Fusion User Manual - Emerson Climate Technologies

Fusion User Manual - Emerson Climate Technologies

Copeland Scroll

TM

Fusion Compressor for refrigeration applications

User Manual

2

About Emerson Climate Technologies

Emerson Climate Technologies, a business segment of Emerson

TM

, 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.

Our Vision:

Emerson Climate Technologies, With Our Partners,

Will Provide Global Solutions To Improve Human Comfort,

Safeguard Food And Protect The Environment.

Table of Contents

Safety Information

Features and Benefits

Nomenclature

Operating Envelopes

Technical Data

Dimensional Drawings

Wiring Diagram

Contact Lists

05

06

07

04

05

10

14

24

3

Safety Information

Copeland

TM

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 qualifi ed and authorized personnel are permitted to do installation, commissioning and repairing of this compressor. Electrical connections must be made by qualifi ed electrical personnel.

ICON DEFINITION

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.

4

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 specifi 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.

Warning

• When operating the compressor or checking a refrigeration system leakage, do not exceed operating pressures out of the application envelope.

• 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.

Product Description

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

Features and Benefi ts

• Emerson’s Copeland Scroll technology

• Serviceability in the fi eld

• CoreSense™ Diagnostics

• Integrated vapor injection technology

• Wide range envelope and effi cient operation

• Ability to handle various refrigerants

Nomenclature

Family

Q – Copeland Scroll Fusion

Type of Oil

Code Description

E POE

Blank Mineral Oil

Intelligence and Motor Protection

Code Type

W CoreSense™

Scroll Displacement

(cc/rev)

Bill of Material

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

Model Variation

A

Motor Types

Code Phase

T 3

Application Range

Code Application Approved Refrigerants

F Full Range R22/R404A

Low/Med/High

Note: QF205 has low temperature model only.

Typical Electrical Codes

Code 60 Hz 50 Hz

D 460-3 380/420-3

5 200/230-3

200/220-3

7 380-3 –

5

Operating Envelopes

R22/R404A

QF115/QF125/QF145/QF175/QF185

70

60

R22

R404A

R22

R404A

6

R22/R404A

10

-50 -40 -30 -20 -10

Evaporating Temperature o

C

0

0 o C Return Gas Temperature. No Fan Cooling

-50 -40 -30 -20 -10

Evaporating Temperature o

C

0

Note: 20 o

C Return Gas Temperature. No Fan Cooling

QF205

10 20

10 20

70

60

R22 / R404A

R22 / R404A

10

-50 -40 -30 -20 -10

Evaporating Temperature o

C

0 o

C Return Gas Temperature. No Fan Cooling

0

-50 -40 -30 -20 -10 0

Evaporating Temperature o

C

Note: 20 o C Return Gas Temperature. No Fan Cooling

10 20

10 20

Nameplate Information

Figure 1.

Nameplate and nameplate location

Technical Data

Model

Displacement

MOC 1

LRA

2

Motor Speed

50 Hz

TWD 50 Hz

Crankcase Heater

Oil Charge

Service Valves

Dimensions

Base Mounting

Weight

50 Hz

Power

Voltage

Initial

Recharge

Suction

Discharge

Length

Width

Height

Length

Width

Bolt

Net

Gross

Notes: 1. MOC: Maximum Operating Current

2. LRA: Locked Rotor Current

3. QF205AE has low temperature model only

R22

R404A

m

3

/h

A rpm

W

V

L in mm mm kg

QF115A QF125A QF145A QF175A QF185A QF205A

QF115AE QF125AE QF145AE QF175AE QF185AE QF205AE

19.3

24

80

21.1

25

80

23.5

27

80

26.4

32

105

30.4

33

105

36.9

25

105

1

675

355

389

350

200

2,900

60

220

2.66

2.54

1-1/8

M10

130

140

7

8

Maximum Operating Pressures

Caution

A high-pressure control with a maximum cut-out

setting of 28 bar(g) is required. The high-pressure cutout 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 -10 o

C for R22 and -16 o

C 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.

Warning

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.

Mineral oils such as Suniso 3GS are approved for R22 application. Operation with R404A and R507 requires

Polyol Ester (POE) lubricants, and POE oil models are fi lled with Emkarate RL 32-3MAF ex-factory. Emkarate RL 32-

3MAF and Mobil EAL Arctic 22 CC are both approved for top up and servicing.

Caution

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

The compressor is supplied with an initial oil charge.

The standard oil charge for use with refrigerant R404A is a polyolester (POE) lubricant Emkarate RL 32-3MAF. In the fi eld, the oil level could be topped up with Mobil EAL

Arctic 22 CC if 3MAF is not available. See nameplate for original oil charge in litres. A fi eld recharge is from 50-100 ml less than the original charge.

Caution

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.

Caution

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 suffi cient moisture to make it unfi t for use in a refrigeration system. Since POE holds moisture more readily than mineral oil, it is more diffi 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 fi 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.

PPM

1500

POE

1000

500

Mineral Oil

50 100 150

hours

200 250 300

Figure 2.

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

Installation

Compressor Handling

Delivery

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 fi nal location.

The packing list included with each shipment should be carefully checked to determine if all parts and equipment have been received. Defi ciencies should be immediately reported in writing to your local Emerson Sales Offi ce.

Standard delivery

• Suction and discharge shut-off valves

• Oil charge, oil sight glass

• Oil level switch

• Differential oil pressure 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

M16x2.0 Thread

Figure 3.

Compressor lifting method

Mounting Parts

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.

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.

Transport

Compressors should be moved only with mechanical handling equipment appropriate for the weight involved. For safety reasons, one lifting eye should be fi tted before moving a compressor (M16x2.0). Please refer to the illustrations on Figure 3 to see how to lift the compressor safely.

Warning

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

Figure 4.

Mounting Kit

Mounting Kit Part Code: 027-0443-00

9

Piping Connection and Compressor

Installation

Brazing

• It is important to flow 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% silver.

• Be sure valves I.D. and connecting tube O.D. are clean prior to assembly. If oil film is present, wipe with denatured alcohol, Dichlorotrifluoroethane or other suitable solvent.

• Using a double-tipped torch apply heat in Area 1. As tube approaches brazing temperature, move torch flame 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 flow braze material around circumference.

Dimensional Drawings

• After brazing material flows 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 final 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.

Area

3

Area

2

Area

1

Compressor

Valve

Figure 5.

Brazing

Connecting

Tube

10

Figure 6.

Compressor connection and ports. For identification refer to the Table on the next page.

All dimensions are in mm

No.

1

9

11

13

15

3

5

7

17

19

21

23

25

Notes: SL: Suction Line

DL: Discharge Line

Connection/Port

DPS sensor

Bolt-mounting

Nut-oil out fi tting

Connector EXV

Connector optional

Liquid out

DLT sensor

Nut- EVI fi tting

Vapor in temperature sensor

Built-in oil screen

Crankcase heater

Suction valve

Discharge valve

3/4”-16UNF

M10

M16

3/4”

M20

M20

Size

28.7 ID

25.7 ID

No.

2

10

12

14

16

4

6

8

18

20

22

24

26

Connection/Port

Plug low-pressure connection

Plug oil drain

Connector DLT/VI/VO/optical OLS/PDS

Screw grounding

Nut- oil in fi tting

Liquid in

Vapor out temperature sensor

EXV Coil

Optical oil level sensor

Oil level sight glass

Low pressure port

Plug high-pressure connection

High pressure port

Size

1/4”-18NPTF

1/4”-18NPTF

M5

M16

3/4”

7/8”-14UNF

1/4”-18NPTF

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 fi tting and connect to the system with tubing connectors. Follow instructions on Brazing (3.2.1).

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.

Min.

200 mm

Figure 7.

Piping guideline

Min. Distance

500 mm

Min. R

57 mm

Recommended minimum straight length from discharge valve to fi 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 effi ciency and provides a reliable LT envelope. Vapor injection subcools 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 offi ce for liquid line temperatures.

11

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 effi 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.

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 -10 o

C 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.

Condenser

Receiver

Discharge

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 fi 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 fi 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 signifi 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.

Suction

VI

Oil

Oil Line VI EXV

Evaporator

X

Filter Drier

(min 100 mesh)

Economizer

(Plate Heat

Exchanger)

Economizer Liquid

Out Line must be insulated

Sight Glass

Solenoid Valve

X

TXV

VI: Vapor Injection

EXV: Electronic Expansion Valve

TXV: Thermostatic Expansion Valve

Fusion Standard BOM

Figure 8.

Schematic Diagram

12

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.

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

4-

2 & 3 ON

Electrical Shock

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

Warning

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.

1A

2A

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 “Alarm” CCC

(compressor contactor coil) and a spare 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 terminals, the transformer output and the green fuse.

The green fuse (250 V 2A) protects the transformer and other 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.

Figure 9.

CoreSense™ Diagnostics Board

CoreSense Diagnostics

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

• Reverse rotation by differential oil pressure sensor

• Compressor not pumping by differential oil pressure sensor

• High discharge temperature by discharge port 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

High Pressure and Low Pressure switches must be fi 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.

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.

Warning

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

13

Wiring Diagram

PRI

INPUT:220V/240VAC

OUTPUT:16VAC

SEC

DPT VIT VOT

1 2 3 4 5 6

OLS

PDS

7 8 9 10 11

FUSE

1A/250VAC

SE

AC

0V

FU

2A

14

Figure 10.

Wiring Diagram

Wiring Instruction

H G F E D C A B

K

L

I

J

4 3 2 1

Step 1: Connect Compressor Motor Wires

Figure 11.

CoreSense™ Wiring and Joints

Step 2: Connect “PWR” Terminal Wires Step 3: Connect “Demand” Terminal Wires

Step 4: Connect “CCC” Terminal Wires

Step 5: Connect “Alarm” Terminal Wires

Figure 12.

CoreSense Recommended Wiring Sequence

15

Gland

(Waterproof)

Number

Gland 1 Gland 2 Gland 3 Gland 4

Gland Description

Wire Function

For “PWR” and

“Demand” Connector’s

Wires

One jacket line with four wires goes through the joint

For “CCC” Connector’s

Wires

One jacket line with two wires goes through the joint

For “Alarm” Connector’s

Wires

For Compressor Motor

Power Supply Wires

One jacket line with two wires goes through the joint

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

A(Red) and B(Blue):

Controller Power Supply

Input(220-240VAC

50/60Hz)

C(Black) and D(Yellow):

Compressor Start/Stop

Feedback Input(220-

240VAC 50/60Hz)

E(Brown) and F(Blue):

Compressor Diagnostic/

Protection Contact

Output

G(Brown) and H(Blue):

Dry Contact Output For

Alarm Devices

I, J, K: Compressor

Motor Power Supply

L: Earth Wire

Wire Connection

Wires A and B: “PWR”

(Green) connectors

Wires C and D:

“Demand” (Blue) connectors

Gland Internal

Diameter Range

5-10 mm

Wires E and F: “CCC”

(Green) connectors

Wires E and F: “Alarm”

(Orange) connectors

N/A

5-10 mm

Internal wire size: 18-20 AWG

5-10 mm 18-25mm

Internal wire seize: 8

AWG or above (4 wires in total)

Jacket Line

Requirement

Recommended wire size: 18 AWG

Rated voltage: 300V/500V

Table 1

Rated voltage:

600V/1000V 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.

Warning

High discharge temperatures often occur when the system is short of refrigerant: suction temperature rises, bubbles form in the liquid line and there is insuffi cient liquid to feed the injection EXV properly. The control module will stop the compressor, display a fault code and

16

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

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 rectifi ed quickly, could cause complete compressor failure and system contamination. Common mechanical problems that lead to motor trips include worn bearings or worn scroll is coated by system contaminants. The lens will need to be removed and cleaned to restore correct operation.

The differential pressure switch is normally open when the compressor is off and pressure has equalised. It can be checked for continuity using an ohmmeter. When the compressor starts the resistance should change from infi nity to 0 Ohms. The reed switch, which is enclosed in plastic, can also be closed by holding it close to a magnet.

Crankcase Heaters

Differential Oil

Pressure Sensor

Discharge Port

Temp. Sensor

Vapor Out

Temp. Sensor

and Sensors

several useful temperatures.

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

Caution

Use a voltage no higher than 3 VDC when testing.

used at 100 o

C.

used at 100 o

C.

o

C and boiling water can be

Location

Location

Discharge

Discharge

Vapor In

Vapor In

Vapor Out

Vapor Out

0

0

o

o

C

C

Temperature

Temperature

25

25

o

o

C

C

326 K Ohm 100 K Ohm

326 K Ohm 100 K Ohm

28 K Ohm

28 K Ohm

28 K Ohm

28 K Ohm

Table 2

Table 2

10 K Ohm

10 K Ohm

10 K Ohm

10 K Ohm

100

100

o

o

C

C

7 K Ohm

7 K Ohm

950 Ohm

950 Ohm

950 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

M25, 5 Sensors

M20, EXV Wires

M20, Motor Power

3xM16, Reserved for customer

Remove Terminal Box Cover for Customer Wiring

Figure 13.

Terminal Box Location For Wiring

Optical Oil Level Sensor

Vapor In Temp.

Sensor

Figure 14.

Sensor Location

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.

Caution

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.

17

Warning

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 fi 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 operation, 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.

Warning

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

Refrigerant Charging

PC 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 fi 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.

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 fi 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 fi tted

• Correctly charged with refrigerant

• Compressor electrical isolator location & position

Warning

The majority of the charge should be placed in the high side of the system to prevent bearing washout during fi 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 fi 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 fi rst-time start on the assembly line.

Warning

Never install a system in the fi 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.

Initial Startup

Warning

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.

.

18

Maintenance

Refrigerant Exchange

Qualifi 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.

driers. A 100% activated alumina suction line fi 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 orifi 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 fi 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.

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

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

/ R407A / R407C / R407F / R134a is a polyolester (POE) lubricant Emkarate RL 32 3MAF. In the fi 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 Suniso

3GS. Therefore it is recommended that a properly sized fi lter drier is installed in all POE systems. This will maintain the moisture level in the oil to less than 50 ppm.

Warning

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

Warning

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.

Warning

Change the accumulator after replacing a compressor with a burned out motor. The accumulator oil return orifi 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.

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 fi lter

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.

19

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

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.

20

Appendix

Fault Diagnostic Code

0

Code

ON

Description

Normal compressor operation

Status Compressor Action

Normal Normal compressor operation

0

0

1

2

3

4

5

6

7

8

3 and F

1 to 8

3

4

FLASH

FLASH

FLASH

FLASH

FLASH

FLASH

FLASH

FLASH

FLASH

FLASH

Alternate display

Number

FLASH

Number

FLASH/'.' on

Number

FLASH/'.' on

Normal compressor off

If it flashes during operation, follow Emerson Wiring Diagram

Normal Normal compressor standby

Fault EXV will not work so compressor must stop

Motor overheat

High discharge temperature

Low oil level

Low differential oil pressure

(HP - LP)

Motor Thermistor failure

PHE inlet temperature sensor failure

PHE outet temperature sensor failure

Less oil level, still OK but soon dangerous

All sensors

Low oil level/Require manual reset

Low differential oil pressure/ require manual reset

Fault

Fault

Fault

Fault

Fault

Scroll temperature sensor failure Fault

Fault

Fault

Normal

Fault

Fault

Fault

Compressor shutdown and automatic reset after 10 min delay

Compressor shutdown and automatic reset after 10 min delay

Compressor shutdown and automatic reset after 5 min delay

Compressor shutdown and automatic reset after 3 min delay

Compressor shutdown and automatic reset after 3 min delay

Compressor shutdown and automatic reset after 3 min delay

Compressor shutdown and automatic reset after 3 min delay

Compressor shutdown and automatic reset after 3 min delay

Show alarming and continue running. Give precaution

When power on 1st time, if any sensor (except ols, dps) is wrong, immediately locked

The 4th low oil level in 1 hour, compressor shutdown and locked, manual reset (cut off power)

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

21

Tool List

1, 2, 3, 4, 5, 6

9, 10 11

16,17

7

13,14

15 18

19

20

21

22 23

24

25

29

31 30 28 12

8

22

Components

Pressure Differential Sensor

(Mechanical Part, Lower Cover)

Three-phase Terminal Plate

PTC Thermistor

Oil Charge Fitting Plug

(Lower Cover)

Oil Drain Oil Fitting Plug

(Lower Cover)

Lower Cover Bolts

Check Valve Bolts

Suction Valve Bolts

Oil Drain Oil Fitting Plug

(Oil screen, Top Cap)

Oil Sight Glass Bolts

Oil Charge Fitting Plug

(Top Cap)

4

19

20

24

Item No.

on Page 11

(Table)

1

2

Tool

No.

8, 29

1, 28

1, 28

2, 29

2, 29

3, 29

2, 29

2, 29

4, 29

5

2, 29

Tool

Description

Metric Hexagon

Socket,

Torque Wrench

Tool

Specification

1''

10 mm

10 mm

18 mm

18 mm

16 mm

18 mm

18 mm

26 mm

10 mm

18 mm

Torque Value

(N.m)

100–110

12–15

12–15

32–42

32–42

57–68

90–100

90–100

130–140

7.5–10

32–42

26

27

Components

Oil Level Sensor

Discharge Valve (Rotate)

Rotalock Nut for Oil Out Tube

Rotalock Nut for Oil In Tube

Nuts of Tube-Oil Pulsation

EVI Rotalock Nut

Pressure Differential Sensor

(Mechanical Part, Lower Cover)

Terminal Box Cover Screws

Screw - CoreSense™ Connect to Terminal Box

CoreSense Terminal

Connectors

Transformer Bolts

Thrust Plate Bolts

Oil Separator Bolts

Bolt - Terminal Box Connect to Body

Top Cap Bolts

Top Cap and Lower Cover

Top Cap and Lower Cover

Top Cap

HVE Holder

Scroll Set

Screw-Upper Counterweight

For Torque Wrench

For Socket

For Socket

For Torque Wrench

——

Item No.

on Page 11

(Table)

18

25

5

10

15

1

25, 28

26

24

20

28

29

31

21

30

15, 28

16, 28

17, 28

18, 28

19, 29

22

23

27

Tool

No.

9

9

11

9

12

13

14

Tool

Description

Opening Wrench

Cross Screwdriver

Voltage Tester

Metric Internal

Hexagon Socket,

Torque Wrench

M3

3 mm

4 mm

4 mm

5 mm

Flat Chisel

Rubber Hammer

Special Bolts

Special Socket,

Torque Wrench

Torque Wrench

Opening Wrench

Connecting Piece

Torque Wrench

Extension Bars

Offset Socket Screw

Key Set

10 mm

M12

M10

13 mm

1/2 to 3/8

1.5 to 10 mm

Tool

Specification

29 mm

50 mm

22 mm

22 mm

22 mm

24 mm

1''

H3/6''

H3/6''

Torque Value

(N.m)

130–140

54–60

25–30

25–30

25–30

40–50

100–110

1–2

1–2

N/A

3.40–5.10

5.65–7.75

5–6

3.40–5.10

80–90

N/A

N/A

N/A

12–15

N/A

12–15

N/A

5–25

30–150

N/A

For Teardown

Only

23

Contact Lists

Asia Pacific Headquarters

Emerson Climate Technologies

Suite No. 2503-8, 25/F,

Exchange Tower, 33 Wang Chiu Road,

Kowloon Bay, Kowloon, Hong Kong

Tel: (852) 2866 3108

Fax: (852) 2520 6227

India - Mumbai

Emerson Climate Technologies (India) Ltd

Delphi B-Wing, 601-602, 6th Floor

Central Avenue, Hiranandani Business Park,

Powai, Mumbai 400076

Tel: (9122) 2500 6630 / 2500 6632

Fax: (9122) 2500 6570

Australia

Emerson Climate Technologies Australia

Pty Ltd

356 Chisholm Road

Auburn NSW 2144, Australia

Tel: (612) 9795 2800

Fax: (612) 9738 1699

India - PUNE

Emerson Climate Technologies (India) Ltd

Plot No. 23, Rajiv Gandhi Infotech Park,

Phase - II, Hinjewadi,

Pune 411 057, Maharashtra, India

Tel: (9120) 2553 4988

Fax: (9120) 2553 6350

China - Beijing

Emerson Climate Technologies (Suzhou)

Co. Ltd

Beijing Sales Office

Room 1017 JianWei Building,

66 Nan Lishi Road, XiCheng District,

Beijing, PRC

Tel: (8610) 5763 0488

Fax: (8610) 5763 0499

Indonesia

PT Emerson Indonesia

BSD Taman Tekno 8

Jl. Tekno Widya Blok H10 No 2 & 3

Tangerang Selatan 15314

Indonesia

Tel: (6221) 2666244

Fax: (6221) 2666245

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: (8620) 2886 7668

Fax: (8620) 2886 7622

Japan

Emerson Japan Ltd

Shin-yokohama Tosho Building

No. 3-9-5 Shin-Yokohama, Kohoku-ku

Yokohama 222-0033 Japan

Tel: (8145) 475 6371

Fax: (8145) 475 3565

Middle East & Africa

Emerson Climate Technologies

PO Box 26382

Jebel Ali Free Zone – South

Dubai, UAE

Tel: (9714) 811 8100

Fax: (9714) 886 5465

Philippines

Emerson Climate Technologies

10/F SM Cyber West Avenue, EDSA cor.

West Avenue, Barangay Bungad, Diliman,

Quezon City 1105 Philippines

Tel: (632) 689 7200

South Korea

Emerson Electric Korea Ltd.

3F POBA Gangnam Tower

343, Hakdong-ro, Gangnam-gu,

Seoul 135-820, Republic of Korea

Tel: (822) 3483 1500

Fax: (822) 592 7883

Taiwan

Emerson Electric (Taiwan) Co. Ltd

3F No. 2 DunHua South Road Sec.1,

Taipei (105), Taiwan

Tel: (8862) 8161 7688

Fax: (8862) 81617614

Thailand - Bangkok

Emerson Electric (Thailand) Ltd

34th Floor, TCIF Tower,

1858/133, Bangna Trad,

Bangkok 10260, Thailand

Tel: (662) 716 4700

Fax: (662) 751 4241

China - Shanghai

Emerson Climate Technologies

(Suzhou) Co. Ltd

Shanghai Sales Office

1801 Building B, New CaoHeJing

International Business Center,

391Guiping Rd, Shanghai, PRC

Tel: (8621) 3418 3968

Malaysia

Emerson Electric (Malaysia) Sdn. Bhd.

Level M2, Blk A, Menara PKNS-PJ

Jalan Yong Shook Lin

46050 Petaling Jaya, Selangor, Malaysia

Tel: (603) 7949 9222

Fax: (603) 7949 9333

Vietnam

Emerson Climate Technologies - Vietnam

Suite 307-308,

123 Truong Dinh St., Dist.3

Ho Chi Minh, Vietnam

Tel: (84) 908 009 189

EmersonClimateAsia.com

Asia 02 B04 10 – R00 Issued 03/2015 – GSCAA032

Emerson, CoreSense Diagnostics and Copeland Scroll Fusion are trademarks of Emerson Electric Co. or one of its affi liated companies.

©2013 Emerson Climate Technologies, Inc. All rights reserved.

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