Emerson Copeland 4MI-30X Application Manuallines Download Page 1

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Copeland

™

Stream

Semi-Hermetic Compressors

4MF-13X to 6MK-50X

Application Guidelines

Summary of Contents for Copeland 4MI-30X

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

Page 2: ... Compressor cooling 5 2 5 3 Liquid injection Demand cooling 6 2 5 4 Unloaded start 6 2 5 5 Capacity control 7 2 5 6 Oil pumps 8 2 5 7 Oil pressure 8 2 5 8 Oil circulation 8 2 5 9 Oil level 8 2 5 10 System oil return 8 2 6 Dimensions of Stream compressors 9 2 6 1 4M models 9 2 6 2 6M models 10 3 Installation 11 3 1 Compressor handling 11 3 1 1 Delivery 11 3 1 2 Transport and storage 11 3 1 3 Positi...

Page 3: ...ters 30 5 Start up operation 31 5 1 Compressor tightness test 31 5 2 System evacuation 31 5 3 Preliminary checks Pre starting 31 5 4 Charging procedure 32 5 5 Initial start up 32 5 6 Minimum run time 33 5 7 Recommended inverter range 33 6 Maintenance repair 34 6 1 Qualification of workers 35 6 2 Preparation and work procedure 35 6 3 Unbrazing system components 35 6 4 Disassembling system component...

Page 4: ...pressors 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 They must comply with any and all...

Page 5: ...ke all necessary precautions to mitigate the risk as determined in the risk assessment Use personal safety equipment Safety goggles gloves protective clothing safety boots and hard hats should be worn where necessary 1 3 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 sy...

Page 6: ... 4MK 35X 32 202 50 7 32 4 44 1 48 2 52 3 6MM 30X 27 120 215 59 0 39 9 53 0 58 1 62 9 6MI 40X 35 219 61 9 38 5 53 0 56 5 63 1 6MT 35X 32 135 221 65 3 44 7 59 1 64 1 70 0 6MJ 45X 40 223 69 1 44 9 58 7 64 3 70 4 6MU 40X 40 153 225 76 3 49 1 64 4 71 6 77 4 6MK 50X 50 230 76 4 48 3 65 1 72 3 77 8 A2L refrigerants Conditions Evaporating 10 C condensing 45 C suction gas temperature 20 C subcooling 0 K Ta...

Page 7: ...taller Figure 1 Stream compressor nameplate and nameplate location The year and month of production are shown as part of the serial number Jan A Feb B Dec L Example the serial number 21H 18110 M indicates a compressor manufactured in August 2021 2 4 Application range 2 4 1 Qualified refrigerants and oils IMPORTANT Some refrigerant blends have a significant temperature glide It is essential that th...

Page 8: ... Also refer to section 3 2 3 Maximum allowable pressures Compressor PS High pressure side PS Low pressure side 4M and 6M 32 5 bar g 22 5 bar g Table 3 Maximum allowable pressures 2 5 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...

Page 9: ...ntially 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 Secure the installation with a screw Unloaded start is mainly required for compressors connected for part winding star...

Page 10: ...tion 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 Secure the installation with a screw A mechanical capacity control is available for 4M and 6M compressors The system used is blocked suction The suction port of the valve plate will be closed by a control piston When a compressor is ordered with...

Page 11: ...tween motor side and crankcase thus slowing down pressure decrease in the crankcase over a certain period of time It reduces the foaming of the oil refrigerant mixture that would occur if the pressure decreased rapidly The valve does not reopen until the pressure has been equalized by means of a crankcase ventilating valve This second valve connects the crankcase and suction side cylinder head It ...

Page 12: ...ems to check oil return and oil balancing in the tandem or rack testing conditions shall be at the corner points of the system application envelope in continuous and frequent start stop cycling The system shall also be tested with regards to liquid refrigerant floodback and the superheat level of the refrigerant gas at compressor suction These checks should be carried out for standard operation bu...

Page 13: ...re 10 6MI and 6MM compressors dimensions Figure 11 6MJ 6MT 6MK and 6MU compressors dimensions Compressor A mm B mm C mm D mm 6MJ 45X 6MT 35X 729 206 137 8 446 6MK 50X 776 255 186 7 445 6MU 40X 759 238 169 8 445 Table 5 6MJ 6MT 6MK and 6MU compressors dimensions ...

Page 14: ...ndling equipment according to weight Keep in the upright position Respect stacking loads according to Figure 12 Check the tilting stability and if needed take action to ensure the stability of the stacked loads Keep the packaging dry at all times Respect the maximum number of identical packages which may be stacked on one another where n is the limiting number Transport n 1 Storage n 1 Figure 12 M...

Page 15: ...thout springs In this case more shock and vibration loading will be transmitted to the frame Unevenness in the mounting surface will have to be compensated by the rack and or the compressor bottom plate feet Excessive unevenness can result in too high mechanical stress to the system and could damage the compressor or rack Therefore the flatness of the mounting location is essential In addition bot...

Page 16: ...e hazard During operation below atmospheric pressure a flammable mixture can form inside the system Make sure that air does not enter the system CAUTION Operation outside the application envelope Compressor breakdown A low pressure protection shall be fitted in the suction line to stop the compressor when it operates outside the envelope limits CAUTION Low suction pressure operation Compressor dam...

Page 17: ...m compressors can be brazed in approximately the same manner as any copper tube Recommended brazing material any Silfos material is recommended preferably with a minimum of 5 silver However 0 silver is acceptable For brazing connections where dissimilar or ferric metals are joined a silver alloy rod with a minimum silver content of 30 shall be used being either flux coated or with a separate flux ...

Page 18: ...nly 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: ... 5 to 5 7 Nm A cable strain relief device must be added Cable and wires must be protected against sharp edges 4 2 Electrical installation WARNING Conductor cables Electrical shock Shut off power supply before undertaking any tasks on electrical equipment WARNING Ignition source in a potentially flammable atmosphere Fire hazard In applications with A2L refrigerants the electrical connection of the ...

Page 20: ...nternally connected in star and operated in parallel The voltage cannot be adapted by changing the electrical connections as the motor is only suitable for one voltage The first part winding ie the 2 3 winding on terminals 1 2 3 can be used for part winding start by removing the bridges After a time delay of 1 0 1 seconds the second part winding ie the 1 3 winding on terminals 7 8 9 must be brough...

Page 21: ...1E59371 May 2021 onwards Stream compressors can also be ordered in a version with the CoreSense Protection basic protection system Protection Designation example Copeland compressor electronics N 4MK2 35X AWM D N From S N 21E59371 May 2021 onwards Next Generation CoreSense N 4MK1 35X AWM D N From S N 19L55XXX Dec 2019 to S N 21E59371M May 2021 CoreSense Diagnostics D 4MK1 35X AWM D D From S N 10A5...

Page 22: ... 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 Figure 20 Inside view of the Copeland compressor electronics module with the modular boards Basic features Motor overheat protection High discharge temperature protection Insufficient ...

Page 23: ...ssor electronics Electrical connections wiring diagrams 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 ...

Page 24: ...AGL_Stream_ST_A2L_A1_4M_6M_EN_Rev00 21 Figure 23 Wiring diagram Part winding motors AW for direct on line start Figure 24 Wiring diagram Star Delta motors EW ...

Page 25: ...ol signal CTR2 DP Gateway E1 Heater CH Control oil heater F1 F2 F3 Compressor fuses PTC Motor thermic protection F4 F5 Fan fuses PM Phase monitoring F6 Module and heater fuse PS Power supply F7 Control circuit fuse H1 Diagnosis LED K11 Time relay for part winding if used M2 Fan motor Q11 Compressor contactor Q15 Fan contactor Q12 Compressor contactor Y if Y Δ start Q13 Compressor contactor Δ if Y ...

Page 26: ...tandard protection system for Stream 4M and 6M compressors until December 2019 included CoreSense Diagnostics combines oil and motor protection including the oil differential pressure protection and the observation of the internal thermistor chain It provides advanced protection against faults such as high discharge temperature locked rotor single missing phase voltage imbalance and low voltage Th...

Page 27: ...or module K1 Contactor M1 A5 Compressor terminal box K4 Contactor M1 for 2nd part winding CCH Crankcase heater M21 Fan motor condenser F6 Fuse for control circuit R2 Crankcase heater F7 Fuse for control circuit Y21 Solenoid valve capacity control 1 F8 Fuse for control circuit Y22 Solenoid valve capacity control 2 F10 Thermal protection switch M21 Figure 29 Wiring diagram Part winding motors AW NOT...

Page 28: ...nection F6 Fuse for control circuit M21 Fan motor condenser F7 Fuse for control circuit R2 Crankcase heater F8 Fuse for control circuit Y21 Solenoid valve capacity control 1 F10 Thermal protection switch M21 Y22 Solenoid valve capacity control 2 Figure 30 Wiring diagram Star Delta motors EW NOTE The sensor module inside the terminal box requires a separate 24 V AC power supply ...

Page 29: ...t 11 14 Module malfunction Use the same potential for the power supply L and the switch contact of the control loop 11 14 Stream compressors with P at the end of the description are equipped with a CoreSense Protection device The temperature dependent resistance of the thermistor PTC resistance is used to sense the winding temperature Two chains of three thermistors each connected in series are em...

Page 30: ...A2 OPS2 Oil pressure switch K4 Contactor M1 for second part winding A5 Compressor terminal box M21 Fan motor condenser F6 Fuse for control circuit R2 Crankcase heater F7 Fuse for control circuit Y21 Solenoid valve capacity control 1 F8 Fuse for control circuit Y22 Solenoid valve capacity control 2 F10 Thermal protection switch M21 Y3 Solenoid valve unloaded start Figure 32 Wiring diagram Part wind...

Page 31: ...rankcase is too low The switch must be properly adjusted and tamper proof If the oil differential pressure drops below the minimum acceptable value the compressor will be stopped after a 120 second delay After having solved the problem the control has to be reset manually NOTE Proper oil pressure safety control with an approved switch is a condition of warranty The following oil pressure switches ...

Page 32: ...geover contact from the daisy chain Orange OG Output changeover contact linked to the compressor contactor Pink PK Output changeover contact linked to the alarm Blue BU Power supply output Figure 34 Wiring diagram OPS2 NOTE Where a 5 or 7 wire cable is stated a 4 or 6 wire cable is required In some countries only a 5 or 7 wire cable is available See more information about OPS2 in Technical Informa...

Page 33: ...refrigerant from migrating into the compressor crankcase during standstill periods Crankcase heaters for 4M and 6M compressors are available in 120 V 230 V and 480 V The operation of 120 V and 230 V crankcase heaters is controlled by the Copeland compressor electronics module this is not possible with 480 V heaters The crankcase heater is screwed into a sleeve see Figure 36 The recommended torque ...

Page 34: ...ith a vacuum pump For A2L systems the vacuum pump and all tools have to be approved for A2L refrigerant air mixture The installation should be evacuated down to an absolute pressure of 3 mbar Proper evacuation reduces residual moisture to 50 ppm During the initial procedure suction and discharge shut off valves on the compressor remain closed The installation of adequately sized access valves at t...

Page 35: ...tem is grounded prior to charging with refrigerant especially for systems with A2L refrigerants The system shall be liquid charged through the liquid receiver shut off valve or through a valve in the liquid line The use of a filter drier in the charging line is highly recommended Systems shall be liquid charged on both the high and low sides simultaneously to ensure a positive refrigerant pressure...

Page 36: ... 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 Cycling the compressor for a shorter period than this for instance to maintain very tight temperature control will result in progressive loss of oil and damage to the compressor 5 7 Recommended inverter rang...

Page 37: ...ior to and during work on an A2L refrigerant system to ensure the technician is aware of a potentially toxic or flammable atmosphere Ensure that the leak detection equipment being used is suitable for use with all applicable refrigerants Personnel performing work on a refrigeration system that involves exposing the pipework shall avoid using any ignition source in a way that could lead to a fire o...

Page 38: ...flame Fire hazard Oil refrigerant mixtures are highly flammable Remove all refrigerant before opening the system Avoid working with an unshielded flame in a refrigerant charged system Before opening up a system it is important to remove all refrigerant from both the high and low sides of the system If a brazing torch is then applied to the low side while the low side shell and suction line contain...

Page 39: ... Qualified refrigerants and oils are given in Section 2 4 1 It is not necessary to replace the refrigerant unless contamination for example due to an error such as topping up the system with a non condensable gas or incorrect refrigerant is suspected To verify correct refrigerant composition a sample can be taken for chemical analysis A check can be made during shutdown by comparing the refrigeran...

Page 40: ...inutes The compressor should be returned free of oil and with connections open do not close connections with valves or plugs Collect and secure the oil properly Provide information about the quantity of oil drained from the compressor and its colour Ideally send a good picture Dispose of the oil according to local rules and regulations Use a proper cardboard box package when preparing the compress...

Page 41: ...nt The actual moisture level of POE would be higher than the sight glass indicates This is due to the high hygroscopicity of the POE oil To determine the actual moisture content of the lubricant samples have to be taken from the system and analysed 6 8 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 a...

Page 42: ...ase mountings Ø 25 5 mm 5 Crankcase heater 2 Magnetic plug 1 16 UN 6 Plug oil charge 1 4 3 Oil sight glass 1 4 20 UNC 7 Plug high pressure connection 1 8 4 Plug low pressure connection 1 8 6M 6MM 30X 6MT 35X 6MU 40X 6MI 40X 6MJ 45X 6MK 50X SL Suction line size sweat 6MM 30X 6MT 35X 6MI 40X 6MJ 45X Ø 2 1 8 DL Discharge line size sweat 6MT 35X 6MU 40X 6MJ 45X 6MK 50X Ø 1 5 8 SL Suction line size swe...

Page 43: ...4 In case of replacement of the piston con rod assemblies clean the Torx screws and apply Loctite 2701 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 DISCLAIMER 1 The contents of this publication are pres...

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