Emerson Copeland 4MTL-05 Series Application Manuallines
Semi-hermetic compressors for transcritical & subcritical applications
Hide thumbs
Also See for Copeland 4MTL-05 Series:
- Application manuallines (46 pages) ,
- Technical information (2 pages)
Related Manuals for Emerson Copeland 4MTL-05 Series
Summary of Contents for Emerson Copeland 4MTL-05 Series
- Page 1 Application Guidelines Copeland Stream CO ™ Semi-Hermetic Compressors for Transcritical & Subcritical Applications 4MTL-05_ to 4MTL-50_ 4MSL-03_ to 4MSL-15_...
-
Page 2: Table Of Contents
About these guidelines ....................1 Safety instructions ..................1 1.1 Icon explanation ....................1 1.2 Saf ety statements....................1 1.3 General instructions .................... 2 Product description ..................3 2.1 Compressor range....................3 2.2 Nomenclature ....................4 2.3 Nameplate information ..................4 2.4 Application range .................... - Page 3 Star / Delta motors (Y/∆) – Code E .............18 4.2.3 4.2.4 Terminal box isolators and jumpers position ..........19 4.3 Compressor protection ..................20 4.3.1 Compressors with Copeland Compressor Electronics (formerly Next Generation CoreSense) .......................20 4.3.2 Copeland Protection ................24 4.3.3 Compressors with CoreSense Diagnostics (until December 2019) ....27 4.4 Electrical protection (fuses) .................30 4.5 Crankcase heater ....................30 Start-up &...
-
Page 4: About These Guidelines
Conformity to local legislation and regulations must also be observed. For relevant standards please ref er to the Manuf acturer’s Declaration, available at www.climate.emerson.com/en-gb. The Material Saf ety Datasheet (MSDS) for R744 shall be considered when working with this type of ref rigerant - please check this document provided by the gas supplier. -
Page 5: General Instructions
General instructions WARNING Pressurized system! Serious personal injuries and/or system breakdown! Accidental system start before complete set-up must be avoided. Never leave the system unattended without locking it out electrically when it is on vacuum and has no ref rigerant charge, when it has a holding charge of nitrogen, or when the compressor service valves are closed. -
Page 6: Product Description
Product description Compressor range These application guidelines cover Copeland™ Stream semi-hermetic compressors using CO (R744). The series of 4MTL* transcritical models ranges f rom 5 to 50 hp; the series of 4MSL* subcritical models ranges f rom 3 to 15 hp. The perf ormance values shown in Table 1 are valid for 50 Hz supply frequency. -
Page 7: Nomenclature
maximum standstill pressures of 135 bar at high side and 90 bar at low side – see section 3.2.1 "Safety relief valves". Ref rigerant flow and heat transfer have been optimized for best performance. NOTE: The pressure values shown with the bar(a) or bar unit in these guidelines are absolute pressures. -
Page 8: Application Range
POE oil. Large models (4MTL-35 to 4MTL-50) can alternatively be delivered on request with PAG oil. recharge values can taken f rom Copeland Select sof tware available at www.climate.emerson.com/en-gb. Qualified refrigerant R744 (CO RL 68 HB (POE 68) Copeland standard oils... -
Page 9: Recommendations For Minimum Suction Superheat - Lubrication Conditions
Figure 4: Operating envelopes for transcritical applications with R744 – Models 4MTL-30 to 4MTL-50 Figure 5: Operating envelope for subcritical applications with R744 – Models 4MSL-03 to 4MSL-15 2.4.3 Recommendations for minimum suction superheat – Lubrication conditions The operation of CO compressors at conditions where the viscosity of the oil is low might become very harmf ul with regard to compressor lif etime expectancy. -
Page 10: Design Features
to the discharge shut-off valve) the temperature is expected to be 15-20 K lower than inside the cylinder head. This fact must be taken into account when applying the values in Table 4 below. Maximum Minimum Minimum oil acceptable Application superheat temperature discharge... -
Page 11: Oil Level
Compressor Transcritical Lubrication Subcritical Lubrication size mode system mode system 4MTL-05 4MSL-03 Small 4MTL-07 Splasher 4MSL-04 Splasher 4MTL-09 4MSL-06 4MTL-12 4MSL-08 Medium 4MTL-15 Splasher 4MSL-12 Splasher 4MTL-30 4MSL-15 4MTL-35 Large 4MTL-40 Oil pump 4MTL-50 Table 5: Lubrication system on Stream CO compressors 2.5.4 Oil level Small- and medium-size models (4MSL-03 to 4MSL-15, 4MTL-05 to 4MTL-30) are equipped with... - Page 12 More inf ormation about this product can be found Figure 11: TraxOil OM5 with sight glass & coil at www.climate.emerson.com/en-gb. 2.5.4.2 Oil level monitoring system OW4/OW5 TraxOil The OW4 and OW5 TraxOil are intended f or systems which only require oil level monitoring and alarming and do not need active oil level balancing.
- Page 13 (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 inf ormation about this product can be found at www.climate.emerson.com/en-gb. AGL_Stream_ST_4MTL_4MSL_EN_Rev02...
-
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 def iciency should be reported immediately in writing. Standard delivery: ▪... -
Page 15: Installation Location
3.1.4 Installation location Ensure the compressors are installed on a solid level base. Horizontal installation is recommended. Temperatures around the compressor should not exceed 65 °C in order to avoid suction gas temperature increase and malfunctioning of electronics. 3.1.5 Mounting parts To minimize vibration and start/stop impulses f lexible mounting should be used. - Page 16 Usually af ter a blow-off, pressure relief valves are no longer perf ectly tight. Theref ore it is recommended to replace them after any blow-off. The f ollowing pictures show the position of the pressure relief valve (high side) and the position of the plug (low side).
-
Page 17: Maximum Allowable Pressures Ps
NOTE: The compressor operating range may be restricted for various reasons. Check the application range limitations in Copeland Select software at www.climate.emerson.com/en- Shut-off valves Stream CO compressors are f actory-equipped with shut-off valves on both the suction and discharge sides. -
Page 18: Shut-Off Valves Design
Flange Suction connection Discharge connection Displacement Compressor mountings Inner Drawing Inner Drawing (m³/h) Description Description (mm) diameter number diameter number W22 / ODS W17.2 / 4MSL-03 4.60 5/8" 1/2" ODS 1/2 510- W22 / ODS 510-0809- W17.2 / 4MSL-04 6.20 45 x 45 5/8"... -
Page 19: Variations For Shut-Off Valves
Emerson also offers variations for connection sizes – see Tables 9 & For Stream CO 10 below f or details. Additionally, a compression f itting can be used f or the discharge part of the compressors. -
Page 20: Screens
Variation smaller Ø Compressor Suction connection Discharge connection Flange Displ. Mountings Inner Ø Valve Inner Ø Valve (m³/h) Transcritical Subcritical (mm) brazing description brazing description 4MTL-05 4MSL-03 4.60 W17.2 / W17.2 / 4MTL-07 4MSL-04 6.20 45 x 45 1/2" 1/2" ODS 1/2 ODS 1/2 4MTL-09... -
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 that the supply voltage, the phases and the f requency match the nameplate data. The knockouts 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. -
Page 22: Terminal Box Isolators And Jumpers Position
4.2.4 Terminal box isolators and jumpers position 4.2.4.1 Part-winding motors (AW… or FW…) Part-winding motors can be connected Direct-On-Line or part-winding start. Make sure that the 2 wires (L2) which are guided through the current sensor are in the same direction. The black wire (voltage sensing) from the sensor module must be connected to the same terminal as the wires that are guided through the current sensor. -
Page 23: Compressor Protection
Compressor protection All Stream 4MTL* and 4MSL* models are f actory-fitted with a compressor protection. The standard scope of delivery contains the Copeland™ Compressor Electronics extended and advanced compressor protection system. Alternatively the compressors can be ordered with Copeland™ Protection (f ormerly CoreSense Protection), a less advanced protection system. - Page 24 Figure 26: 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 Insuf f icient oil pressure protection TraxOil) Current protection Phase f ailure protection...
- Page 25 Copeland Compressor Electronics – Electrical connections 4.3.1.3 The Copeland compressor electronics standard version is originally delivered with the basic modules preconnected. Figure 27: Basic modules connections Copeland Compressor Electronics – Wiring diagrams 4.3.1.4 IMPORTANT For small and medium compressor models (4MTL-05 to 4MTL-30 & 4MSL-03 to 4MSL-15), the blue positions 1U, 2V, 3W, 7Z, 8X, 9Y diagrams below must be considered.
- Page 26 part) for Star/Delta motors (EW…) Wiring diagram (1 part) for Star/Delta motors (EW…) Figure 29: Wiring diagram (1 part) for part-winding and Star/Delta motors (AW… & EW…) Wiring diagram (2 part) for part-winding and Star/Delta motors (AW… & EW…) Figure 30: Wiring diagram (2 AGL_Stream_ST_4MTL_4MSL_EN_Rev02...
-
Page 27: Copeland Protection
Legend B1 ....Discharge gas sensor DGT... Discharge gas temperature monitoring B2 ....Oil level watch (TraxOil) OW ..Digital oil level watch B3 ....Oil differential pressure switch (OPS) OPS... Oil differential pressure protection B11 ..High-pressure switch AR..Alarm relay B12 ..Low-pressure switch DS .. - Page 28 Copeland Protection – Wiring diagrams 4.3.2.2 Wiring diagram for part-winding motors (AW…, FW…) Legend A1 ..Protection module K1 ..Contactor M1 A5 ..Terminal box compressor K4 ..Contactor M1 for 2 part-winding F6 ..Fuse f or control circuit M21 ..
- Page 29 Wiring diagram for Star/Delta motors (EW…) Legend A1 ..Protection module K2 ..Contactor M1 Y-connection K3 ..Contactor M1 Δ-connection A5 ..Terminal box compressor F6 ..Fuse f or control circuit M21 ..Fan motor / condenser F7 ..Fuse f or control circuit R2 ..
-
Page 30: Compressors With Coresense Diagnostics (Until December 2019)
4.3.3 Compressors with CoreSense Diagnostics (until December 2019) CoreSense Diagnostics was the standard protection system f or Stream 4MTL* and 4MSL* compressors until December 2019 included. Stream compressors with "-D" at the end of the description are equipped with a CoreSense Diagnostics device. CoreSense Diagnostics provides advanced protection against f aults such as high discharge temperature, locked rotor, single/missing phase, voltage imbalance and low voltage. - Page 31 CoreSense Diagnostics – Wiring diagrams 4.3.3.2 Wiring diagram for part-winding motors (AW…, FW…) Legend A4 ..Sensor module K1 ..Contactor M1 Y-connection A5 ..Compressor terminal box K4 ..Contactor M1 YY-connection CCH ... Crankcase heater L1..Current transducer CoreSense F6 ..
- Page 32 Wiring diagrams for Star/Delta motors (EW…) Legend A4 ..Sensor module L1..Current transducer CoreSense A5 ..Compressor terminal box M21 ..Fan motor / condenser F6 ..Fuse f or control circuit R2 ..Crankcase heater F7 ..Fuse f or control circuit Y7 ..
-
Page 33: Electrical Protection (Fuses)
Electrical protection (fuses) Independently from the internal motor protection, fuses must be installed before the compressor. The selection of fuses has to be made according to VDE 0635, DIN 57635, IEC 269-1 or EN 60-269-1. Crankcase heater IMPORTANT Oil dilution! Bearing malfunction! Turn the crankcase heater on 12 hours bef ore starting the compressor. - Page 34 Remove the plug before heater installation. The crankcase heater is secured into position. Insert the heater in the hole. It is also possible to secure the heater more firmly The mounting ring (preassembled on the by using a rubber hammer on the flat surface. heater bef ore insertion) has to be pressed into the hole.
-
Page 35: Start-Up & Operation
Start-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. Leak test As a general rule, the reduction of leaks is a legal obligation. Refrigeration systems must be checked f or leakage before they get into operation. -
Page 36: Charging Procedure
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. -
Page 37: Inverter Operation
This phenomenon strongly depends on the system design and operating conditions. Emerson conducted extensive tests to investigate compressor behaviour in terms of resonances. The testing indicates that the f ollowing hardware variables have a significant impact on possible resonances: ▪... -
Page 38: Maintenance & Repair
Since POE holds moisture more readily than mineral oil it is more dif ficult to remove it through the use of vacuum. Compressors supplied by Emerson contain oil with low moisture content, and it may rise during the system assembling process. Theref ore it is recommended that a properly sized filter-drier is installed in all POE systems. -
Page 39: Oil Additives
Figure 41: Oil removal plug location Oil additives Although Emerson cannot comment on any specific product, f rom our own testing and past experience, we do not recommend the use of any additive to reduce compressor bearing losses or f or any other purpose. Furthermore, the long-term chemical stability of any additive in the presence of ref rigerant, low and high temperatures, and materials commonly found in ref rigeration systems is complex and difficult to evaluate without rigorously controlled chemical laboratory testing. -
Page 40: Appendix 1: Connections Of Stream Co
Appendix 1: Connections of Stream CO compressors 4MTL* 4MSL* 4MTL-05 4MTL-07 4MTL-09 4MSL-03 4MSL-04 4MSL-06 4MTL-12 4MTL-15 4MTL-30 4MSL-08 4MSL-12 4MSL-15 4MTL-35 4MTL-40 4MTL-50 Figure 42 Suction line size (sweat) ID: 5/8" Discharge line size (sweat) ID: 1/2" 4MSL-03, 4MSL-04, 4MSL-06 Tube OD: 4MSL-03, 4MSL-04, 4MSL-06 Tube OD:... -
Page 41: Appendix 2: Tightening Torques In Nm
Appendix 2: Tightening torques in Nm M24 X 1.5 3/8" - 16 UNC Pressure relief valve Shut-off valve screws 90 - 110 Nm 36 - 44 Nm LP/HP side Discharge and suction SW 24 mm SA 8 mm Shut-off valve cap 3/4"... - Page 42 Figure 44: Hexagon socket screws (Allen / Inbus) & hexagon heads (Wrench) The ranges of torque values given in this specification are assembly torques. Torque af ter 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: Appendix 3: T-Plate Isolators Depending On Motor Version & Power Supply
Appendix 3: T-plate isolators depending on motor version & power supply AGL_Stream_ST_4MTL_4MSL_EN_Rev02... -
Page 44: Disclaimer
3. Emerson does not assume responsibility for the selection, use or maintenance of any product. Responsibility f or proper selection, use and maintenance of any Emerson product remains solely with the purchaser or end user. - Page 45 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.