Application Guidelines
Copeland Stream™ Semi-Hermetic Compressors
4MF-13X to 4MK-35X & 6MM-30X to 6MK-50X
C6.3.1/0116-0716/E
1 Safety instructions ............................................................................................ 1
1.1 Icon explanation ................................................................................................................. 1
1.2 Safety statements .............................................................................................................. 1
1.3 General instructions ........................................................................................................... 1
2 Product description .......................................................................................... 3
2.1 Common information about Copeland Stream™ semi-hermetic compressors ................. 3
2.2 About these guidelines ....................................................................................................... 3
2.3 Nomenclature ..................................................................................................................... 3
2.4 Nameplate information ....................................................................................................... 4
2.5 Application range ............................................................................................................... 4
2.5.1 Qualified refrigerants and oils ................................................................................ 4
2.5.2 Application limits ..................................................................................................... 5
2.6 Design features .................................................................................................................. 5
2.6.1 Compressor construction ....................................................................................... 5
2.6.2 Compressor cooling ............................................................................................... 5
2.6.3 Demand cooling ..................................................................................................... 5
2.6.4 Unloaded start ........................................................................................................ 5
2.6.5 Capacity control ...................................................................................................... 5
2.6.6 Oil pumps ............................................................................................................... 6
2.6.7 Oil pressure ............................................................................................................ 6
2.6.8 Oil circulation .......................................................................................................... 6
2.6.9 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
C6.3.1/0116-0716/E
4.3 Wiring diagrams ............................................................................................................... 10
4.3.1 Wiring diagram for part-winding motors (AW…) .................................................. 11
4.3.2 Wiring diagram for Star / Delta motors (EW…) .................................................... 13
4.4 Protection devices ............................................................................................................ 15
4.5 CoreSense™ Diagnostics ................................................................................................ 15
4.6 CoreSense™ Protection .................................................................................................. 16
4.6.1 Motor protection ................................................................................................... 16
4.6.2 Oil pressure control .............................................................................................. 17
4.7 Crankcase heaters ........................................................................................................... 18
5 Starting up & operation................................................................................... 19
5.1 Leak test........................................................................................................................... 19
5.2 System evacuation ........................................................................................................... 19
5.3 Preliminary checks – Pre-starting .................................................................................... 19
5.4 Charging procedure ......................................................................................................... 19
5.5 Initial start-up ................................................................................................................... 20
5.6 Minimum run time ............................................................................................................ 20
5.7 Recommended inverter range ......................................................................................... 20
6 Maintenance & repair ...................................................................................... 21
6.1 Exchanging the refrigerant ............................................................................................... 21
6.2 Replacing a compressor .................................................................................................. 21
6.3 Lubrication and oil removal .............................................................................................. 21
6.4 Oil additives ..................................................................................................................... 22
6.5 Unbrazing system components ....................................................................................... 22
7 Dismantling & disposal ................................................................................... 22
Appendix 1: Stream compressor connections ......................................................... 23
Appendix 2: Tightening torques in Nm ..................................................................... 24
Disclaimer ................................................................................................................... 24
C6.3.1/0116-0716/E 1
1 Safety instructions
Copeland™ brand products 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 on request.
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 frostbite
This icon indicates operations with a
danger of burning or frostbite.
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.
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 compressors without
refrigerant charge or without being connected to the system.
Safety
instruction
s
Product
description
Installation
Electrical
connection
Starting up &
operation
Maintenance &
repair
Dismantling &
disposal
2 C6.3.1/0116-0716/E
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 might be harmed by POE, including without limitation, certain
polymers, eg,. PVC/CPVC and polycarbonate.
IMPORTANT
Transit damage! Compressor malfunction! Use original packaging. Avoid
collisions and tilting.
C6.3.1/0116-0716/E 3
2 Product description
2.1 Common 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.
Cooling
capacity
(kW)
COP
-
Cooling
capacity
(kW)
COP
-
Cooling
capacity
(kW)
COP
-
4MF-13X 13 33.20 3.28 31.60 2.29 10.65 1.43 177
4MA-22X 22 34.60 3.41 32.70 2.39 10.45 1.44 178
4ML-15X 15 39.70 3.30 38.40 2.31 13.30 1.48 180
4MH-25X 25 39.90 3.30 38.50 2.37 12.40 1.44 187
4MM-20X 17 43.50 3.28 42.00 2.31 15.10 1.49 182
4MI-30X 27 43.70 3.30 42.80 2.37 14.40 1.47 188
4MT-22X 22 49.30 3.26 47.60 2.31 16.95 1.48 183
4MJ-33X 30 48.60 3.30 47.60 2.38 16.15 1.49 190
4MU-25X 25 55.10 3.20 53.10 2.27 18.60 1.45 186
4MK-35X 32 54.50 3.17 53.50 2.31 18.25 1.45 202
6MM-30X 27 65.80 3.21 64.20 2.30 22.70 1.45 215
6MI-40X 35 64.70 3.16 64.60 2.34 21.90 1.44 219
6MT-35X 32 73.60 3.17 72.40 2.30 25.60 1.47 221
6MJ-45X 40 72.60 3.16 72.40 2.32 24.30 1.45 223
6MU-40X 40 81.10 3.07 81.40 2.29 28.40 1.44 225
6MK-50X 50 80.70 3.05 80.90 2.29 27.30 1.41 230
Footprint
(mm)
Medium temperature
2)
High temperature
1)
Low temperature
3)
Displacement
(m3/h)
Nominal
horsepower
hp
Model
62
381 x 305
717888
99
120
135
153
R404A
R134a
R404A
Net
weight
(kg)
1)
R134a Evaporating 5°C, condensing 50°C, suction superheat 10K, subcooling 0K
2)
R404A Evaporating -10°C, condensing 45°C, suction gas temperature 20°C, subcooling 0K
3)
R404A Evaporating -35°C, condensing 40°C, suction gas temperature 20°C, subcooling 0K
Table 1: Stream compressors range and performance
Stream 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.
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 About these guidelines
These guidelines are intended to enable users to ensure the safe installation, starting, operation
and maintenance of semi-hermetic compressors. They are not intended to replace the system
expertise available from system manufacturers.
2.3 Nomenclature
The model designation contains the following technical information about Stream compressors:
Safety
instruction
s
Product
description
Installation
Electrical
connection
Starting up &
operation
Maintenance &
repair
Dismantling &
disposal
4 C6.3.1/0116-0716/E
2.4 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
The year and month of production are shown as part of the serial number (Jan = A, Feb = B, …
Dec = L).
2.5 Application range
2.5.1 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.emersonclimate.eu.
Qualified refrigerants
R134a, R22, 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
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.
C6.3.1/0116-0716/E 5
2.5.2 Application limits
For application envelopes please refer to Copeland brand products Select software at
www.emersonclimate.eu.
2.6 Design features
2.6.1 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 highpressure 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
2.6.2 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.emersonclimate.eu).
2.6.3 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.
2.6.4 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.
2.6.5 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 the compressors with capacity control, refer to
Technical Information D7.21.2 "Stream semi-hermetic compressor capacity control".
Safety
instruction
s
Product
description
Installation
Electrical
connection
Starting up &
operation
Maintenance &
repair
Dismantling &
disposal
6 C6.3.1/0116-0716/E
2.6.6 Oil pumps
The oil pumps used for Stream compressors are independent of their rotating direction.
On compressors delivered with CoreSense™ Diagnostics (-D), the oil pump integrates the
electronic switch for integrating 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).
2.6.7 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.
2.6.8 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.
2.6.9 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
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