Emerson 4MF-13X, 6MK-50X User manual
Application Guidelines
Copeland Stream
™
Semi-Hermetic Compressors
4MF-13X to 6MK-50X
AGL_Stream_ST_4M_6M_E_Rev01
About these guidelines ............................................................................................... 1
1 Safety instructions ........................................................................................... 1
1.1 Icon explanation ............................................................................................................... 1
1.2 Safety statements ............................................................................................................ 1
1.3 General instructions ......................................................................................................... 2
2 Product description ......................................................................................... 3
2.1 General information about Copeland Stream™ semi-hermetic compressors ................. 3
2.2 Nomenclature ................................................................................................................... 3
2.3 Nameplate information ..................................................................................................... 4
2.4 Application range ............................................................................................................. 4
2.4.1 Qualified refrigerants and oils .............................................................................. 4
2.4.2 Application limits ................................................................................................... 5
2.5 Design features ................................................................................................................ 5
2.5.1 Compressor construction ..................................................................................... 5
2.5.2 Compressor cooling ............................................................................................. 5
2.5.3 Demand cooling ................................................................................................... 5
2.5.4 Unloaded start ...................................................................................................... 5
2.5.5 Capacity control .................................................................................................... 6
2.5.6 Oil pumps ............................................................................................................. 6
2.5.7 Oil pressure .......................................................................................................... 6
2.5.8 Oil circulation ........................................................................................................ 6
2.5.9 Oil level ................................................................................................................. 6
3 Installation ........................................................................................................ 7
3.1 Compressor handling ....................................................................................................... 7
3.1.1 Delivery................................................................................................................. 7
3.1.2 Transport and storage .......................................................................................... 7
3.1.3 Positioning and securing ...................................................................................... 7
3.1.4 Installation location ............................................................................................... 8
3.1.5 Mounting parts ...................................................................................................... 8
3.2 Pressure safety controls .................................................................................................. 8
3.2.1 High-pressure control ........................................................................................... 8
3.2.2 Low-pressure control ............................................................................................ 8
3.2.3 Maximum allowable pressures ............................................................................. 8
3.3 Brazing procedure ............................................................................................................ 9
3.4 Screens ............................................................................................................................ 9
4 Electrical connection ..................................................................................... 10
4.1 General recommendations............................................................................................. 10
4.2 Electrical installation ...................................................................................................... 10
4.2.1 Part-winding motors (YY/Y) – Code A ................................................................ 10
4.2.2 Star / Delta motors (Y/∆) – Code E .................................................................... 10
AGL_Stream_ST_4M_6M_E_Rev01
4.2.3 Terminal box isolators and jumper position........................................................ 11
4.3 Wiring diagrams ............................................................................................................. 11
4.3.1 Compressors with Next Generation CoreSense module ................................... 11
4.3.2 Compressors with CoreSense Protection module ............................................. 14
4.3.3 Compressors with former CoreSense Diagnostics module ............................... 16
4.4 Protection devices .......................................................................................................... 17
4.5 Next Generation CoreSense™ ...................................................................................... 18
4.5.1 Next Gen CoreSense specifications .................................................................. 18
4.5.2 Next Gen CoreSense features ........................................................................... 18
4.6 CoreSense™ Protection ................................................................................................ 19
4.6.1 Motor protection ................................................................................................. 19
4.6.2 Oil pressure control ............................................................................................ 20
4.7 CoreSense™ Diagnostics (until December 2019 included) .......................................... 21
4.8 Crankcase heaters ......................................................................................................... 22
5 Starting up & operation.................................................................................. 24
5.1 Leak test......................................................................................................................... 24
5.2 System evacuation ......................................................................................................... 24
5.3 Preliminary checks – Pre-starting .................................................................................. 24
5.4 Charging procedure ....................................................................................................... 24
5.5 Initial start-up ................................................................................................................. 25
5.6 Minimum run time .......................................................................................................... 25
5.7 Recommended inverter range ....................................................................................... 25
6 Maintenance & repair ..................................................................................... 26
6.1 Provisions of legislation & leak check requirements ...................................................... 26
6.2 Exchanging the refrigerant ............................................................................................. 27
6.3 Replacing a compressor ................................................................................................ 27
6.4 Lubrication and oil removal ............................................................................................ 27
6.5 Oil additives ................................................................................................................... 28
6.6 Unbrazing system components ..................................................................................... 28
7 Dismantling & disposal .................................................................................. 28
Appendix 1: Stream compressor connections ........................................................ 29
Appendix 2: Tightening torques in Nm .................................................................... 30
Disclaimer .................................................................................................................. 30
AGL_Stream_ST_4M_6M_E_Rev01 1
About these guidelines
The purpose of these application guidelines is to provide guidance in the application of Copeland™
Stream™ semi hermetic compressors 4M* and 6M*. They are intended to answer the questions
raised while designing, assembling and operating a system with these products.
Besides the support they provide, the instructions listed herein are also critical for the proper and
safe functioning of the compressors. The performance and reliability of the product may be impacted
if the product is not used according to these guidelines or is misused.
These application guidelines cover stationary applications only. For mobile applications, contact
Application Engineering as other considerations may apply.
1 Safety instructions
Copeland™ semi-hermetic compressors are manufactured according to the latest European safety
standards. Particular emphasis has been placed on the user’s safety.
These compressors are intended for installation in systems according to the Machinery Directive MD
2006/42/EC. They may be put to service only if they have been installed in these systems according
to instructions and conform to the corresponding provisions of legislation. For relevant standards
please refer to the Manufacturer’s Declaration, available at www.climate.emerson.com/en-gb.
These instructions should be retained throughout the lifetime of the compressor.
You are strongly advised to follow these safety instructions.
1.1 Icon explanation
WARNING
This icon indicates instructions to
avoid personal injury and material
damage.
CAUTION
This icon indicates instructions to avoid
property damage and possible
personal injury.
High voltage
This icon indicates operations with a
danger of electric shock.
IMPORTANT
This icon indicates instructions to avoid
malfunction of the compressor.
Danger of burning or frost burn
This icon indicates operations with a
danger of burning or frost burn.
NOTE
This word indicates a recommendation
for easier operation.
Explosion hazard
This icon indicates operations with a
danger of explosion.
1.2 Safety statements
▪ Refrigerant compressors must be employed only for their intended use.
▪ Only qualified and authorized HVAC or refrigeration personnel are permitted to install,
commission and maintain this equipment.
▪ Electrical connections must be made by qualified electrical personnel.
▪ All valid standards for connecting electrical and refrigeration equipment must be
observed.
▪ The national legislation and regulations regarding personnel protection must be observed.
Use personal safety equipment. Safety goggles, gloves,
protective clothing, safety boots and hard hats should be worn
where necessary.
2 AGL_Stream_ST_4M_6M_E_Rev01
1.3 General instructions
WARNING
System breakdown! Personal injuries! Never install a system in the field
and leave it unattended when it has no charge, a holding charge, or with the
service valves closed without electrically locking out the system.
System breakdown! Personal injuries! Only approved refrigerants and
refrigeration oils must be used.
WARNING
High shell temperature! Burning! Do not touch the compressor until it has
cooled down. Ensure that other materials in the area of the compressor do not
get in touch with it. Lock and mark accessible sections.
CAUTION
Overheating! Bearing damage! Do not operate compressor without
refrigerant charge or without it being connected to the system.
CAUTION
Contact with POE! Material damage! POE lubricant must be handled
carefully and the proper protective equipment (gloves, eye protection, etc.)
must be used at all times. POE must not come into contact with any surface
or material that it might damage, including without limitation, certain polymers,
eg, PVC/CPVC and polycarbonate.
IMPORTANT
Transit damage! Compressor malfunction! Use original packaging. Avoid
collisions and tilting.
AGL_Stream_ST_4M_6M_E_Rev01 3
2 Product description
2.1 General information about Copeland Stream™ semi-hermetic compressors
These 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 13 hp to 50 hp.
Model
Nominal
horsepower
[cv]
Displa-
cement
[m3/h]
High
temperature
(1)
Medium
temperature
(2)
Low
temperature
(3)
Net
weight
[kg]
Footprint
[mm]
Cooling
capacity
[kW]
COP
Cooling
capacity
[kW]
COP
Cooling
capacity
[kW]
COP
R134a
R448A / R449A
R448A / R449A
4MF-13x
13
62
33.20
3.28
28.00
2.17
8.60
1.37
177
381 x 305
4MA-22X
22
34.60
3.41
31.80
2.54
8.24
1.34
178
4ML-15X
15
71
39.70
3.30
36.10
2.40
10.90
1.43
180
4MH-25X
25
39.90
3.30
36.20
2.44
9.93
1.31
187
4MM-20X
17
78
43.50
3.28
39.40
2.36
12.25
1.44
182
4MI-30X
27
43.70
3.30
41.00
2.48
11.30
1.38
188
4MT-22X
22
88
49.30
3.26
44.50
2.36
14.00
1.45
183
4MJ-33X
30
48.60
3.30
45.10
2.43
12.70
1.38
190
4MU-25X
25
99
55.10
3.20
49.40
2.28
14.95
1.39
186
4MK-35X
32
54.50
3.17
50.70
2.37
14.40
1.35
202
6MM-30X
27
120
65.80
3.21
59.00
2.32
18.35
1.40
215
6MI-40X
35
64.70
3.16
61.90
2.48
17.85
1.38
219
6MT-35X
32
135
73.60
3.17
65.30
2.28
20.60
1.41
221
6MJ-45X
40
72.60
3.16
69.10
2.43
20.40
1.42
223
6MU-40X
40
153
81.10
3.07
76.30
2.41
23.20
1.42
225
6MK-50X
50
80.70
3.05
76.40
2.39
22.10
1.35
230
1)
R134a: Evaporating 5 °C, condensing 50 °C, suction superheat 10 K, subcooling 0 K
2)
R448A / R449A: Evaporating -10 °C, condensing 45 °C, suction gas temperature 20 °C, subcooling 0 K
3)
R448A / R449A: Evaporating -35 °C, condensing 40 °C, suction gas temperature 0 °C, subcooling 0 K
Table 1: Stream compressors range and performance
Stream compressors are suitable for a wide range of applications in the form of either single
compressors, condensing units or as multi-compressor equipment.
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 with standard equipment and
accessories only.
2.2 Nomenclature
The model designation contains the following technical information about Stream compressors:
4 AGL_Stream_ST_4M_6M_E_Rev01
2.3 Nameplate information
All important information for identification of the compressor is printed on the nameplate located
below the compressor oil pump. The type of refrigerant used should be stamped on the nameplate
by the installer.
Figure 1: Nameplate location
The year and month of production are shown as part of the serial number (Jan = A, Feb = B, … Dec
= L).
2.4 Application range
2.4.1 Qualified refrigerants and oils
WARNING
Use of R450A and R513A refrigerants! Risk of compressor damage!
Refrigerant migration of R450A or R513A into the compressor crankcase
could cause low oil viscosity, which could lead to compressor damage. When
using R450A or R513A it is critical to meet the following requirements:
▪ maintain adequate superheat settings with a minimum superheat of
8-10K;
▪ no liquid refrigerant migration into the compressor at any time, especially
during standstill, during or after defrost, or after reverse mode for example
in heat pumps;
▪ pumpdown is recommended;
▪ the use of a crankcase heater is mandatory;
▪ retrofit to R450A and R513A is only allowed for compressors which are
approved for these refrigerants.
Contact Application Engineering for any further information.
IMPORTANT
It is essential that the glide of refrigerant blends (primarily R407C) is carefully
considered when adjusting pressure and superheat controls.
Oil recharge values can be taken from Copeland™ brand products Select software available at
www.climate.emerson.com/en-gb.
Qualified refrigerants
R134a, R404A, R407A, R407C,
R407F, R448A, R449A, R450A,
R507, R513A
R22
Copeland brand
products standard oils
Emkarate RL 32 3MAF
Suniso 3 GS
Servicing oils
Emkarate RL 32 3MAF
Mobil EAL Arctic 22 CC
Shell 22-12, Suniso 3 GS
Fuchs Reniso KM 32, Capella WF32
Table 2: Qualified refrigerants and oils for recharging and topping up
AGL_Stream_ST_4M_6M_E_Rev01 5
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).
To top up:
▪ During commissioning, planned maintenance or servicing, add oil so that the compressor oil level
is between min ¼ and max ¾ of sight glass.
2.4.2 Application limits
For application envelopes please refer to Copeland brand products Select software at
www.climate.emerson.com/en-gb.
2.5 Design features
2.5.1 Compressor construction
All compressors are fitted with Stream valve plates which cannot be dismantled. To maintain the high
capacity of these compressors in case of exchange, the correct valve-plate-to-body gasket must
always be selected.
Each cylinder head has 2 plugged 1/8" - 27 NPTF
tapped holes for connecting high-pressure
switches.
These high-pressure switches must be calibrated
and tested before putting the compressor into
service. They must stop the compressor if the
allowable pressure is exceeded.
The complete cylinder head is under discharge
pressure.
Figure 2
2.5.2 Compressor cooling
Compressor motors must always be cooled, and cylinder head cooling may also be needed at certain
operating conditions.
All Stream compressors are suction gas-cooled. With suction gas-cooled compressors, the motor is
cooled by refrigerant gas that is led over the motor. An additional fan may be required depending
upon the operating conditions – see Copeland brand products Select software at
www.climate.emerson.com/en-gb.
2.5.3 Demand cooling
"Demand Cooling" as the term implies means liquid refrigerant injection on demand.
For low temperature applications with R407F, R407A, R448A, R449A and R22, Demand Cooling
can be required on the following compressors:
4MF-13X 4ML-15X 4MM-20X 4MT-22X 4MU-25X
6MM-30X 6MT-35X 6MU-40X
NOTE: R22 is no longer allowed for new refrigeration systems in Europe.
2.5.4 Unloaded start
With direct starting the motor of a compressor is switched directly into the mains by means of a
switch. The resulting breakaway starting current amounts to multiple times the rated motor current
operating maximum, without consideration being given to transient phenomena.
In the case of high-powered motors the breakaway starting currents become so large that they lead
to disruptive voltage dips in the mains. The compressors that are subject to current limitation must
therefore by all means be equipped with starting load reduction to guarantee perfect starting even
when the voltages amount to less than approximately 85% of the voltage on the nameplate.
6 AGL_Stream_ST_4M_6M_E_Rev01
2.5.5 Capacity control
For 4M* and 6M* compressors a mechanical capacity control is available. The system used is
blocked suction. Be aware that unloaded operation changes the application range of the compressor.
NOTE: For the application range of compressors with capacity control, refer to Technical
Information D7.21.2 "Stream Semi-Hermetic Compressor Capacity Control".
2.5.6 Oil pumps
The oil pumps used for Stream compressors are independent of their rotating direction.
On compressors with Next Generation CoreSense™ (-N) or formerly delivered with CoreSense™
Diagnostics (-D), the oil pump integrates an electronic switch to ensure the oil pressure safety
functionality.
Compressors with CoreSense™ Protection (-P) are designed to accommodate fittings for an OPS2,
FD-113ZU or Sentronic oil safety system, or a standard oil pressure switch (OPS2 oil sensor included
in the oil pump).
2.5.7 Oil pressure
Normal oil pressure is between 1.05 and 4.2 bar higher than crankcase pressure. Net oil pressure
can be read by connecting two pressure gauges to the compressor and comparing the readings.
One gauge should be connected to the oil pump. The second gauge should be connected to the
crankcase (T-fitting instead of plug on the compressor crankcase) or the suction service valve.
During irregular operating conditions, eg, a blockage of the suction filter, the pressure measured at
the suction shut-off valve of the compressor may differ widely from that measured at the crankcase.
Therefore pressure drops have to be avoided.
2.5.8 Oil circulation
Oil returns with the suction gases through a suction strainer and separates in the motor chamber
reaching the crankcase by way of oil return relief valve in the partition between motor housing and
crankcase. This relief valve closes on compressor start-up due to the pressure difference arising
between 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 reduces the pressure difference by means of a very small bore in the plate of the
valve so slowly that oil foams less and only limited oil/refrigerant foam is transferred to the oil pump.
Four-cylinder compressors have one crankcase ventilating valve on the left cylinder bank whereas
six-cylinder compressors have two ventilating valves on the left and right cylinder banks.
2.5.9 Oil level
All compressors are delivered with sufficient oil for normal operation – see Table 2. The optimum oil
level should be checked by operating the compressor until the system is stable and then comparing
the sight glass reading with the appropriate diagram below. The oil level should be min ¼ and max
¾ of the sight glass.
For service compressors when an oil regulator is used the oil level should be min ¼ and max ¾ of
the sight glass. The level can also be checked within 10 seconds of compressor shutdown.
For 4M* and 6M* compressors a higher oil level may be accepted when an oil regulator is in use
because the oil separator will reduce excessive oil circulation.
Figure 3: Sight glass reading on 4M* and 6M* compressors
AGL_Stream_ST_4M_6M_E_Rev01 7
3 Installation
WARNING
High pressure! Injury to skin and eyes possible! Be careful when opening
connections on a pressurized item.
3.1 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:
▪ Suction and discharge shut-off valves
▪ Oil charge, oil sight glass
▪ Mounting kit
▪ Next Generation CoreSense™, CoreSense™ Diagnostics or CoreSense™ Protection module
▪ Holding charge up to 2.5 bar(g) (dry air)
3.1.2 Transport and storage
WARNING
Risk of collapse! Personal injuries! Move compressors only with
appropriate mechanical or handling equipment according to weight. Keep in
the upright position. Respect stacking loads according to Figure 4. 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 4: Maximum stacking loads for transport and storage
NOTE: The compressor is pre-charged with dry air to avoid any moisture contamination.
3.1.3 Positioning and securing
IMPORTANT
Handling damage! Compressor malfunction! Only use the lifting eyes
whenever the compressor requires positioning. Using discharge or suction
connections for lifting may cause damage or leaks.
If possible, the compressor should be kept horizontal during handling.
For safety reasons two lifting eyes should be fitted before moving a compressor (½" - 13 UNC).
Otherwise refer to drawings on Figure 5 to see how to apply other lifting methods.
4M* 6M*
max. 220 kg max. 260 kg
Figure 5
8 AGL_Stream_ST_4M_6M_E_Rev01
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.
3.1.5 Mounting parts
To minimize vibration and start/stop impulses flexible mounting should be used. For this purpose,
one set of spring mounting parts for each of the Stream models is delivered with each 4M* and 6M*
compressor.
Due to differences in weight (cylinder / motor side), different springs have to be used on both sides.
Springs have different colours for easier identification: violet on motor side and orange on cylinder
side.
Operational position Transport position
Figure 6: Position of vibration dampers during transport and operation
When Stream compressors are mounted in racks rubber mounting parts should be used.
A compressor may be rigidly mounted, ie, without 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, both vibration/shock and mechanical stress to compressor can be avoided by using
rubber mounting parts.
If the installation requires a very high level of vibration absorption, additional vibration absorbers –
available on the market – can be fitted between the rails and the foundation.
3.2 Pressure safety controls
3.2.1 High-pressure control
A high-pressure control with a maximum cut-out setting of 28.8 bar(g) is required.
The high-pressure cut-out should have a manual reset feature for the highest level of system
protection.
3.2.2 Low-pressure control
The normal minimum cut-out setting is 0.1 bar(g) for R404A.
The low-pressure cut-out should have a manual reset feature for the highest level of system
protection.
3.2.3 Maximum allowable pressures
The maximum allowable pressures according to EN 12693 shown on the compressor nameplate are
obligatory and must not be exceeded.
▪ High-pressure side (HP): 28.0 bar (g) (up to S/N 14K46143M)
32.5 bar (g) (from S/N 14K46144M onwards)
▪ Low-pressure side (LP): 22.5 bar
Transport clamp
Loading...