Related Manuals for Copeland 4MTL-05
Summary of Contents for Copeland 4MTL-05
- Page 1 APPLICATION GUIDELINES Copeland Stream CO semi-hermetic compressors 4MTL-05 to 4MTL-50 for transcritical applications 4MSL-03 to 4MSL-15 for subcritical applications...
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Page 2: Table Of Contents
APPLICATION GUIDELINES Table of contents About these guidelines......................1 Safety instructions ....................1 Icon explanation....................1 Safety statements ....................1 General instructions ..................... 2 Product description....................3 Compressor range ....................3 Nomenclature ...................... 4 Nameplate information..................4 Application range ....................5 2.4.1 Qualified refrigerant and oils ................. - Page 3 4.2.3 Star / Delta motors (Y/∆) – Code E ............. 18 4.2.4 Terminal box isolators and jumpers position ..........19 Electrical protection (fuses)................19 Compressor protection..................20 4.4.1 Copeland Compressor Electronics.............. 20 4.4.2 Copeland Protection ................... 24 4.4.3 CoreSense Diagnostics (until December 2019) .......... 27 Crankcase heater ....................30 Start-up &...
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Page 4: About These Guidelines
About these guidelines The purpose of these application guidelines is to provide guidance in the application of Copeland Stream semi-hermetic compressors in user’s systems operating with CO (R744). They are intended to answer the questions raised while designing, assembling and operating a system with these products. -
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 under vacuum and has no refrigerant 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 from 5 to 50 hp; the series of 4MSL* subcritical models ranges from 3 to 15 hp. The performance values shown in Table 1 are valid for 50 Hz supply frequency. -
Page 7: Nomenclature
NOTE: The compressor is only one component which must be combined with many others to build a functional and efficient refrigeration system. Therefore the information in this manual relates to Copeland Stream semi-hermetic compressors for CO transcritical and subcritical applications with standard equipment and accessories only. -
Page 8: Application Range
4MTL-05 / 4MTL-07 / 4MTL-09 4MTL-12 / 4MTL-15 R744 R744 Evaporating temperature ( Evaporating temperature ( 10 K Suction superheat 20 K Suction superheat Figure 3: Operating envelopes for transcritical applications with R744 – Models 4MTL-05 to 4MTL-15 AGL_Stream_ST_4MTL_4MSL_EN_Rev04... -
Page 9: Recommendations For Minimum Suction Superheat - Lubrication Conditions
4MTL-30 R744 Evaporating temperature ( Figure 4: Operating envelopes for transcritical applications with R744 – Models 4MTL-30 to 4MTL-50 4MSL-03 / 4MSL-04 / 4MSL-06 R744 Evaporating temperature ( Figure 5: Operating envelopse for subcritical applications with R744 – Models 4MSL-03 to 4MSL-15 2.4.3 Recommendations for minimum suction superheat –... -
Page 10: Design Features
▪ On compressors delivered with Copeland Compressor Electronics (-N), the oil pump integrates an electronic switch to ensure the oil pressure safety functionality. ▪ Compressors with Copeland Protection (-P) are designed to accommodate fittings for an OPS2 or a standard oil pressure switch (OPS2 oil sensor included in the oil pump). -
Page 11: Oil Level
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 three identical sight glasses, one at each side of the compressor and one at the front. Sight glasses (3) - Page 12 The oil level control is divided into 3 zones: normal, warning and alarm. Figure 11: OM5 TraxOil with sight glassl More information about this product can be found at www.copeland.com/en-gb. 2.5.4.2 Oil level monitoring system OW4/OW5 TraxOil Copeland Flow Controls The OW4 and OW5 TraxOil are intended for 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 the compressor down. The alarm will be reset when the oil level goes back to normal. More information about this product can be found at www.copeland.com/en-gb. AGL_Stream_ST_4MTL_4MSL_EN_Rev04...
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Page 14: Installation
▪ Oil charge, oil sight glasses ▪ Crankcase heater 230 V ▪ Mounting parts kit (rubber) ▪ Copeland Compressor Electronics or Copeland Protection module ▪ Holding charge up to 2.5 bar(g) (dry air) ▪ Electrical terminals 3.1.2 Transport and storage... -
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, flexible mounting should be used. -
Page 16: Maximum Allowable Pressures Ps
(low side). PRV (high side) Plug (low side) Figure 16: Position of the pressure relief valve – Models 4MTL-05 to 4MTL-09 & 4MSL-03 to 4MSL-06 PRV (high side) Plug (low side) Figure 17: Position of the pressure relief valve – Models 4MTL-12 to 4MTL-30 & 4MSL-08 to 4MSL-15 Figure 18: Position of the pressure relief valve –... -
Page 17: Maximum Operating Pressures
NOTE: The compressor operating range may be restricted for various reasons. Check the application range limitations in Copeland Select software at www.copeland.com/en-gb. Shut-off valves... -
Page 18: Shut-Off Valves Design
3.3.1 Shut-off valves design The standard shut-off valves on Stream CO compressors are flange valves with one flare connection port (lockable) for service. The service connection port is a 7/16" – 20 UNF, with a blind cap SAE 1/4" (blind cap material: stainless steel 1.4301). -
Page 19: Variations For Shut-Off Valves
Copeland also offers variations for connection sizes – see Tables 9 & 10 For Stream CO below for details. Additionally, a compression fitting can be used for the discharge part of the compressors. -
Page 20: Screens
Screens CAUTION Screen blocking! Compressor breakdown! Use screens with at least 0.6 mm openings. The use of screens finer than 30 x 30 meshes (0.6 mm openings) anywhere in the system should be avoided with these compressors. Field experience has shown that finer mesh screens used to protect thermal expansion valves, capillary tubes or accumulators can become temporarily or permanently plugged with normal system debris and block the flow of either oil or refrigerant to the compressor. -
Page 21: 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. Copeland recommends to use a subland twist driller to avoid any damage to the box while removing the knockouts. -
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
The Copeland Compressor Electronics module has a compact design with a base board and optional plug-in modules with advanced functionalities. The base board with current, discharge temperature and oil sensor, provides advanced diagnostics and protection against faults such as high discharge temperature, locked rotor, single/missing phase, voltage imbalance, low voltage, etc. - Page 24 Copeland Compressor Electronics – Features 4.4.1.2 Copeland Compressor Electronics is a modular system. This modular design gives the customers the flexibility to choose individual protection and/or control levels. It is possible to extend the compressor protection from just basic functions to a high tier protection to enlarge the lifetime of the compressor.
- Page 25 Copeland Compressor Electronics – Basic modules connections 4.4.1.3 The Copeland Compressor Electronics module is originally delivered with the basic modules preconnected. Figure 27: Basic modules connections Copeland Compressor Electronics – Electrical connections & wiring diagrams 4.4.1.4 Legend of the wiring diagrams B1 ...
- Page 26 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 in diagrams below must be considered. The position of the terminals in large models (4MTL-35 to 4MTL-50) is inverted and corresponds to the black positions. The factory delivery is correct, DO NOT reverse the connections.
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Page 27: Copeland Protection
Copeland Protection, a more basic compressor protection system. This compressor variation is available as an option in compressor production and must be ordered accordingly. The compressors equipped with a Copeland Protection device will have a "-P" at the end of the description. Copeland Protection – Electrical connections 4.4.2.1... - Page 28 Copeland Protection – Wiring diagrams 4.4.2.2 Legend A1 ... Copeland Protection module M21 ..Fan motor / condenser A5 ... Compressor terminal box S1..Thermistor chain motor temperature F6,F7,F8. Fuses for control circuit S2..Thermistor chain motor temperature F10 ..Thermal protection switch M21 Y21..
- Page 29 Legend K3..Contactor M1 Δ-connection A1 ... Copeland Protection module A5 ... Compressor terminal box M21 ..Fan motor / condenser F6,F7,F8. Fuses for control circuit S1..Thermistor chain motor temperature F10 ..Thermal protection switch M21 S2..Thermistor chain motor temperature R2...
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Page 30: Coresense Diagnostics (Until December 2019)
4.4.3 CoreSense Diagnostics (until December 2019) CoreSense Diagnostics was the standard protection system for 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 faults such as high discharge temperature, locked rotor, single/missing phase, voltage imbalance and low voltage. - Page 31 CoreSense Diagnostics – Wiring diagrams 4.4.3.1 Legend A4 ... Sensor module L1 ..Current transducer CoreSense A5 ... Compressor terminal box M21 ..Fan motor / condenser F6,F7,F8. Fuses for control circuit R2 ..Crankcase heater F10 ..Thermal protection switch M21 S1..
- Page 32 Legend A4 ... Sensor module L1 ..Current transducer CoreSense A5 ... Compressor terminal box M21 ..Fan motor / condenser F6,F7,F8. Fuses for control circuit R2 ..Crankcase heater F10 ..Thermal protection switch M21 S1..Thermistor chain motor temperature CCH ..
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Page 33: Crankcase Heater
▪ 1 x crankcase heater; ▪ 1 x heat-conductive paste tube; ▪ 1 x mounting ring. The operation of 115 V and 230 V crankcase heaters can be controlled by the Copeland Compressor Electronics module. Figure 38: 100-Watt crankcase heater element Figure 39: Crankcase heater kit The crankcase heater has to be inserted in a special chamber. - 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 heater by using a rubber hammer on the flat surface. before insertion) has to be pressed into the hole.
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Page 35: Start-Up & Operation
Avoid operating with air. Compressor leak and tightness test Copeland compressors are leak-tested during manufacturing. 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 indicates that the compressor does not leak. -
Page 36: Charging Procedure
To avoid motor damage, NEVER start the compressor or carry out high- potential testing when the compressor is under vacuum. Minimum run time Copeland 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. AGL_Stream_ST_4MTL_4MSL_EN_Rev04... -
Page 37: Inverter Operation
Table 15: Inverter operation – Approved frequency ranges NOTE: The frequency range depends on the operating conditions. For approved application envelope please contact Application Engineering at Copeland or refer to Select software at www.copeland.com/en-gb. 5.7.1 Maximum Operating Current – Models 4MTL-35 to 4MTL-50 Large Stream CO compressors from 35 to 50 hp have a different MOC in operation with frequency drives. -
Page 38: Maintenance & Repair
PAG systems. Copeland compressors contain oil with low moisture content, which however may rise during the system assembling process. Therefore, it is recommended to install a properly sized filter-dryer in all systems to maintain the moisture level in the oil to less than 50 ppm. -
Page 39: Oil Additives
Figure 41: Oil removal plug location Oil additives Although Copeland 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 40: Dismantling & Disposal
▪ Replace the 135 bar pressure relief valve (caution: left-handed thread!). Torque to 90-110 Nm. ▪ Check all screwed / thread connections for tightness and proper torque. ▪ Use a vacuum pump to remove any air that may have entered the compressor. ▪... -
Page 41: Appendix 1: Connections Of Stream Co
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: 4MTL-05, 4MTL-07, 4MTL-09 16.15 mm 4MTL-05, 4MTL-07, 4MTL-09 12.85 mm Suction line size (sweat) ID: 7/8" Discharge line size (sweat) ID: 5/8"... -
Page 42: Appendix 2: Tightening Torques In Nm
Magnetic plug fitting 35 - 40 Nm SW 7/16" * For small & medium models: 4MTL-05 to 4MTL-30 & 4MSL-03 to 4MSL-15 ** For large models: 4MTL-35 to 4MTL-50 Table 18: Tightening torques for main components Figure 44: Tightening torques around oil pump... - Page 43 Figure 45: Hexagon socket screws (Allen / Inbus) & hexagon heads (Wrench) The ranges of torque values given in this specification are assembly torques. Torque after 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.
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Page 44: 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_Rev04... - Page 45 DISCLAIMER: The Copeland logo is a trademark and service mark of Copeland LP or one of its affiliates. Copeland Europe GmbH shall not be liable for errors in the stated capacities, dimensions, etc., as well as typographic errors. Products, specifications, assumptions, designs and technical data contained in this document are subject to modification by us without prior notice.
- Page 46 Tel. +49 (0) 2408 929 0 - Fax: +49 (0) 2408 929 570 – Internet: copeland.com/en-gb The Copeland logo is a trademark and service mark of Copeland LP or one of its affliates. Copeland Europe GmbH shall not be liable for errors in the stated capacities, dimensions, etc., as well as typographic errors.
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