigerant system but could become one if not installed properly according to the installation instructions. CoreSense Diagnostics was the standard protection system for Stream 4M* and 6M* compressors until December 2019 included.
  • Page 27 Figure 28: CoreSense Diagnostics module wiring diagram NOTE: For more information please refer to Technical Information D7.8.4 "CoreSense™ Diagnostics for Stream Refrigeration Compressors". CoreSense Diagnostics – Wiring diagrams 4.5.2.1 Legend A4 ..Sensor module K1 ..Contactor M1 A5 ..Compressor terminal box K4 ..
  • Page 28 Legend A4 ..Sensor module K1 ..Contactor M1 A5 ..Compressor terminal box K2 ..Contactor M1 Y-connection K3 ..Contactor M1 Δ-connection CCH ..Crankcase heater F6 ..Fuse for control circuit M21 ..Fan motor / condenser F7 ..

  • Page 29: Compressors With Coresense Protection

    4.5.3 Compressors with CoreSense Protection WARNING Ignition source in a potentially flammable atmosphere! Fire hazard! The CoreSense protection module is not an ignition source during normal operation in an A2L-refrigerant system but could become one if not installed and connected properly. As an alternative to the standard Copeland compressor electronics, the compressors can also be delivered with CoreSense Protection, a more basic compressor protection.
  • Page 30 CoreSense Protection – Wiring diagrams 4.5.3.2 Part-winding motors can be connected direct-on-line or part-winding start. Legend A1 ..CoreSense protection module K1 ..Contactor M1 A2 ..OPS2 Oil pressure switch K4 ..Contactor M1 for second part winding A5 ..Compressor terminal box M21 ..
  • Page 31 Legend A1 ..CoreSense Protection module K1 ..Contactor M1 A2 ..OPS2 Oil pressure switch K2 ..Contactor M1 Y-connection K3 ..Contactor M1 Δ-connection A5 ..Compressor terminal box F6 ..Fuse for control circuit M21 ..Fan motor / condenser F7 ..
  • Page 32 Wiring diagrams for OPS2 are shown in Technical Information D7.8.3 "DWM Copeland™ Semi-hermetic Compressor Oil Pressure Differential Switch OPS2" available at www.climate.emerson.com/en-gb. The wiring diagram in Figure 34 below relates to an option using a 7-wire cable.

  • Page 33: Crankcase Heaters

    Crankcase heaters WARNING Ignition source in a potentially flammable atmosphere due to hot surface temperature! Fire hazard! The crankcase heater is not an ignition source during normal operation in an A2L-refrigerant system but could become one if not installed properly according to installation instructions. Ensure correct mechanical installation of the crankcase heater into the sleeve and compressor housing.

  • Page 34: Start-Up & Operation

    DO NOT USE other industrial gases. The compressor has been tested for tightness in the Emerson factory. All compressors get a factory holding charge of dry air (about 1 to 2.5 bar, relative pressure). The presence of an intact holding charge serves as a proof of quality against penetrating moisture.

  • Page 35: Charging Procedure

    ▪ suitable ventilation according to the room volume and to the refrigerant charge, especially for systems with A2L refrigerants; ▪ visual check of the electrics, wiring, fuses etc; ▪ cable glands in good state, all electrical connections well connected and terminal box closed to ensure corresponding IP protection;...

  • Page 36: Minimum Run Time

    Minimum run time Emerson 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. The minimum on time becomes the time required for oil lost during compressor start-up to return to the compressor sump.

  • Page 37: Maintenance & Repair

    Maintenance & repair WARNING Conductor cables! Electrical shock! Follow the lockout/tag out procedure and the national regulations before undertaking any maintenance or service work on the system. Use compressor with grounded system only. Screwed electrical connections must be used in all applications. Refer to original equipment wiring diagrams. Electrical connections must be made by qualified electrical personnel.

  • Page 38: Qualification Of Workers

    The compressor shall be tested for tightness before it is charged with refrigerant. For proper tightness test, see applicable standards, eg, EN 378. All joints shall be tested with detection equipment with a capability of 5 g/year of refrigerant or better. Qualification of workers Personnel working on the maintenance, repair and decommissioning of an A2L refrigerant system shall be adequately trained.

  • Page 39: Exchanging The Refrigerant

    Drain, recover and dispose of compressor oil as appropriate. To disconnect: ▪ Using a pipe cutting tool, cut off the suction and discharge lines in such a manner that the new compressor can easily be re-connected into the system. ▪ Heat joint areas 2 and 3 slowly and uniformly until the braze material softens and the tube end can be pulled out from the fitting.

  • Page 40: Compressor Return Procedure For A2L Systems

    POE to absorb sufficient moisture to make it unacceptable for use in a refrigeration system. Since POE holds moisture more readily than mineral oil it is more difficult to remove it through the use of vacuum. The compressors supplied by Emerson contain oil AGL_Stream_ST_A2L_A1_4M_6M_EN_Rev00...

  • Page 41: Oil Additives

    Oil additives Although Emerson cannot comment on any specific product, from our own testing and past experience, we do not recommend the use of any additive to reduce compressor bearing losses or for any other purpose.

  • Page 42: Appendix 1: Stream Compressor Connections

    Appendix 1: Stream compressor connections 4MF-13X 4ML-15X 4MM-20X 4MT-22X 4MU-25X 4MA-22X 4MH-25X 4MI-30X 4MJ-30X 4MK-32X Discharge line size (sweat) Suction line size (sweat) Ø 1 5/8" 4MF-13X, 4ML-15X, 4MA-22X, Ø 1 1/8" 4MF-13X, 4ML-15X, 4MA-22X 4MM-20X, 4MH-25X, 4MI-30X Suction line size (sweat) Discharge line size (sweat) 4MM-20X, 4MH-25X, 4MI-30X, Ø...

  • Page 43: Appendix 2: Tightening Torques In Nm

    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 44 The Emerson logo is a trademark and service mark of Emerson Electric Co. Emerson Climate Technologies Inc. is a subsidiary of Emerson Electric Co. Copeland is a registered trademark and Copeland Scroll is a trademark of Emerson Climate Technologies Inc.. All other trademarks are property of their respective owners.

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