Related Manuals for Emerson Copeland 2D
Summary of Contents for Emerson Copeland 2D
- Page 1 Application Guidelines Copeland Semi-Hermetic ™ Compressors for A2L & A1 Applications 2D*, 3D* & 8D*...
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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 3.4 Filter screens ......................... 14 3.5 Insulation material ......................14 Electrical connection ..................15 4.1 General recommendations..................... 15 4.2 Electrical installation ...................... 16 4.2.1 Part-winding motors (YY/Y) – Code A ..............16 4.2.2 Star / Delta motors (Y/∆) – Code E ..............16 4.2.3 Terminal box jumpers positions .................
- Page 4 7.3 Inadequate suction superheat ..................32 7.4 Acid formation ........................ 32 7.5 Inadequate compressor cooling ..................32 7.6 High discharge temperatures ..................33 7.7 Motor burnout due to undersized contactors ..............33 7.8 Motor burnout due to by-passed or disconnected protectors ........33 Dismantling &...
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Page 6: About These Guidelines
Manufacturer’s Declaration, available at www.climate.emerson.com/en-gb. 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 7: 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 8: Product Description
Product description Compressor range These application guidelines cover Copeland semi-hermetic compressor models 2D*, 3D* and 8D* with displacement ranging from 16.8 to 181 m /h. The optimized valve plate design of these compressors provides the highest energy efficiency. Copeland semi-hermetic compressors are suitable for a wide range of applications in the form of either single compressors, condensing units or as multi-compressor equipment. -
Page 9: Nameplate Information
Select software available www.climate.emerson.com/en-gb. To recharge: When the compressor is completely empty of oil, the amount of oil to be "recharged" is typically 0.12 litre less than the original oil charge (oil will already be present in the system). -
Page 10: Application Limits
With suction-gas cooled compressors, the motor is cooled by the incoming refrigerant, which enters the compressor and is then passed over the motor area. An additional fan may be required depending upon the operating conditions – see Select software at www.climate.emerson.com/en-gb. 2.5.3 Liquid injection / Demand cooling... -
Page 11: Unloaded Start
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. Never operate the solenoid coil when not positioned on the solenoid valve. -
Page 12: Capacity Control
Usually, the unloaded start is activated once for about 5-10 seconds shortly before compressor start and then kept closed during operation. The unloaded start solenoid valve opens a suction channel in the valve plate and the pressure in the discharge line equalizes to the suction side. Assembly Installation of the modified cylinder head and valve plate for unloaded start is only possible at certain positions on the compressor. -
Page 13: Oil Circulation
gauge should be connected to the oil pump. The second gauge should be connected to the crankcase (oil service plug or any other crankcase connection plug). NOTE: The pressure measured on the suction service valve, where the refrigerant enters the compressor housing, does not correspond to the crankcase pressure and should not be used as a reference for the indication of oil differential pressure. -
Page 14: Dimensions
Dimensions Figure 9: 2D* compressors dimensions Figure 10: 3D* compressors dimensions Figure 11: 8D* compressors dimensions AGL_HA_ST_Discus_A2L_A1_EN_Rev00... -
Page 15: 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 16: Installation Location
Lifting eye max. 350 kg ½" – 13 UNC Figure 13: Compressor lifting methods 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. 3.1.5 Mounting parts To minimize vibration and start/stop impulses flexible mounting should be used. -
Page 17: Low-Pressure Protection
The minimum cut-out setting shall be determined according to the refrigerant and the allowed operation envelope – see Select software at www.climate.emerson.com/en-gb. The low-pressure cut-out should have a manual reset feature for the highest level of system protection. -
Page 18: Internal Pressure Relief Valve
Low-pressure side (LP): 22.5 bar (g) NOTE: The compressor operating range may be restricted for various reasons. Check the application range limitations in Select software at www.climate.emerson.com/en-gb. Brazing procedure WARNING Air/flammable refrigerant mixture! Creation of a potentially flammable atmosphere! Fire hazard! Remove all refrigerant before opening the system. -
Page 19: Filter Screens
CAUTION Contamination or moisture! Bearing failure! Do not remove the connection plugs until the compressor is set into the unit. This minimises any entry of contaminants and moisture. Refer to Figure 15 and procedure below for the brazing of the suction and discharge lines: Flushing oxygen-free nitrogen through the piping ... -
Page 20: 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 its cover. Emerson recommends to use a subland twist driller to avoid any damage to the box while removing the knockouts. -
Page 21: Electrical Installation
Electrical installation WARNING Conductor cables! Electrical shock hazard! Shut off power supply before undertaking any task on electrical equipment. WARNING Ignition source in a potentially flammable atmosphere! Fire hazard! The electrical connection of the compressor 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. -
Page 22: Terminal Box Jumpers Positions
4.2.3 Terminal box jumpers positions Part-winding motors can be connected direct-on-line or part-winding start: Part-winding start Direct-on-line start First start step 1-2-3 Part-winding motor: Code A Star / Delta motors can be connected direct-on-line or Star / Delta start: Direct-on-line start Direct-on-line start Star/Delta start ∆... -
Page 23: Compressor Protection
Compressor protection All Copeland 2D*, 3D* and 8D* compressor models are factory-fitted with a compressor protection. The letter "W" in the motor code of the 3-phase motors indicates a thermistor protection device. The temperature-dependent resistance of the thermistor (PTC-resistance) is used to sense the winding temperature. -
Page 24: Demand Cooling
Demand Cooling™ Liquid injection with "Demand Cooling™" can be used to extend application limits of 2D* and 3D* compressors in low-temperature applications with refrigerants such as R448A, R449A, R407A and R407F. The Demand Cooling system uses modern electronics. A temperature sensor in the cylinder head measures the discharge temperature and gives temperature signals to the Demand Cooling driver. - Page 25 Legend A1 ..Kriwan motor protection A2 ..Oil pressure switch A6 ..Demand Cooling driver / XEV01D B1 ..Room thermostat B12 ... Demand Cooling discharge temperature sensor E2 ..Crankcase heater F1 ..Fuse for control circuit F2 ..Fuse for crankcase heater F5 ..
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Page 26: Oil Differential Pressure Control
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 25 below relates to an option using a 7-wire cable. -
Page 27: Crankcase Heaters
Legend: 11 = Voltage connection 21 = Control voltage connection 22 = Control circuit 24 = Alarm connection A5 = Compressor terminal box R = Relay N = Neutral connection t = Time delay Figure 26: Wiring diagram FD-113ZU Protection class: IP30. Crankcase heaters WARNING Ignition source in a potentially flammable atmosphere due to hot surface... -
Page 28: 200-Watt Heater Element
4.8.2 200-Watt heater element In compressors equipped with a deep oil sump, the heater element is inserted into a special chamber and fixed to the compressor body. Magnetic plug Securing piece Heater element 200 W Deep oil sump Figure 28: 200-Watt crankcase heater element AGL_HA_ST_Discus_A2L_A1_EN_Rev00... -
Page 29: 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 30: 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 31: Minimum Run Time
Copeland 2D*, 3D* and 8D* compressors must be equipped with the correct accessories, according to Emerson documentation and considering the application intended. Make sure this requirement is met before start-up. Bolt torque settings are listed in Appendix 2. With the exception of rubber-coated metallic gaskets (Wolverine) all gaskets should be oiled before fitting. -
Page 32: Maintenance & Repair
Maintenance & repair WARNING Conductor cables! Electrical shock hazard! 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 33: Qualification Of Workers
A risk analysis to evaluate all possible risks shall be carried out by the service technician before any repair work on an A2L system. The compressor shall be tested for tightness before it is charged with refrigerant. For proper tightness test, see applicable standards, eg, EN 378. -
Page 34: Exchanging The Refrigerant
free nitrogen charge is used, the system shall be vented down to atmospheric pressure to enable work to take place. Disassemble components with a cutting tool. Drain, recover and dispose of compressor oil as appropriate. To disconnect: Using a pipe cutting tool, cut off the suction and discharge ... -
Page 35: Compressor Return Procedure For A2L Systems
6.6.2 Compressor return procedure for A2L systems Compressors from A1-refrigerant systems can be sent back to Emerson for diagnosis with closed suction and discharge valves and the oil filling inside. However, the refrigerant should be removed first. -
Page 36: Oil Additives
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 with low moisture content, which may rise during the system assembling process. Therefore, it is recommended that a properly sized filter-drier be installed in all POE systems. -
Page 37: 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 Compressors are delivered with an initial oil charge. The correct oil level is shown in Section 2.5.9 "Oil level". -
Page 38: High Discharge Temperatures
High discharge temperatures The limit is 120 °C measured on the discharge line a few centimetres from the service valve. Symptoms of high discharge temperatures are cutting-out on the high-pressure switch (dirty condenser), oil carbonisation, black oil and acid formation. Inadequate lubrication is the result. The condenser should be cleaned regularly. -
Page 39: Appendix 1: Compressor Connections
Appendix 1: Compressor connections 2DC-50 2DD-50 2DL-40 2DB-50 2DL-75 2DB-75 Discharge line size (sweat) Discharge line size (sweat) 2DC-50, 2DD-50, Ø 7/8" Ø 1 1/2" 2DL-75, 2DB-75 2DL-40, 2DB-50 SL Suction line size (sweat) Ø 1 3/8" Plug oil charge 1/4"... - Page 40 8DL-370 8DH-500 8DT-450 8DJ-600 Suction line size (sweat) Suction line size (sweat) Ø - 2 5/8" Ø - 3 1/8" 8DL-370, 8DH-500 8DT-450, 8DJ-600 DL Discharge line size (sweat) Ø 15/8" Plug oil charge 1/4" - 18 NPTF Base mountings Ø...
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Page 41: Appendix 2: Tightening Torques (Nm)
Appendix 2: Tightening torques (Nm) 1/2"-13 UNC 5/8"-11 UNC Suction shut-off valve 69 - 85 Nm 104 - 164 Nm SW 19 SW 23.8 5/16"-18 UNC 1/2"-13 UNC 1/2"-13 UNC Discharge 33 - 39 Nm 53 - 84 Nm 53 - 84 Nm shut-off valve SW 12.7 SW 19... -
Page 42: 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 43 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.