AE4-1396 R3 September 2014 Application Guidelines for Copeland

AE4-1396  R3 September 2014 Application Guidelines for Copeland
AE4-1396 R3
AE4-1396 R3
September 2014
Application Guidelines for Copeland™
Semi-Hermetic Compressors for Transcritical CO2 Applications
Table of Contents
Safety
Safety Instructions.................................................... 2
Safety Icon Explanation............................................ 2
Instruction Pertaining to Risk of Electrical Shock,
Fire, or Injury to Persons.......................................... 3
Safety Statements.................................................... 3
Startup and Operation.............................................. 7
Leak Test................................................................. 7
System Evacuation.................................................. 7
Preliminary Checks – Pre-Starting.......................... 7
Charging Procedure................................................ 7
Initial Start-Up.......................................................... 8
Minimum Run Time.................................................. 8
Recommended Inverter Range............................... 8
Introduction............................................................... 4
Nomenclature.......................................................... 4
Application Range................................................... 4
Qualified Refrigerants and Oils............................ 4
Application Limits................................................. 4
Design Features...................................................... 4
Compressor Construction.................................... 4
Compressor Cooling............................................ 4
Oil Lubrication...................................................... 4
Oil Level............................................................... 5
Maintenance and Repair.......................................... 8
Exchanging the Refrigerant..................................... 8
Replacing a Compressor......................................... 8
Lubrication and Oil Removal................................... 8
Oil Additives............................................................. 9
Unbrazing System Components.............................. 9
Dismantling and Disposal........................................ 9
Figures and Tables
4MTLS Name Plate................................................... 10
CO2 Envelope........................................................... 10
4MTLS Sight Glasses................................................ 10
Sight Glass Oil Level..................................................11
Stacking Configuration...............................................11
Lifting Eyes.................................................................11
Mounting Springs...................................................... 12
Terminal Box Insulator............................................... 12
Safety Valve Location................................................ 12
Compressor Electrical Wiring Configuration.............. 13
Figure 11 – Electronics Locations.............................. 14
Wiring Diagram for CoreSense................................. 14
Crankcase Heater..................................................... 14
Oil Sensor.................................................................. 14
Oil Dilution Graph...................................................... 14
4MTLS Model Selection............................................ 15
Qualified Refrigerants and Oils................................. 15
Oil Sensor Kit............................................................ 15
Crankcase Heater Kits.............................................. 15
Installation................................................................. 5
Compressor Handling.............................................. 5
Delivery................................................................ 5
Transport and Storage......................................... 5
Positioning and Securing..................................... 5
Installation Location............................................. 5
Mounting Parts..................................................... 5
Pressure Safety Controls......................................... 6
Safety Valve......................................................... 6
Maximum Operating Pressures........................... 6
Shut Off Valve Properties........................................ 6
Screens................................................................... 6
Electrical Connection............................................... 6
General Recommendations..................................... 6
Electrical Installation................................................ 6
Three Phase Motors............................................ 6
Part-Winding Motor (Yy/Y) – Code A................... 6
Wiring Diagrams.................................................. 6
Terminal Box Isolator........................................... 6
Breaker................................................................ 6
CoreSense Protection............................................. 7
Crankcase Heaters.................................................. 7
© 2014 Emerson Climate Technologies, Inc.
Appendix 1: CO2 Transcritical Compressor
Connections........................................ 16
Appendix 2: 4MTLS Tightening Torques.................. 17
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Safety Instructions
Copeland™Scroll
compressors
are manufactured
according
to the to
latest
U.S. and
SafetySafety
Standards.
™
Copeland
compressors
are manufactured
according
the latest
U.S.European
and European
Particular
emphasis
has
been
placed
on
the
user's
safety.
Safety
icons
are
explained
below
and
safety
Standards. Particular emphasis has been placed on the user's safety. Safey icons are explained below
instructions
applicable
to
the
products
in
this
bulletin
are
grouped
on
page
3.
These
instructions
should
and safety instructions applicable to the products in this bulletin are grouped on Page 3. These
be retained throughout
the lifetime
of the compressor.
strongly advised
to follow advised
these safety
instructions
should be retained
throughout
the lifetime You
of theare
compessor.
You are strongly
instructions.
to follow these safety instructions.
Safety Icon Explanation
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result
in death or serious injury.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION
CAUTION, used with the safety alert symbol, indicates a hazardous
situation which, if not avoided, could result in minor or moderate injury.
NOTICE
CAUTION
© 2014 Emerson Climate Technologies, Inc.
NOTICE is used to address practices not related to personal injury.
CAUTION, without the safety alert symbol, is used to address practices
not related to personal injury.
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Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons
WARNING
ELECTRICAL SHOCK HAZARD
• Disconnect and lock out power before servicing.
• Discharge all capacitors before servicing.
• Use compressor with grounded system only.
• Molded electrical plug must be used when required.
• Refer to original equipment wiring diagrams.
•
• Failure to follow these warnings could result in serious personal injury.
WARNING
PRESSURIZED SYSTEM HAZARD
• System contains refrigerant and oil under pressure.
• Remove refrigerant from both the high and low compressor side before
removing compressor.
•
• Never install a system and leave it unattended when it has no charge,
a holding charge, or with the service valves closed without electrically
locking out the system.
• Use only approved refrigerants and refrigeration oils.
• Personal safety equipment must be used.
• Failure to follow these warnings could result in serious personal injury.
WARNING
BURN HAZARD
• Do not touch the compressor until it has cooled down.
• Ensure that materials and wiring do not touch high temperature areas of
the compressor.
• Use caution when brazing system components.
• Personal safety equipment must be used.
• Failure to follow these warnings could result in serious personal injury or
property damage.
CAUTION
COMPRESSOR HANDLING
• Use the appropriate lifting devices to move compressors.
• Personal safety equipment must be used.
• Failure to follow these warnings could result in personal injury or
property damage.
Safety Statements
• Refrigerant compressors must be employed only for their intended use.
•
install, commission and maintain this equipment.
•
• All valid standards and codes for installing, servicing, and maintaining electrical and
refrigeration equipment must be observed.
© 2014 Emerson Climate Technologies, Inc.
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INTRODUCTION
Application Range
This manual covers semi-hermetic Copeland
CO2- transcritical compressors. The 4MTLS Medium
Temperature models range from 12 hp to 30 hp. The
performance in Table 1 at the end of this bulletin
corresponds to 60Hz.
™
Qualified Refrigerants and Oils
Copeland 4MTLS are only applicable for transcritical
CO2 (R-744) applications. The approved oil is a
polyolester (POE) lubricant, Emkarate RL68HB. Oil
charge and recharge values can found in Emerson's
Online Product Information at EmersonClimate.com.
See Table 1 for oil charge limits. For other oil types,
contact Emerson.
The lineup of four cylinder semi-hermetic compressors
for CO2 - transcritical applications is the ideal solution
for R744 medium temperature cascade and booster
systems. It is characterized by a design pressure of
1985 psig (135 bar) at high side and 970 psig (66 bar)
at low side.
Recommended quality for carbon dioxide purity
grade is 4.0 [(≥ 99.99 %) H2O≤10ppm, O2≤10ppm,
N2≤50ppm] or higher.
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 bulletin relates to all 4MTLS
compressors for CO2 - transcritical applications with
standard equipment and accessories only.
Application Limits
CAUTION
Oil dilution! Bearing malfunction! A minimum
superheat of 18F (10K) at the compressor inlet is
required at all operating conditions to avoid oil dilution
with CO2 (R-744).
This bulletin is intended to enable users to ensure the
safe installation, starting, operation and maintenance
of semi-hermetic compressors. It is not intended to
replace the system expertise available from system
manufacturers.
The compressor superheat should be controlled
so that it is always above 18F (10K) to avoid oil
dilution in the compressor but low enough to keep
the compressor head discharge temperature below
310 °F (154°C), especially at high compression ratios
(high condensing and low evaporating temperatures).
See Figure 2 for compressor operating envelope.
Nomenclature
The model designation contains the following technical
information:
The Copeland 4MTLS compressor model numbers
include the nominal capacity at 60 Hertz, at 14°F/1300
psig/32°F/95°F (evaporating temperature / discharge
pressure / return gas temperature / gas cooler exit
temperature) with R-744 refrigerant.
Design Features
Compressor Construction
All compressors are fitted with reed-style valve plates
which cannot be dismantled. To maintain the high
capacity of these compressors the correct valve-plateto-body gasket must always be selected in case of
exchange.
Example:
4MTLS82KE-FSD-C00
4=
Number of Cylinders
Each cylinder head has a plugged 1/8" - 27 NPTF
tapped hole for connecting high-pressure switches.
MTLS = Application (Medium Temp. Transcritical Stream)
82K = Nominal Capacity (kBtu/hr)
High-pressure switches must be calibrated and tested
before putting the compressor into service, they
must stop the compressor if 1740 psig ( 120 Bar) is
exceeded.
E,L = Oil Type (POE), Less oil
FSC = 208-230 Volts Motor Version
FSD = 460 Volts Motor Version
The complete cylinder head is under discharge
pressure.
TSE = 575 Volts:Motor Version
C00 = Build of Materials
Note: Copeland 4MTLS compressors come equipped
with an external high side safety valve that opens at
© 2014 Emerson Climate Technologies, Inc.
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1958 psig (135 bar). Refer to Safety Valves section.
The sensor detects oil without detecting refrigerant.
It is calibrated so that it is unaffected by oil spray and
only allows a small amount of foam.
Compressor Cooling
All 4MTLS CO2 compressors are suction gas-cooled.
With suction gas-cooled compressors, the motor is
cooled by refrigerant gas that is led over the motor.
The sensor is constructed so as to resist high
pressure and temperatures, so it is suited for use on
transcritical CO2 refrigeration systems.
Maintaining a good return gas temperature and
pressures will ensure proper motor cooling.
For more information on applying the HBS01 refer
http://www.hbproducts.dk/en/products/oil-sensor/
hbso1-oil-switch.
Oil Lubrication
The 4MTLS compressors employ an oil splasher
system to ensure lubrication at constant and variable
speed conditions.
INSTALLATION
Oil Level
High pressure! Injury to skin and eyes possible! Be
careful when opening connections on a pressurized item.
WARNING
All 4MTLS CO2 compressors are equipped with
three sight glasses, two of them on the sides of the
compressor and one on the front. See Figure 3.
Compressor Handling
Delivery
The optimum oil level should be checked by operating
the compressor until the system is stable. Oil level on
the side sight glasses should be a minimum 1/4 and
maximum 3/4 of the sight glass. The level can also
be checked within 10 seconds of compressor shutdown. See Figure 4.
Please check whether the delivery is correct
and complete; deficiencies should be reported
immediately in writing.
Standard Delivery:
• Suction and discharge shut-off valves
The third sight glass in the front of the compressor
is used as an oil level check. It is located in the
oil sump of the housing cover. The oil level during
operation should be at least 3/4 of the sight glass at
all times. If the oil level is less than this on the front
of the compressor, check the oil levels on the side
sight glasses.
• Oil charge, oil sight glass
• Mounting kit
• CoreSense Protection module
• Holding charge up to a gauge pressure of 2.5 bar
(36.25 psig) (dry air)
Transport and Storage
Oil sensors are available through Emerson. Refer to
Table 3. These sensors can be installed in the sight
glass port on the side of the compressor.
WARNING
Risk of collapse! Personal injuries! Move
compressors only with appropriate mechanical or
handling equipment according to weight. Keep in the
upright position. Refer to carton graphics for stacking
instructions. Keep thepackaging dry at all times. See
Figure 5.
Oil Level Control
4MTLS CO2 compressors do not have any oil pump,
so an oil pressure safety control cannot be used to
protect the compressor against oil problems.
A float level switch for oil can be used to protect the
compressor against oil loss. HBSO1 is a level switch
for detecting common lubricating oils in refrigeration
systems. The HBSO1 oil level switch/sensor can be
used to secure or control lubrication of compressors
at high and low pressure applications.
© 2014 Emerson Climate Technologies, Inc.
Compressors are individually packed and may be
delivered on pallets depending on quantity and size.
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AE4-1396 R3
Positioning and Securing
discharge side. If excessive pressures are reached,
the safety valves open and prevent further pressure
increase. See Figure 9. The CO2 is released to the
ambient.
NOTICE
Handling damage! Compressor malfunction!
Safety Valve Settings
Only use the lifting eyes whenever the compressor
requires positioning. Using discharge or suction
connections for lifting may cause damage or leaks.
High pressure side (HP) 1958 psig (135 bar)
Low pressure side (LP) 957 psig (66 bar)
If possible, the compressor should be kept horizontal
during handling.
Maximum Operating Pressures
High pressure side (HP) 1740 psig (120 bar)
For safety reasons two lifting eyes should be fitted
before moving a compressor (½" - 13 UNC). Refer
to Figure 6.
Low pressure side (LP) 609 psig (42 bar(g))
Shut Off Valve Properties
Installation Location
Suction and discharge shut off valves are suitable for
welding or brazing. For brazing connections where
dissimilar or ferric metals are joined, a silver alloy rod
with a minimum of 30 % silver should be used, either
flux coated or with a separate flux.
Ensure the compressors are installed on a solid level
base.
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 4MTLS
models is delivered with each 4MTLS compressor.
Four yellow springs have to be used on both sides.
See Figure 7.
Screens
CAUTION
Screen blocking! Compressor breakdown! Use
screens with at least 0.6 mm openings.
The use of screens finer than 30 x 30 mesh (0.6 mm
openings) anywhere in the system should be avoided
with these compressors. Field experience has shown
that finer mesh screens used to protect thermal
expansion valves, capillary tubes, or accumulators
can become temporarily or permanently plugged with
normal system debris and block the flow of either oil or
refrigerant to the compressor. Such blockage can result
in compressor failure.
When 4MTLS 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.
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.
In the event of a released charge through the suction
safety relief valve, ensure that the suction screen does
not need to be replaced. If a replacement is required,
refer to www.emersonclimate.com
Pressure Safety Controls
Safety Valves
ELECTRICAL CONNECTION
WARNING
General Recommendations
In the event that a safety valve activates, it is
recommended to replace the valve to avoid
nuisance trips. Always check the system for CO2
loss after activation of the external pressure
safety valve
The compressor terminal box has a wiring diagram
on the inside of its cover. Before connecting the
compressor, ensure the supply voltage, the phases and
the frequency match the nameplate data.
The compressor is fitted with two external pressure
safety valves, one valve each on the suction and
© 2014 Emerson Climate Technologies, Inc.
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Electrical Installation
CoreSense Protection for Copeland Discus compressors
can also provide valuable discharge temperature
protection. By installing the temperature probe into the
head of the Discus compressor and connecting to the
CPM, CoreSense will protect the compressor from high
discharge temperature conditions. If the temperature
sensor detects a head temperature greater than
310°F, CoreSense will trip the compressor off until the
temperature cools down to an acceptable level (about
267°F) and a two minute off time has been achieved. A
high discharge temperature lockout can also be enabled
through the E2. Please refer to AE8-1367 for more
information about the CoreSense Protection and E2
setup screens.The module is capable of communication
via MODBUS protocol.
Three Phase Motors
All compressors can be started Direct-On-Line.
Note: Pay special attention to the position of the
voltage terminals. Refer to Figure 10.
Part-Winding Motor (YY/Y) – Code A
Part winding PWS motors contain two separate
windings (2/3 + 1/3) which are internally connected
in star and operated in parallel. You cannot change
the voltage by changing the electrical connections,
the motor is only suitable for one voltage.
The first part winding, the 2/3 winding on terminals
1-2-3 ,can be used for part winding start. After a time
delay of 1 ± 0.1 seconds the second part winding (1/3)
must be brought on line.
Because there is no oil pump, the low oil pressure
protection feature is disabled on the 4MTLS
compressors.
Wiring Diagrams
The CoreSense Protection module comes factory
installed on each 4MTLS compressor. For electrical
connections to the module, refer to AE8-1367.
The position of the jumpers in the terminal box and
the recommended wiring diagrams are shown in
Figure 10.
Crankcase Heaters
Terminal Box Isolator
NOTICE
FSD (460v) and TSE (575v) compressor models are
equipped with two isolators. One is for across the
line start and one is for part winding start applicators.
Refer to Figure 8.
Oil dilution! Bearing malfunction! Turn the crankcase
heater on 12 hours before starting the compressor.
Two voltages (115V and 208V) are available for use on
the 4MTLS compressors. Please refer to Figure 13 at
the end of this bulletin.
FSC (208/230v) compressor models do not include
isolators.
Note: It is recommended to use these isolators on
FSD & TSE compressor models in order to keep the
terminals isolated.
STARTUP AND OPERATION
WARNING
Diesel effect! Compressor destruction! The mixture
of air and oil at high temperature can lead to an
explosion. Avoid operating with air.
Breaker
Independently from the internal motor protection,
fuses must be installed before the compressor. The
selection of fuses has to be carried out according to
VDE 0635, DIN 57635, IEC 269-1or EN 60-269-1.
Leak Test
The suction shut-off valve and discharge shut-off valve
on the compressor must remain closed during pressure
testing to prevent air and moisture from entering the
compressor. The test pressure (dry nitrogen) must be
not exceed 882 psi (60 bar) provided no other system
component’s pressure is lower, in this case the lower
pressure is the test pressure
CoreSense Protection
CoreSense Protection provides motor protection for
4MTLS compressors. The CoreSense Protection
module (CPM) will communicate a motor protection
trip when the resistance caused by an increasing
motor temperature has risen above 4.5 K Ohms. The
compressor will restart once the resistance drops below
2.5 K Ohms and five minutes has elapsed.
© 2014 Emerson Climate Technologies, Inc.
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System Evacuation
Low moisture content! Corrosive impact on
refrigeration systems! Use only highly dried CO2.
Before commissioning the system, remove the holding
charge and 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
operation, close the compressor valves and evacuate
the system. Pressure must be measured using a
vacuum pressure 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.
Do not operate compressor without enough system
charge to maintain at least 88 psig (6 bar) absolute
suction pressure. Allowing an absolute pressure to drop
below 88 psig (6 bar) for more than a few seconds might
cause CO2 solidification and block valves or pipes.
Charge the system with vapor CO2 up to a minimum
absolute pressure of 88 psig (6 bar) to prevent forming
of dry ice. Then continue with charging liquid CO2. The
system should be charged through the liquid-receiver
shut-off valve or through a valve in the liquid line.
Due to the factory holding charge of dry air the
compressor is under pressure of about 14.5 to 36 psi
(1 to 2.5 bar), this is to indicate that the compressor
does not leak.
The use of a filter drier in the charging line is highly
recommended. Because there may be several valves
in the system, it is recommended to charge on both the
high and low sides simultaneously to ensure sufficient
pressure is present in the compressor before it runs.
The majority of the charge should be placed in the high
side of the system to prevent bearing washout during
first-time start.
When plugs are removed from the compressor in order
to connect a pressure gauge or to fill in oil, the plug may
pop out under pressure and oil residue can spurt out.
Preliminary Checks – Pre-starting
Initial Start-Up
Discuss details of the installation with the installer. If
possible, obtain drawings, wiring diagrams, etc. It is
ideal to use a check-list but always check the following:
CAUTION
Oil dilution! Bearing malfunction! It is important to
ensure that new compressors are not subject to flooded
start. For initial start up, turn the crankcase heater on 12
hours prior to starting the compressor. During normal
operation, when the compressor is off the crankcase
heater should be on.
• Visual check of the electrics, wiring, fuses etc.
• Visual check of the plant for leaks, loose fittings such
as TXV bulbs etc.
• Compressor oil level ¼ - ¾ sight glass (see Figure 3)
• Calibration of high and low pressure switches and
any pressure actuated valves
• Pressure and compound gauges fitted
With the exception of rubber coated metallic gaskets.
All gaskets should be oiled before fitting. O-rings should
also be oiled. A compressor should never be operated
beyond its approved application range. To avoid motor
damage, the compressor must not be started or highpotential tested under vacuum.
• Ensure compressor electrical isolator is correct
Minimum Run Time
• Check setting and operation of all safety features
and protection devices
• All valves in the correct running position
Emerson Climate Technologies recommends a
maximum of 10 starts per hour. The most critical
consideration is the minimum run time required to return
oil to the compressor after start-up.
Charging Procedure
CAUTION
Low suction pressure operation! Compressor
damage! Do not operate with a restricted suction. Do
not operate with the low pressure cut-out jumpered.
© 2014 Emerson Climate Technologies, Inc.
Recommended Inverter Range
4MTLS compressors can be applied with a variable
frequency drive. The approved operating range is 25
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AE4-1396 R3
to 60Hz.
contact with any surface or material that might be
harmed by POE, including certain polymers (e.g. PVC/
CPVC and polycarbonate).
MAINTENANCE AND REPAIR
Exchanging the Refrigerant
Compressors that are not shipped "less oil" are supplied
with an initial oil charge. The standard oil charge for use
with refrigerants R744 is a polyolester (POE) lubricant
Emkarate RL 68 HB.
4MTLS compressors are only released for usage with
CO2.
For service kit part numbers, refer to the Online Product
Information at www.emersonclimate.com or contact
your Emerson sales representative.
One disadvantage of POE is that it is far more
hygroscopic than mineral oil (see Figure 15). Only brief
exposure to ambient air is needed for POE to absorb
sufficient moisture to make it unacceptable for use in a
refrigeration system. Since POE holds moisture more
readily than mineral oil it is more difficult to remove it
through the use of vacuum. Compressors supplied by
Emerson Climate Technologies contain oil with low
moisture content, and it may rise during the system
assembling process. Therefore it is recommended
that a properly sized filter-drier is installed in all POE
systems. This will maintain the moisture level in the oil
to 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.
Replacing a Compressor
CAUTION
Inadequate lubrication! Bearing destruction!
Exchange the accumulator after replacing a compressor
with a burned out motor. The accumulator oil return
orifice 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.
In 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 suction
and liquid line filter driers. A 100 % activated alumna
suction line filter 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 orifice 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 compressor is exchanged in the field, 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.
The diagram below compares the hygroscopic
characteristics of POE oil with mineral oil (moisture
absorption in PPM at 25 °C and 50 % relative humidity).
See Figure 15.
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 an absolute pressure of 4.35 kips 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 the sight
glass indicates. This is due to the high hygroscopicity of
the POE oil. To determine the actual moisture content
of the lubricant, samples have to be taken from the
system and analyzed.
Lubrication and Oil Removal
WARNING
Chemical reaction! Compressor destruction! Do not
mix up ester oils with mineral oil and/or alkyl benzene.
Oil Additives
CAUTION
Although Emerson Climate Technologies cannot
comment on any specific product, from our own testing
Handle carefully! Material harm! POE must be
handled carefully and the proper protective equipment
(gloves, eye protection, etc.) must be used when
handling POE lubricant. POE must not come into
© 2014 Emerson Climate Technologies, Inc.
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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. 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
WARNING
Explosive flame! Burning! Oil-refrigerant mixtures are
highly flammable. Remove all refrigerant before opening
the system. Avoid working with an unshielded flame in
a refrigerant charged system.
Before opening up a system it is important to remove
all refrigerant from both the high and low sides of the
system. If a brazing torch is then applied to the low
side while the low side shell and suction line contain
pressure, the pressurized refrigerant and oil mixture
could ignite when it escapes and contacts the brazing
flame. 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 rather than
unbrazed.
Dismantling and Disposal
Removing oil and refrigerant:
• Use the correct equipment and method of removal.
• Dispose of oil and refrigerant properly.
• Dispose of compressor properly.
© 2014 Emerson Climate Technologies, Inc.
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Figure 1 – 4MTLS Name Plate
Saturated Suction Temperature
Discharge Pressure
°F -40 -31 -22 -13 -4
°C -40 -35 -30 -25 -20
2058
140
1764
120
5
-15
14
-10
23
-5
32
0
50
10
41
5
59
15
68
20
79
26
°F
°C
1470 100
1176
80
882
60
588
40
294
psia
20
bar 10
147
15
20
25
30
35
40
45
50
55
60
65
70
221
294
368
441
515
588
662
735
809
882
956
1029
Suction Pressure
Low side LPCO: 12.1 BAR/178 PSIA
Low side HPCO : 45 BAR/662 PSIA
Figure 2 – CO2 Envelope
Figure 3 – 4MTLS Sight Glasses
© 2014 Emerson Climate Technologies, Inc.
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AE4-1396 R3
Figure 4 – Sight Glass Oil Level
Figure 5 – Stacking Configuration
Lifting Eyes
Figure 6 – Lifting Eye Location
© 2014 Emerson Climate Technologies, Inc.
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AE4-1396 R3
Transport
Clamp
Transport Position
Figure 7 – Mounting Springs
Direct-On-Line-Start
Part-Winding Start
Figure 8 – Terminal Box Isolator
Safety
Valves
Figure 9 – Safety Valve Location
© 2014 Emerson Climate Technologies, Inc.
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Operational Position
AE4-1396 R3
ACROSS THE LINE
CONNECTED
MOTOR CODE LINE VOLTAGE
FSD
50 HZ. 380-420
CURRENT
SENSOR
01
02
MOTOR CODE LINE VOLTAGE
FSD
TSE
60 HZ. 460
60 HZ. 575
CURRENT
SENSOR
01
03
PART WINDING START
CONNECTED
LINE VOLTAGE
CONTROL CIRCUIT
VOLTAGE
C1
02
03
7
Z
1
U
2
V
7
Z
9
Y
1
U
3
W
8
X
2
V
01 02 03
L1 L2 L3
L1 L2 L3
7(Z)
8(X)
9(Y)
TD
TD
8
X
01 02 03
T 1 T 2 T 3 C1 T 1 T 2 T 3
1(U)
7
9
Y
3
W
C2
C2
Z
CONTROLS
1
U
8
X
2
V
2(V)
3(W)
9
Y
MOTOR WINDING
CONNECTIONS
3
W
L M PROTECTOR MODULE
052-2753-00
ACROSS THE LINE
CONNECTED
WIRING DIAGRAM
CURRENT
SENSING
PART WINDING START
7 8 9
2 3
1
ORANGE
L1
L2
L3
CURRENT
SENSOR
L7
L8
L9
COMPRESSOR
WIRING
HARNESS
BLACK
USE COPPER CONDUCTORS ONLY.
WHEN CHECKING MOTOR PROTECTION SYSTEM:
USE MINIMUM 75° C (167° F) WIRE FOR AMPACITY DETERMINATION.
MODULE POWER MUST BE DISCONNECTED BEFORE CHECKING MOTOR
SENSORS.
USE THIS EQUIPMENT ON A GROUNDED SYSTEM ONLY.
PRIMARY SINGLE PHASE FAILURE PROTECTION IS PROVIDED.
USE OHMMETER ONLY TO CHECK SENSOR RESISTANCE. DO NOT SHORT
ACROSS THE TERMINALS.
OPTIONAL CRANKCASE HEATER, FAN OR CAPACITY CONTROL VALVE(S) MUST
BE CONNECTED ONLY TO THEIR RATED VOLTAGE.
SENSOR RESISTANCE MEASURED FROM TERMINALS (C TO S1,S2,S3) WITH
MOTOR TEMPERATURE BELOW 60° C (140° F), SHOULD BE WITHIN THE
FOLLOWING LIMITS: 30 TO 2400 OHMS. REFER TO EMERSON EUROPEAN
PUBLICATIONS GUIDELINE SH DISCUS COMPRESSORS DEC. 2001 AND US
PUBLICATIONS AE BULLETIN #8-1367.
OVERCURRENT PROTECTION DEVICE RATING AND TYPE MUST BE IN
ACCORDANCE WITH REGULATORY AGENCY END PRODUCT APPROVALS SEE SYSTEM NAMEPLATE.
Figure 10 – Compressor Electrical Wiring Configuration
© 2014 Emerson Climate Technologies, Inc.
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AE4-1396 R3
CoreSense
Control Module
Current Sensor
Figure 11 – Electronics Locations
Figure 12
Wiring Diagram for CoreSense
Figure 13
Crankcase Heater
Figure 14
Oil Sensor
Figure 15
Oil Dilution Graph
© 2014 Emerson Climate Technologies, Inc.
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AE4-1396 R3
Table 1 – 4MTLS Model Selection
Model
Voltage
Initial
Oil
Charge
(oz)
4MTLS82KL
FSD/TSE
0
4MTLS82KE
FSD/TSE
61
4MTLS11ML
FSD/TSE
0
4MTLS11ME
FSD/TSE
61
4MTLS15ML
FSD/TSE
0
4MTLS15ML
FSD/TSE
61
1
60Hz
Displacement
(CFH)
Cooling
Capacity1
(kBtu/hr)
406
82
530
108
764
155
Abs Pressure
(High/low side)
Max
Operating
(psig)
Design
(psig)
Net
Weight
(lbs)
Footprint
(in)
344
1779/617
1985/970
346
14.5 x 10
353
At 14°F Evap. Temp / 1,300 psig Gas Cooler Pressure / 32°F Return Gas Temp/ 95°F Gas Cooler Exit (60Hz)
Table 2
Qualified Refrigerants and Oils for 4MTLS Compressors
Qualified refrigerants
CO2 (R-744)
Copeland™ standard oil
Emkarate RL 68 HB
Servicing oil
Emkarate RL 68 HB
Note! Refer to Form 93-11 for the latest approved refrigerants
and lubricants for Copeland products
Table 3 – Oil Sensor Kit
Kit
Part Description
Kit Part Number
Oil Sensor Kit
Gasket O-Ring
Oil Sensor Adaptor
Oil Control Sensor
998-0244-00
Table 4 Crankcase Heater Kits
Kit
Kit Part Number
Crankcase Heater Kit(115V/100W)
918-0003-00
Crankcase Heater Kit(208V/100W)
918-0003-01
© 2014 Emerson Climate Technologies, Inc.
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Motors
FSD
60Hz
460v/3Ø
50Hz
380-420v/3Ø
TSE
60Hz
575v/3Ø
AE4-1396 R3
Appendix 1: CO2 Transcritical Compressor Connections
© 2014 Emerson Climate Technologies, Inc.
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AE4-1396 R3
Appendix 2: 4MTLS Tightening Torques
Component Description
Thread Type
Torque
(lb-ft)
Torque
(Nm)
Suction Service Valve Mounting
3/8"-16 UNC
26-32
36-44
Suction Service Valve Pressure Tap
7/16"-20 UNF
18-26
24-35
Suction Service Valve Cap
3/4"-16 UNF-2A
3-4
4-5
Discharge Service Valve Mounting
3/8"-16 UNC
26-32
36-44
Discharge Service Valve Pressure Tap
7/16"-20 UNF
18-26
24 -35
Discharge Service Valve Cap
3/4"-16 UNF-2A
3-4
4-5
Stator Cover Mounting
1/2"-13 UNC
88-117
119-159
Housing Cover Mounting
1/2"-13 UNC
88-117
119-159
Cylinder Head
1/2"-13 UNC
75-102
102-138
Head Temperature Probe (CoreSense)
1/8"-27 NPTF
25-26
35
Terminal Plate Mounting
3/8"-16 UNC
26-32
36-44
Stator Mounting
M16
103-133
140-180
Oil Sight Glass
1-1/8"-18 UNEF
37-44
50-60
Oil Drain Plug
1/4"-18 NPTF
22-30
30-40
Misc Plugs
1/4-18 NPTF
22-30
30-40
Oil Flinger Mounting
M10
13-16
18-22
Safety Valves
M24x1.5 LH/RH
66-81
90-110
Deflector mounting
32 UNF
7-8
9-11
Oil Sensor Probe
3/4"-14 NPT
63-66
85-90
Oil Sensor Probe Adaptor
1 1/8" - 18 UNEF
66
90
Torque Final Customer
Installation
30 - 37 lb-ft /
40 - 50 N-m
30 - 37 lb-ft /
40 - 50 N-m
NOTE: The ranges of torque values given in this specification are assembly torque. Torque after joint relaxation
must be within 15 % of the minimum assembly torque unless re-torque is called for and must not be above 10
% of the maximum assembly torque.
The contents of this publication are presented for informational purposes only and are not to be construed as warranties or guarantees,
express or implied, regarding the products or services described herein or their use or applicability. Emerson Climate Technologies, Inc. and/or
its affiliates (collectively "Emerson"), as applicable, reserve the right to modify the design or specifications of such products at any time without
notice. Emerson does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use
and maintenance of any Emerson product remains solely with the purchaser or end user.
© 2014 Emerson Climate Technologies, Inc.
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