Emerson QF125L, QF115LE, QF145L, QF205L, QF175L User Manual

Copeland Scroll

TM

Fusion Compressor

For Refrigeration Applications

User Manual

2 3

About Emerson Climate Technologies

Emerson Climate Technologies, a business segment of EmersonTM, is the world’s leading provider of heating, air­conditioning and refrigeration solutions for residential, industrial, and commercial applications. It combines best-in-class
technology with proven engineering, design, distribution, educational and monitoring services to provide customized,
integrated climate-control solutions for customers worldwide. Emerson Climate Technologies’ innovative solutions,
which include industry-leading brand Copeland Scroll™, improve human comfort, safeguard food and protect the
environment. For more information, visit EmersonClimateAsia.com.

Leading Innovation in Scroll Semi-Hermetic Technology

Emerson realized an increasing need for a versatile, reliable, quiet, lightweight, serviceable compressor for the Cold Room
market and set out to develop a solution for this need. In the development process, the company brought together
70 years of semi-hermetic compressor expertise and 25 years of leadership in scroll technology. What came out of
this endeavor is the newly-designed Copeland Scroll Fusion compressor which combines Emerson’s revolutionary scroll
technology along with the serviceability of a traditional semi-hermetic compressor.

Table of Contents

Safety Information 04

Features and Benefits 05

Nomenclature 05

Operating Envelopes 06

Technical Data 07

Dimensional Drawings 10

Wiring Diagram 14

Contact Lists 24

Emerson Climate Technologies, with our partners,

will provide global solutions to improve human comfort,

safeguard food and protect the environment.

Our Vision:

4 5

• Do not run the compressor with air. When operating

with air, the diesel effect may occur – i.e. the air sucked
in may mix with oil and gas. Such a mixture could
explode due to high temperature in the scroll discharge
port and thereby destroy the compressor and cause
injury or death.

• Open the discharge and suction shut-off valve before

starting the compressor. It is of vital importance that
the discharge shut-off valve is fully opened before the
compressor is started. If the discharge valve is closed or
partly-closed, an unacceptable pressure accompanied
by a proportionately high temperature will develop.

• All local safety regulations must be observed.

Electrical Shock

• Turn off electrical supply and power before servicing.

• Use this equipment only in a grounded system.

• Refer to the applicable system-wiring diagram as shown

in this manual.

Use Personal Safety Equipment

• The new compressor contains oil and dry air under a

pressure of 2.0 bar. While releasing pressure before
installation, the oil drain plug may pop out under
pressure and oil could spurt out.

• Safety gloves, protective clothing, safety boots and

protective eyewear should be worn where necessary.

CAUTION

This icon indicates
instructions to avoid
property damage and
possible personal injury.

WARNING

This icon indicates
instructions to avoid
personal injury and
material damage.

ELECTRICAL SHOCK

This icon indicates
operations with a danger
of electric shock.

Safety Information

CopelandTM brand products semi-hermetic compressors are manufactured according to international safety standards.
Particular emphasis has been placed on the user’s safety. This user manual should be retained throughout the lifetime
of the compressor.

Safety instructions must be followed by all users before compressor operation. Only quali ed and authorized personnel

are permitted to do installation, commissioning and repairing of this compressor. Electrical connections must be made

by quali ed electrical personnel.

Caution

• Make sure that the compressor is upright and there are

no collisions or tilting during transit.

• Use only refrigerants and oils approved by Emerson.

• Make sure that the supply power, voltage, frequency

and phase are exactly as per the speci cations on the

compressor nameplate.

• The dry air inside the compressor should be evacuated

before installation. The compressor comes charged
with dry air at a pressure of 2.0 bar.

Do Not:

• Use the compressor to de-pressurize (to evacuate) a

refrigeration system.

• Start the compressor when it is under vacuum.

• Conduct a test without connecting the compressor to

a system.

• Start the compressor without a refrigerant charge.

• Operate a compressor beyond its approved application

envelope.

• Touch the compressor or pipes when the compressor

is running. High/low temperature may cause burns/
frostbite.

• Release refrigerant into the environment without using

appropriate refrigerant recovery unit and methods
when removing refrigerant from the system.

• When operating the compressor or checking a

refrigeration system leakage, do not exceed operating
pressures out of the application envelope.

ICON DEFINITION

Product Description

Nomenclature

Features and Bene ts

• Emerson’s Copeland Scroll technology

• Serviceability in the  eld

• CoreSense™ Diagnostics

• Integrated vapor injection technology

• Wide range envelope and ef cient operation

• Ability to handle various refrigerants

Copeland ScrollTM Fusion was crafted speci cally to adhere to the refrigeration industry’s need for  eld serviceable solutions. In addition, it
is specially designed for medium and low temperature refrigeration with the ability to handle various refrigerants.

Q F 1 8 5 L E-T W D-2 0 2

Family

Q – Copeland Scroll Fusion

Scroll Displacement

(cc/rev)

Bill of Material

Type of Oil

Code Description

E POE
Blank Mineral Oil

Intelligence and Motor Protection

Code Type

W CoreSense™

Application Range
Code Application Approved Refrigerants
F Full Range R22/R404A

Low/Med/High

Model VariationAMotor Types

Code Phase

T 3

Typical Electrical Codes
Code 60 Hz 50 Hz

D 460-3 380/420-3

7 380-3 –

Note: QF205 has low temperature model only.

Warning

6 7

Operating Envelopes

QF115/QF125/QF145/QF175/QF185

QF205

Nameplate Information

Figure 1. Nameplate and nameplate location

Technical Data

20100-10-20-30-40-50

0

10

20

30

40

50

60

70

Note: 20oC Return Gas Temperature. No Fan Cooling

Condensing Temperature

o

C Condensing Temperature

R404A

R22

-32

o

C Low Temperature

Showcase

-25

o

C Low Temperature

Cold Room

-12

o

C Medium Temperature

Showcase

-7

o

C Medium Temperature

Cold Room

Evaporating TemperatureoC

Model

R22 QF115L QF125L QF145L QF175L QF185L QF205L

R404A QF115LE QF125LE QF145LE QF175LE QF185LE QF205LE

Displacement m

3

/h 19.3 21.1 23.5 26.4 30.4 36.9

MOC

1

TWD 50 Hz A

24 25 27 32 33 25

LRA

2

80 80 80 105 105 105

Motor Speed 50 Hz rpm 2,900

Crankcase Heater

Power W 60

Voltage V 220

Oil Charge

Initial

L

2.66

Recharge 2.54

Service Valves

Suction

in

1-1/8

Discharge 1

Dimensions

Length

mm

675

Width 355

Height 389

Base Mounting

Length

mm

350

Width 200

Bolt M10

Weight

Net

kg

130

Gross 140

Notes: 1. MOC: Maximum Operating Current

2. LRA: Locked Rotor Current

3. QF205LE has low temperature model only

50 Hz

R22/R404A

R22/R404A

R22 / R404A

Evaporating TemperatureoC

-32

o

C Low Temperature

Showcase

-25

o

C Low Temperature

Cold Room

Note: 20oC Return Gas Temperature. No Fan Cooling

20100-10-20-30-40-50

0

10

20

30

40

50

60

70

Note: 20oC Return Gas Temperature. No Fan Cooling

Condensing Temperature

o

C Condensing Temperature

o

C

R404A

R22

-32

o

C Low Temperature

Showcase

-25

o

C Low Temperature

Cold Room

-12

o

C Medium Temperature

Showcase

-7

o

C Medium Temperature

Cold Room

Evaporating TemperatureoC

20100-10-20-30-40-50

0

10

20

30

40

50

60

70

8 9

Mounting Parts

Caution

To minimize vibration and start/stop impulses, fl exible

mountings should be used. Because Copeland Scroll™
Fusion has scroll hermetic compressor level of vibration,
grommets are delivered. A compressor may be rigidly
mounted (i.e. without grommet) - in which case, more
shock and vibration will be transmitted to the frame.

To ensure proper lubrication of moving parts, the
compressor should be installed with four mountings in the
same plane.

Mounting Kit Part Code: 027-0443-00

Installation

Compressor Handling

Deliver y

Please check carefully for unforeseen damage. Any
shortage or damage should be reported to the delivering
carrier. Heavy equipment should be left on its shipping

base until it is moved to the  nal location.

The packing list included with each shipment should be
carefully checked to determine if all parts and equipment

have been received. De ciencies should be immediately
reported in writing to your local Emerson Sales Of ce.

Standard delivery

•Suction and discharge shut-off valves

•Oil charge, oil sight glass

•Oil level sensor

•Oil differential pressure switch

•Oil temperature sensor

•Plate heat exchanger

•Electronic expansion valve

•Crankcase heater

•CoreSense™ Diagnostics

•Holding charge of up to 2.0 bar (dry air)

•For other accessories, please check the packing list

Packaging

All compressors are individually packed. Accessories may
be mounted or delivered loose. Please pay attention to
stacking layers. Stacking in transit should not be more
than two layers and stacking in-store should not be
more than three layers. The packaging must be kept dry
and without damage at all times.

Transport

Compressors should be moved only with mechanical
handling equipment appropriate for the weight
involved. For safety reasons, one lifting eye should be

 tted before moving a compressor (M16x2.0). Please

refer to the illustrations on Figure 3 to see how to lift the
compressor safely.

The compressors must not be lifted by the service valves
or other accessories. Otherwise damage or refrigerant
leaks may occur.

Figure 4. Mounting Kit

Figure 3. Compressor lifting method

Lifting eye

M16x2.0 Thread

Lifting eye

Warning

The compressor is supplied with an initial oil charge.
Mineral oils are approved for R22 application, and Karamay

32BYMO is  lled ex-factory. The standard oil charge for use

with R404A is a polyester (POE) lubricant Emkarate RL 32-

3MAF. In the  eld, the oil level could be topped up with

Mobile EAL Arctic 22 CC if 3MAF is not available.

Do not mix ester oils with mineral oil and/or alkyl
benzene when using chlorine-free (HFC) refrigerants. See

nameplate for original oil charge in litres. A  eld recharge

is from 50-100 ml less than the original charge.

Oil must be drained from both the high and low sides of
the compressor whenever oil is changed.

One disadvantage of POE is that it is far more hygroscopic than
mineral oil (see Figure 2). Brief exposure to ambient air causes

POE to absorb suf cient moisture to make it un t for use in a

refrigeration system. Since POE holds moisture more readily

than mineral oil, it is more dif cult to remove it through the

use of a vacuum. Compressors supplied by Emerson Climate
Technologies contain oil with low moisture content, and
this may rise during the system assembling process. POE oil
should not be exposed to the atmosphere for longer than 15

minutes. A  lter drier is installed to help maintain moisture

level in the oil less than 50 ppm. If oil is charged into a system,
it is recommended to use POE with a moisture content no
higher than 50 ppm.

Maximum Operating Pressures

A high-pressure control with a maximum cut-out
setting of 28 bar(g) is required. The high-pressure cut-

out should have a manual reset feature for the highest
level of system protection.

The low-pressure cut-out should be set as high as possible in
all applications. For medium temperature applications, the
normal minimum is 2.5 bar(g) which corresponds to -10oC
for R22 and -16oC for R404A.

For low temperature applications the minimum cut-out
setting should not be lower than 0.3 bar(g) for a compressor
using R404A, and should not be lower than 0.1 bar(g) for a
compressor using R22. The cut-out point of the LP switch
must be calibrated using an accurate suction

pressure gauge

rather than the scale on the switch which is

provided for rough

setting only.

The Copeland Scroll™ Fusion compressor should
NEVER be allowed to run in a vacuum. The low­pressure cut-out should have a manual reset feature
for the highest level of system protection.

The maximum pressure for leak testing should be no
higher than 22.5 bar(g).

Approved Refrigerants and Oil

Refrigerants R404A and R22 are approved for use with
Copeland Scroll Fusion. Application with other refrigerants
may be possible in special cases. Please contact an Emerson
Climate Technologies Application Engineer.

Caution

Caution

Warning

Caution

Caution

Moisture Absorption

@ 25

o

C & 50% RH

Figure 2. Absorption of moisture in ester oil in comparison to mineral oil in ppm by weight at 25°C and 50% relative humidity.

POE

Mineral Oil

1500

1000

500

50 100 150 200 300250

hours

PPM

10 11

Figure 7. Piping guideline

To disconnect:

• Reclaim refrigerant from both the high and low side of the system. Cut tubing near compressor.

To reconnect:

• Recommended brazing material is one with minimum 45% silver or silver braze material with fl ux. Insert tubing

stubs into  tting and connect to the system with tubing connectors. Follow instructions on Brazing.

Piping Connections

Copeland Scroll™ Fusion has very low vibration
characteristics, so discharge and suction vibration
eliminators should not be necessary in the majority of
installations. The suction, discharge and liquid pipes
should all have sections running close to the compressor
body in parallel with the shaft to absorb any startup or
shutdown torsion. Vibration is much lower than those
found in equivalent piston compressors, and discharge

pulsations are negligible due to the muffl ing effect of the

discharge cover.

Recommended minimum straight length from discharge

valve to  rst bending point is 200 mm, minimum bending

radius is 60 mm.

For ease of service, a minimum space of 500 mm between
top cap surface to casing wall is recommended. Refer to
Figure 7.

Vapor Injection and Liquid Line
Temperatures

Copeland Scroll Fusion compressor package applies
vapor injection technology to improve LT operational

ef ciency and provides a reliable LT envelope. Vapor

injection sub cools the main liquid line and compressor oil
using the integrated plate heat exchanger economizer. The
subcooling of liquid line calls for these recommendations:

1. Liquid line pipe connecting the economizer to the
evaporator expansion valve has to be well insulated
separately. See Liquid Line Insulation for insulation
thickness.

2. The lower liquid line temperature can increase the
evaporator expansion valve capacities. Please follow
valve manufacturers recommended liquid temperature
correction factors for proper selection of evaporator
expansion valve. Refer to catalogue or contact your

local Emerson sales of ce for liquid line temperatures.

No. Connection/Port Size No. Connection/Port Size

1 DPS (differential pressure switch) 3/4”-16UNF 2 Plug low-pressure connection 1/4”-18NPTF

3 Bolt-mounting M10 4 Plug oil drain 1/4”-18NPTF

5 Nut-oil out  tting M16 6 Connector DLT/VIT/VOT/optical OLS/DPS

7 Connector E XV/oil temperature sensor 8 Screw grounding M5

9 Connector optional 10 Nut- oil in  tting M16

11 Liquid out 3/4” 12 Liquid in 3/4”

13 DLT sensor 14 Vapor out temperature sensor

15 Nut- EVI  tting M20 16 EXV Coil

17 Vapor in temperature sensor 18 Optical oil level sensor 7/8”-14UNF

19 Built-in oil screen M20 20 Oil level sight glass

21 Crankcase heater 22 Low pressure port

23 Suction valve 28.7 ID 24 Plug high-pressure connection 1/4”-18NPTF

25 Discharge valve 25.7 ID 26 High pressure port

Notes: SL: Suction Line

DL: Discharge Line

Piping Connection and Compressor
Installation

Brazing

•It is important to fl ow nitrogen through the system

while brazing all joints during the system assembly
process. Nitrogen displaces the air and prevents the
formation of copper oxides in the system.

•Recommended brazing materials: any material is

recommended, preferably with a minimum of 45%
sil ver.

•Be sure valves I.D. and connecting tube O.D. are

clean prior to assembly. If oil  lm is present, wipe with
denatured alcohol, Dichlorotrifl uoroethane or other

suitable solvent.

•Using a double-tipped torch apply heat in Area 1. As

tube approaches brazing temperature, move torch

fl ame to Area 2.

•Heat Area 2 until braze temperature is attained,

moving torch up and down and rotating around tube
as necessary to heat tube evenly. Add braze material to

the joint while moving torch around joint to fl ow braze

material around circumference.

•After brazing material fl ows around joint, move torch to

heat Area 3.

•This will draw the braze material down into the joint.

The time spent heating Area 3 should be minimal.

•As with any brazed joint, overheating may be

detrimental to the  nal results.

•When welding the discharge line connection pipe to the

discharge service valve, the O-ring must be replaced
with a new one. Replacement O-ring can be found on
the accessory bag.

•If the suction and discharge shut-off valve bolts or

rotary valve joint are released while brazing the shut-off
valves, replace the shut-off valve spacer or O-ring. The
non-metal valve spacer and O-ring must be oiled prior
to assembly.

Figure 6. Compressor connection and ports. For identifi cation refer to the Table on the next page.

Dimensional Drawings

Figure 5. Brazing

Compressor

Valve

{

{

Area3Area2Area

1

Connecting

Tube

All dimensions are in mm

12 13

High Pressure and Low Pressure Cut-out
Settings

A high-pressure control with a maximum cut-out setting
of 28 bar(g) is required. The high-pressure cut-out should
have a manual reset feature for the highest level of system
protection.

The low-pressure cut-out should be set as high as
possible in all applications. For medium temperature
applications the normal minimum is 2.5 bar(g) which
corresponds to -10oC with R22 and -16˚C with R404A.
For low temperature applications the minimum cut­out setting should not be lower than 0.3 bar(g) for a
compressor using R404A, and should not be lower than

0.1 bar(g) for a compressor using R22. The cut-out point

of the LP switch must be set using an accurate suction
pressure gauge rather than the scale on the switch which
is provided for rough setting only.

Warning

Copeland Scroll Fusion compressor should NEVER be
allowed to run in a vacuum.

The low-pressure cut-out should have a manual reset
feature for the highest level of system protection.

Liquid Solenoid Valve

A liquid line solenoid valve is effective in keeping liquid
out of the low side when the system cycles on the
thermostat. The solenoid should be installed close to
the expansion valve to keep the main volume of the
liquid line on the high side of the system during off
periods. All solenoid valves leak slightly and may not
be 100% effective in keeping liquid in the high side
during extended shutdown periods which can occur in
cold rooms used for storing seasonal products. In most
cases, opening and closing the solenoid valve when
the compressor starts and stops provides adequate
protection from liquid migration to the compressor
crankcase.

Liquid Line Insulation

Copeland Scroll™ Fusion compressors have many
characteristics found on two-stage piston compressors,
among them, a cold liquid line after the heat exchanger.
The cold liquid is very important for improving the system

capacity and ef ciency, and any increase in liquid line

temperature after the heat exchanger is a system loss.

The liquid line should therefore be insulated with
tightly-fitted closed cell foam. The wall thickness of

the insulation should be at least 10 mm for medium
temperature applications and >15 mm for low
temperature applications. In some low temperature
applications, an uninsulated liquid line could even cause
ice formation, and in humid environments condensation
will occur. The line connecting the receiver to the inlet of
the heat exchanger does not require insulation.

Pumpdown Cycle

Pumpdown cycles are widely applied in systems with
reciprocating compressors. Copeland Scroll Fusion
compressors have inherently superior liquid handling
capability, so a pumpdown at each thermostat cycle is
not recommended. A pumpdown cycle before defrost
will be helpful in reducing the defrost time. Copeland
Scroll Fusion compressors are  tted with a spring loaded
low-leak check valve under the discharge service valve, so
an external check valve should not be necessary. When

pumpdown  nishes, the compressor will stop and contain

a very large volume of high pressure gas in the top cap
area. This refrigerant will quickly leak back to suction and

will cause a signi cant pressure rise that could reset the

low pressure switch. The control circuit should not allow
the compressor to restart; restart should only occur
when the thermostat closes.

Figure 8. Schematic Diagram

High Pressure and Low Pressure switches must be  tted by

the system manufacturer and connected to the pressure
ports shown in the compressor outline drawing on
Figure 6. HP and LP cut-out switches must be electrically
connected as shown in the wiring diagram on Figure 10.

Electrical Installation

The compressor is supplied with a wiring diagram
inside the terminal box cover as shown in Figure

10. Fuses and circuit breakers must be installed in
accordance with local electrical regulations. The
terminal box has an IP54 rating.

Electrical Shock

Conductor Cables! Electrical Shock! Shut Off Power
before High potential testing

The compressor and accessories are tested for leakage to
ground before shipping. Disconnect the control board

PWR and DEMAND connections to avoid any risk of
damage during high potential testing.

Three-phase Motors

All compressors can be started direct on line only.

Control Board Connection

The control board, which is mounted in the terminal
box, monitors the compressor sensors, protects the
compressor, drives the electronic expansion valve and
displays useful information in a seven segment display.
Three red LEDs indicate the status of the CCC (compressor
contractor coil), Alarm and a relay which is connected
to the black terminal block. The board is powered via
a transformer with a nominal output of 16 VAC. When
correctly wired and powered up the board goes through

a self checking routine and displays a fl ashing 0. If the

display is blank, check the power supply on the PWR, the
transparent fuse, the transformer input and output, and the
white fuse. The transparent fuse (250 V 2A) protects the
transformer and other on-board electronic components.
The white fuse (250 V 1A) protects the system control
circuit and the on-board relays from external short circuits.

Wiring Diagram and Wiring Instruction

The position of the 4-Bit Dip Switch in the terminal box and
the recommended wiring diagrams are shown in Figures 9
and 10.

Warning

CoreSense™ Diagnostics

The CoreSense Diagnostics module in the terminal box
monitors several sensors and protects the compressor
from the following malfunctions:

• Reverse rotation by oil differential pressure switch

• Compressor not pumping by oil differential pressure

switch

• High discharge temperature by discharge port

temperature sensor

• High oil temperature by oil temperature sensor

• Low oil level by optical oil level sensor

• Motor overheat by embedded four thermistors

• High pressure – cut-out to be connected by system

manufacturer or installer

• Low pressure – cut-out to be connected by system

manufacturer or installer

Warning

Fusion Control Box Wiring Standard

According to Figure 11, there are 4 joints at the bottom
of the control box. Each joint has dedicated wires to be
assembled. Table 1 explains the function, requirement and
connection method of each joint and wires inside. Wire C,
D and G have been pre-wired in factory. C (Black) and D
(Orange) are for compressor start/stop feedback input,
connecting to “Demand” (Blue) connectors. G (Red) is wire
of power input for Alarm Devices, connecting to “Alarm”

Figure 9. CoreSense™ Diagnostics Board

TXV: Thermostatic Expansion Valve
Fusion Standard BOM

VI: Vapor Injection
EXV: Electronic Expansion Valve

Note: Sight glass is provided and installed as standard ex-factory only in

TWD models

(Orange) connector. The wire size for these three pre­wirings is 18AWG.

Figure 12, on the other hand, shows the recommended
wiring sequence for the control box.

CoreSense Diagnostics module is functioned to record
latest 10 alarm histories. By pushing one button on the
board, the user can check the alarm codes from latest
to distant in sequence on LED display. The display starts
from “H” and ends with “h”. When alarm code is blank,
the display will show “0” instead.

14 15

Figure 10. Wiring Diagram

Wiring Diagram Wiring Instruction

Figure 11. CoreSense™ Wiring and Joints

Step 1: Connect Compressor Motor Wires

Step 3: Connect “CCC” Terminal Wires

Step 4: Connect “Alarm” Terminal Wires

Step 2: Connect “PWR” Terminal Wires

Figure 12. CoreSense™ Recommended Wiring Sequence

L

H G F D BE C A

J

I

4 3 2 1

K

16 17

Crankcase Heaters

Crankcase heaters are very effective in keeping liquid
out of the compressor and are recommended for
all installations. The heater should be on when the
compressor is stopped.

At the time of initial startup, or after any extended pe­riod without power, the heater should be energized 12
hours before starting the compressor. Long off periods
are common in cold stores holding seasonal products, so
it is particularly important to turn on power to the unit
12 hours before restarting after a long idle period. A 220
V 60 W heater is supplied as standard equipment.

Startup and Operation

Leak / Pressure Testing

The compressor has been pressure tested in the factory.
It is not necessary for the system manufacturer or
installer to pressure test or leak-test the compressor
again although the compressor will normally be exposed
to the pressure used as part of system testing. Consider
personal safety requirements and refer to nameplate test
pressures prior to testing.

Figure 14. Sensor Location

Differential Oil
Pressure Sensor

Optical Oil Level Sensor

Discharge Port
Temp. Sensor

Vapor In Temp.

Sensor

Vapor Out

Temp. Sensor

Gland

(Waterproof)

Number

Gland 1 Gland 2 Gland 3 Gland 4

Gland Description

For “PWR” and
“Demand” Connector’s
Wires

For “CCC” Connector’s
Wires

For “Alarm” Connector’s
Wires

For Compressor Motor
Power Supply Wires

One jacket line with two
wires goes through the
joint

One jacket line with two
wires goes through the
joint

One jacket line with two
wires goes through the
joint

One jacket (PVC) line
with four wires goes
through the joint

Wire Function

A(Red) and B(Black):
Controller Power Supply
Input(220-240VAC
50/60Hz)

E(Brown) and F(Blue):
Compressor Diagnostic/
Protection Contact
Output

H(Brown): Output For
Alarm Devices

I, J, K: Compressor
Motor Power Supply

L: Earth Wire

Wire Connection

Wires A and B: “PWR”
(Green) connectors

Wires E and F: “CCC”
(Green) connectors

Wire H: “Alarm”
(Orange) connectors

N/A

Gland Internal

Diameter Range

5-10 mm 5-10 mm 5-10 mm 18-25mm

Jacket Line

Requirement

Internal wire size: 18-20 AWG

Internal wire seize: 8
AWG or above (4 wires
in total)

Recommended wire size: 18 AWG

Rated voltage: 300V/500V

Rated voltage:
600V/1000V

Reverse rotation and lack of pumping have the same
symptoms: the discharge pressure does not rise and
the suction pressure does not fall. If the control module
senses that the differential pressure switch has not closed
after a short time delay, the compressor will stop, an error
message will be displayed on the control board, and a
timer will be started. Three more attempts will be made
to start and if differential pressure is not established, the
compressor will be locked out. The alarm contact will close
and can be used by the installer to turn on a light, sound
a bell, etc. The alarm contact is voltage-free allowing

maximum fl exibility with regard to the type of alarm

device that can be connected. The alarm relay contact is
rated at 250 VAC 1A and 30 VDC 1A.

High discharge temperatures often occur when the
system is short of refrigerant: suction temperature rises,

bubbles form in the liquid line and there is insuf cient

liquid to feed the injection EXV properly. The control
module will stop the compressor, display a fault code and
close the alarm relay. After a time delay, the compressor

will restart. High discharge temperature alarms indicate
a serious system problem, and corrective action must
be taken to avoid long term compressor damage and
possible product loss.

Oil stored in compressor high side oil tank keeps same
pressure and temperature as discharge gas. When oil
flows from oil tank to bearing, it goes through the heat
exchanger in a separate passage for cooling. High oil
temperature could cause to lubricating deterioration
as well as bearing failure. If the oil temperature goes to
its upper limitation, the control module will display an
alarm code. If oil temperature continues to increase up
to a setting point, compressor will be tripped, and could
restart after time delay.

Warning

Oil level is monitored by an optical sensor in the high
side oil sump. If the level falls to the minimum allowable,
a timer will start and the compressor will be stopped if

suf cient oil has not returned to the sump in one minute.

Figure 13. Terminal Box Location For Wiring

Remove Terminal Box Cover
for Customer Wiring

M25, 6 Sensors

M20, EXV Wires

M20, Motor Power

3xM16, Other Wires

Table 1: Glands and Wires

Warning

Warning

Warning

Oil Temperature Sensor

Two restarts will be attempted after short delays, and
if the oil level does not recover, the compressor will
be stopped and locked out. An alarm message will be
displayed and the alarm relay will close.

Motor overheat may occur when the suction gas
temperature is abnormally high, mass flow is low and
discharge pressure is also high. Four thermistors are
embedded in the windings and monitored by the control
module. If the module senses that the winding temperature
is high, it will stop the compressor and start a timer. A
restart will be attempted when the windings have cooled
and the timer has timed out. The compressor will not be
locked out, but the cause of overheat must be investigated
to prevent long term compressor damage. Motor overheat
can be caused by a mechanical problem, which, if not

recti ed quickly, could cause complete compressor failure

and system contamination. Common mechanical problems
that lead to motor trips include worn bearings or worn scroll
sets as a result of overheating.

Oil may not be visible when compressor is stopped. Run
compressor until conditions are stable. Oil level should be
between 1/4 and 3/4 sight glass.

Checking Thermistors and Sensors

Table 2 provides resistance values of the thermistors at
several useful temperatures.

Use a voltage no higher than 3 VDC when testing.

An ice bath can be used at 0oC and boiling water can be
used at 100oC.

Table 2. Thermistors

Location

Temperature

0

o

C 25oC 100oC

Discharge 326 K Ohm 100 K Ohm 7 K Ohm

Oil 326 K Ohm 100 K Ohm 7 K Ohm

Vapor In 28 K Ohm 10 K Ohm 950 Ohm

Vapor Out 28 K Ohm 10 K Ohm 950 Ohm

For the motor thermistor chain, the trip resistance is >

4.5 K Ohms and the reset resistance is < 2.75 K Ohms.
Resistance at room temperature should be < 500 Ohms.
If the oil level switch is not functioning correctly, the
optical part can be easily changed without breaking
into the system. Malfunction is also possible if the lens
is coated by system contaminants. The lens will need to
be removed and cleaned to restore correct operation.

Warning

Caution

Caution

Caution

18 19

Maintenance

Refrigerant Exchange

Quali ed refrigerants and oils were indicated on page 8. It
is not necessary to replace the refrigerant with a new one
unless contamination due to an error such as topping up
the system with an incorrect refrigerant is suspected. To
verify correct refrigerant composition, a sample can be
taken for chemical analysis. A check can be made during
shut down by comparing the refrigerant temperature and
pressure using precision measurements at a location in
the system where liquid and vapor phases are present and
when the temperatures have been stable.

In the event that the refrigerant needs replacing, the charge
should be recovered using a suitable recovery machine.

When R22 in a system with mineral oil is to be replaced
with R407C or R404A, the oil must also be changed.
Please refer to Technical Information “Refrigerant
changeover from HCFC to HFC Refrigerants”.

Replacing Compressor

Rotalock valves should be re-torqued periodically to
ensure that leak tightness is maintained. All gaskets and

 ttings should be inspected for signs of leaks and repaired

if necessary. Electrical connections should be checked for
tightness. All wires should be clamped securely and routed
away from hot surfaces to prevent damage from vibration
and heat.

Some minor repairs like sensor replacement can be done while
the compressor is still under pressure. To replace components
that are under pressure, shut down the compressor, wait 15
seconds, and turn off all power. Close the service valves, recover
the refrigerant and change the faulty component. Evacuate the
compressor only, open the service valves, and recharge the same
quantity of refrigerant that was recovered.

Change the accumulator after replacing a compressor with

a burned out motor. The accumulator oil return ori ce or

screen may be plugged with debris or may become plugged.
This will result in starvation of oil to the new compressor and
a second failure.

I

n the case of a motor burnout, the majority of contaminated

oil will be removed with the compressor. The rest of the oil

is cleaned through the use of suc tion and liquid line  lter

The maximum pressure for leak testing should be no
higher than 22.5 bar(g).

Use only dry nitrogen or dry air for system pressure
testing. DO NOT USE other industrial gases.

If using dry air do not include the compressor in the

pressure test – isolate it  rst. Never add refrigerant to the

test gas (as leak indicator).

System Evacuation and Dehydration

Before the installation is put into operation, remove the
holding charge then evacuate with a vacuum pump.
Proper evacuation reduces residual moisture to 50 ppm.
The installation of adequately sized access valves at the
furthest point from the compressor in the suction and
liquid lines is advisable. To achieve undisturbed operati on,
the compressor valves are closed and the system is
evacuated down to 0.3 mbar / 0.225 Torr. Pressure must
be measured using a vacuum pressure (Torr) gauge on the
access valves and not on the vacuum pump; this serves to
avoid incorrect measurements resulting from the pressure
gradient along the connecting lines to the pump. Then the
compressor must be evacuated. Due to the factory holding
charge of dry air, the compressor is under pressure (about
1-2.5 bar), this is to indicate the compressor does not leak.

Preliminary Check

Discuss installation details with the installer. If possible,
obtain drawings, wiring diagrams, etc. It is ideal to use a
checklist but always check the following:

• Visual check of the electrics, wiring, fuses etc.

• Visual check of the plant for leaks, loose  ttings such

as TXV bulbs etc.

• Compressor oil level

• Calibration of HP and LP switches and any pressure

actuated valves

• Check setting and operation of all safety features and

protection devices

• All valves in the correct running position

• Pressure and compound gauges  tted

• Correctly charged with refrigerant

• Compressor electrical isolator location & position

Never install a system in the  eld and leave it unattended

when it has no charge, a holding charge, or with the service
valves closed without securely electrically locking out the
system. This will prevent unauthorized personnel from
accidentally operating the system and potentially ruining

the compressor by operating with no refrigerant fl ow.

Do not start the compressor while the system is in
a vacuum.

Refrigerant Charging

P

C Board should be powered to close EXV before
charging. The system should be liquid-charged through
the liquid-receiver shut-off valve or through a valve in the

liquid line. The use of a  lter drier in the charging line is

highly recommended. Because scrolls have discharge
check valves, systems should be liquid-charged on both
the high and low sides simultaneously to ensure that a
positive refrigerant pressure is present in the compressor
before it runs.

Charging quantity can be determined by referring to system
discharge and suction pressures. Another very useful
parameter is the liquid line temperature which has been
listed in the Fusion Catalogue. At a measured condensing
temperature and an evaporating temperature, the liquid line
temperature should be around Emerson‘s recommendation
value within +5K tolerance.

The majority of the charge should be placed in the high side

of the system to prevent bearing washout during  rst-time

start on the assembly line or on site.

Do not operate with a restricted suction. Do not operate
with the low-pressure cut-out bridged. Do not operate
compressor without enough system charge to maintain at
least 0.3 bar suction pressure. Allowing pressure to drop
below 0.3 bar for more than a few seconds may overheat
scrolls and cause early drive bearing damage. If the suction
pressure is low on startup, and top up of the refrigerant
charge is required, it is preferable to bleed liquid slowly
into the suction line of a running compressor than to risk
overheating by vapour charging.

The system should be liquid-charged through the liquid­receiver shut-off valve or through a valve in the liquid

line. The use of a  lter drier in the charging line is highly

recommended. The majority of the charge should be
placed in the high side of the system to prevent bearing

washout during  rst-time start on the assembly line.

Initial Startup

It is important to ensure that new compressors are not
subjected to liquid abuse. Turn the crankcase heater on 12
hours before starting the compressor..

Warning

Warning

Warning

driers. A 100% activated alumina suction line  lter drier is

recommended but must be removed after 72 hours. It is highly
recommended that the suction accumulator be replaced if the
system contains one. This is because the accumulator oil-return

ori ce or screen may be plugged with debris or may become

plugged shortly after a compressor failure. This will result in
starvation of oil to the replacement compressor and a second
failure. When a single compressor or tandem is exchanged in

the  eld, it is possible that a major portion of the oil may still

be in the system. While this may not affect the reliability of the
replacement compressor, the extra oil will add to rotor drag
and increase power usage.

Lubrication and Oil Removal

Do not mix up ester oils with mineral oil and/or alkyl
benzene when used with chlorine-free (HFC) refrigerants.
The compressor is supplied with an initial oil charge.
The standard oil charge for use with refrigerants R404A
is a polyolester (POE) lubricant Emkarate RL 32 3MAF.

In the  eld, the oil level could be topped up with Mobil

EAL Arctic 22 CC if 3MAF is not available. The standard
mineral oil for R22 is Karamay 32BYMO. Therefore it is

recommended that a properly sized  lter drier is installed

in all POE systems. This will maintain the moisture level in
the oil to less than 50 ppm.

If the moisture content of the oil in a refrigeration system
reaches unacceptably high levels, corrosion and copper
plating may occur. The system should be evacuated down to

0.3 mbar or lower. If there is uncertainty as to the moisture
content in the system, an oil sample should be taken
and tested for moisture. Sight glass/moisture indicators
currently available can be used with the HFC refrigerants
and lubricants; however, the moisture indicator will just
show the moisture content of the refrigerant. The actual
moisture level of POE would be higher than what the sight
glass indicates.

Oil Additives

Although Emerson Climate Technologies cannot
comment on any specific product, from our own testing
and past experience, we do not recommend the use of
any additives to reduce compressor bearing losses or for
any other purpose. Furthermore, the long term chemical
stability of any additive in the presence of refrigerant, low
and high temperatures, and materials commonly found in
refrigeration systems is complex and difficult to evaluate
without rigorously controlled chemical laboratory testing.

Warning

Warning

Warning

Warning Warning

20 21

The use of additives without adequate testing may result
in malfunction or premature failure of components in the
system and, in specific cases, in voiding the warranty on
the component.

Unbrazing System Components

Oil-refrigerant mixtures are highly fl ammable. Remove all
refrigerant before opening the system. Avoid working with

an unshielded fl ame 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 the
refrigerant charge is removed from a scroll-equipped unit
from the high side only, it is possible for the scrolls to seal,
preventing pressure equalization through the compressor.
This may leave the low side shell and suction line tubing
pressurized. If a brazing torch is applied to the low side while

the low side shell and suction line contain pressure, the
pressurized refrigerant and oil mixture could ignite when

it escapes and comes in contact with the brazing fl ame. To

prevent this occurrence, it is important to check both the
high and low sides with manifold gauges before unbrazing.
Instructions should be provided in appropriate product
literature and assembly (line repair) areas. If compressor
removal is required, the compressor should be cut out of

system instead of unbrazing.

Dismantling and Disposal

Removing oil and refrigerant

•

Do not disperse in the environment.

•

Use the correct equipment and method of removal.

•

Dispose of oil and refrigerant properly.

•

Dispose of compressor properly.

Appendix

Fault Diagnostic Code

Code Description Status Compressor Action

0 ON Normal compressor operation Normal Normal compressor operation

0 FLASH Normal compressor off Normal Normal compressor standby

0 FLASH

If it fl ashes during operation, follow

Emerson Wiring Diagram

Fault EXV will not work so compressor must stop

1 FLASH Motor overheat Fault

Compressor shutdown and automatic reset after 10 min

delay

2 FLASH High discharge temperature Fault

Compressor shutdown and automatic reset after 10 min

delay

3 FLASH Low oil level Fault

Compressor shutdown and automatic reset after 5 min

delay

4 FLASH Low Oil Differential Pressure (HP - LP) Fault

Compressor shutdown and automatic reset after 3 min

delay

5 FLASH Motor Thermistor failure Fault

Compressor shutdown and automatic reset after 10 min

delay

6 FLASH

Discharge port temperature sensor

failure

Fault

Compressor shutdown and automatic reset after 5 min

delay under open/short circuit failure / 10 min delay under

other failure mode

7 FLASH PHE inlet temperature sensor failure Fault Compressor don’t shutdown

8 FLASH PHE outet temperature sensor failure Fault Compressor don’t shutdown

9 FLASH

Oil temperature sensor failure or high oil

temperature

Fault

Compressor don’t shutdown under oil temperature sensor

failure, but oil temperature protection function fail .

Show alarming under high oil temperature, compressor

shutdown if oil temperature continue to increase and

automatic reset after 10 min delay

3 and F Alternate display Less oil level, still OK but soon dangerous Normal Show alarming and continue running. Give precaution

5 to 9 Number FLASH All sensors Fault

When power on 1st time, if any sensor among motor

thermistor, discharge temperature sensor, PHE inlet

temperature sensor, PHE outlet temperature sensor and oil

temperature sensor is wrong, immediately locked

3

Number

FLASH/'.' on

Low oil level/Require manual reset Fault

The 4th low oil level in 1 hour, compressor shutdown and

locked, manual reset (cut off power)

4

Number

FLASH/'.' on

Low differential oil pressure/require

manual reset

Fault

The 4th low differential pressure in 1 hour, compressor

shutdown and locked

• Fault diagnostic code is visible through

a transparent window on the cover

• The code and description can be found

inside of the cover

Warning

22 23

Tool List

Components

Item No.

on Page 11

(Table)

Tool

No.

Tool

Description

Tool

Specication

Torque Value

(N.m)

Pressure Differential Sensor
(Mechanical Part, Lower Cover)

1 8, 29

Metric Hexagon

Socket,

Torque Wrench

1'' 100–110

Three-phase Terminal Plate – 1, 28 10 mm 12–15

PTC Thermistor – 1, 28 10 mm 12–15

Oil Charge Fitting Plug
(Lower Cover)

2 2, 29 18 mm 32–42

Oil Drain Oil Fitting Plug
(Lower Cover)

4 2, 29 18 mm 32–42

Lower Cover Bolts – 3, 29 16 mm 57–68

Check Valve Bolts – 2, 29 18 mm 90–100

Suction Valve Bolts – 2, 29 18 mm 90–100

Oil Drain Oil Fitting Plug
(Oil screen, Top Cap)

19 4, 29 26 mm 130–140

Oil Sight Glass Bolts 20 5 10 mm 7.5–10

Oil Charge Fitting Plug
(Top Cap)

24 2, 29 18 mm 32–42

1, 2, 3, 4, 5, 6

9, 10 11

7

15 18

13,14

16,17

19

20

21

22

23

24

25

26

27

8

12283031

29

Components

Item No.

on Page 11

(Table)

Tool

No.

Tool

Description

Tool

Specication

Torque Value

(N.m)

Oil Level Sensor 18 –

Opening Wrench

29 mm 130–140

Discharge Valve (Rotate) 25 – 50 mm 54–60

Rotalock Nut for Oil Out Tube 5 9 22 mm 25–30

Rotalock Nut for Oil In Tube 10 9 22 mm 25–30

Nuts of Tube-Oil Pulsation – 9 22 mm 25–30

EVI Rotalock Nut 15 11 24 mm 40–50

Pressure Differential Sensor
(Mechanical Part, Lower Cover)

1 12 1'' 100–110

Terminal Box Cover Screws – 13

Cross Screwdriver

H3/6'' 1–2

Screw - CoreSense™ Connect
to Terminal Box

– 14 H3/6'' 1–2

CoreSense Terminal
Connectors

– 30 Voltage Tester M3 N/A

Transformer Bolts – 15, 28

Metric Internal

Hexagon Socket,

Torque Wrench

3 mm 3.40–5.10

Thrust Plate Bolts – 16, 28 4 mm 5.65–7.75

Oil Separator Bolts – 17, 28 4 mm 5–6

Bolt - Terminal Box Connect
to Body

– 18, 28 5 mm 3.40–5.10

Top Cap Bolts – 19, 29 10 mm 80–90

Top Cap and Lower Cover – 22 Flat Chisel – N/A

Top Cap and Lower Cover – 23 Rubber Hammer – N/A

Top Cap – 27 Special Bolts M12 N/A

HVE Holder – 25, 28

Special Socket,

Torque Wrench

– 12–15

Scroll Set – 26 Torque Wrench M10 N/A

Screw-Upper Counterweight – 24 Opening Wrench 13 mm 12–15

For Torque Wrench – 20 Connecting Piece 1/2 to 3/8 N/A

For Socket – 28

Torque Wrench

– 5–25

For Socket – 29 – 30–150

For Torque Wrench – 31 Extension Bars – N/A

—— – 21

Offset Socket Screw

Key Set

1.5 to 10 mm

For Teardown

Only

Asia 02 B04 10 – R00 Issued 07/2016 – GSCAA032

Emerson, CoreSense Diagnostics and Copeland Scroll Fusion are trademarks of Emerson Electric Co. or one of its af liated companies.
©2013 Emerson Climate Technologies, Inc. All rights reserved.

EmersonClimateAsia.com

Asia Pacific Headquarters

Emerson Climate Technologies

Suite No. 2503-8, 25/F,
Exchange Tower, 33 Wang Chiu Road,
Kowloon Bay, Kowloon, Hong Kong
Tel: [phone]
Fax: [phone]

Australia

Emerson Climate Technologies Australia
Pty Ltd

356 Chisholm Road
Auburn NSW 2144, Australia
Tel: [phone]
Fax: [phone]

China - Beijing

Emerson Climate Technologies (Suzhou)
Co. Ltd
Beijing Sales Office

Room 1017 JianWei Building,
66 Nan Lishi Road, XiCheng District,
Beijing, PRC
Tel: [phone]
Fax: [phone]

China - Guangzhou

Emerson Climate Technologies (Suzhou)
Co. Ltd
Guangzhou Sales Office

508-509 R&F Yinglong Plaza,
No. 76 Huangpu Road West,
Guangzhou, PRC
Tel: [phone]
Fax: [phone]

China - Shanghai

Emerson Climate Technologies
(Suzhou) Co. Ltd
Shanghai Sales Office

7F, Emerson Building, 1582 Gumei
Rd, Shanghai, PRC
Tel: [phone]

India - Mumbai

Emerson Climate Technologies (India) Ltd

Delphi B-Wing, 601-602, 6th Floor
Central Avenue, Hiranandani Business Park,
Powai, Mumbai 400076
Tel: [phone]
Fax: [phone]

India - PUNE

Emerson Climate Technologies (India) Ltd

Plot No. 23, Rajiv Gandhi Infotech Park,
Phase - II, Hinjewadi,
Pune 411 057, Maharashtra, India
Tel: [phone]
Fax: [phone]

Indonesia

PT Emerson Indonesia

BSD Taman Tekno 8
Jl. Tekno Widya Blok H10 No 2 & 3
Tangerang Selatan 15314
Indonesia
Tel: [phone]

Fax: [phone]

Japan

Emerson Japan Ltd

Shin-yokohama Tosho Building
No. 3-9-5 Shin-Yokohama, Kohoku-ku
Yokohama 222-0033 Japan
Tel: [phone]
Fax: [phone]

Malaysia

Emerson Electric (Malaysia) Sdn. Bhd.

Level M2, Blk A, Menara PKNS-PJ
Jalan Yong Shook Lin
46050 Petaling Jaya, Selangor, Malaysia
Tel: [phone]
Fax: [phone]

Middle East & Africa

Emerson Climate Technologies

PO Box 26382
Jebel Ali Free Zone – South
Dubai, UAE
Tel: [phone]
Fax: [phone]

Philippines

Emerson Climate Technologies

10/F SM Cyber West Avenue, EDSA cor.
West Avenue, Barangay Bungad, Diliman,
Quezon City 1105 Philippines
Tel: [phone]

South Korea

Emerson Electric Korea Ltd.

3F POBA Gangnam Tower
343, Hakdong-ro, Gangnam-gu,
Seoul 135-820, Republic of Korea
Tel: [phone]
Fax: [phone]

Taiwan

Emerson Electric (Taiwan) Co. Ltd

3F No. 2 DunHua South Road Sec.1,
Taipei (105), Taiwan
Tel: [phone]
Fax: [phone]

Thailand - Bangkok

Emerson Electric (Thailand) Ltd

34th Floor, TCIF Tower,
1858/133, Bangna Trad,
Bangkok 10260, Thailand
Tel: [phone]
Fax: [phone]

Vietnam

Emerson Climate Technologies - Vietnam

Suite 307-308,
123 Truong Dinh St., Dist.3
Ho Chi Minh, Vietnam
Tel: [phone]

Contact Lists

Scan With Your
Smartphone For
More Information