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Emerson Copeland 2D User Manual

Emerson Copeland 2D
43 pages
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Copeland
Semi-Hermetic
Compressors for A2L & A1 Applications
2D*, 3D* & 8D*
Application Guidelines

Table of Contents

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Emerson Copeland 2D Specifications

General IconGeneral
CategoryAir Compressor
Power SourceElectric
Model2D
RefrigerantR-22
Voltage230V

Summary

Product Description

Compressor range

Overview of 2D*, 3D*, and 8D* compressor models and their displacement range.

Nomenclature

Explanation of the model designation code and its technical information.

Nameplate information

Details on crucial identification information printed on the compressor nameplate.

Application range

Covers qualified refrigerants, oils, and application limits for compressors.

Design features

Details on compressor construction, cooling, liquid injection, and capacity control.

Dimensions

Provides physical dimensions and port sizes for 2D*, 3D*, and 8D* compressor models.

Safety instructions

Icon explanation

Explanation of warning icons used in the manual for safety.

Safety statements

Critical statements regarding safe use, handling, and qualifications for personnel.

General instructions

General warnings and precautions for system operation and handling.

Installation

Compressor handling

Guidelines for receiving, transporting, and storing compressors safely.

Positioning and securing

Instructions for safely placing and securing compressors to prevent damage.

Mounting parts

Details on using vibration dampers and mounting parts for compressor installation.

Pressure safety controls

Requirements for high and low-pressure safety controls and their installation.

Brazing procedure

Recommended steps and safety precautions for brazing system components.

Electrical connection

General recommendations

Advice on matching supply voltage, phases, and frequency to compressor specifications.

Electrical installation

Procedures for safe electrical wiring, connections, and RCD installation.

Electrical protection

Guidance on selecting and installing fuses for compressor electrical protection.

Compressor protection

Information on factory-fitted motor protection devices like thermistors and Kriwan modules.

Demand Cooling™

Details on the optional liquid injection system for extending application limits.

Oil differential pressure control

Explanation of oil pressure switches (OPS2) for compressor lubrication protection.

Crankcase heaters

Importance and installation of crankcase heaters to prevent oil dilution.

Terminal box jumpers positions

Diagrams for direct-on-line, part-winding, and star/delta motor electrical connections.

Start-up & operation

Compressor tightness test

Procedures for verifying system integrity and leak testing.

System evacuation

Requirements for vacuum pump down and moisture reduction for A2L systems.

Preliminary checks – Pre-starting

Essential checks before initiating system start-up, especially for A2L systems.

Charging procedure

Safe methods for charging the system with refrigerant, including precautions for A2L.

Initial start-up

Critical steps and precautions for the first compressor start-up to avoid damage.

Minimum run time

Importance of adequate run time for oil return and compressor longevity.

Recommended inverter range

Guidance on operating compressors with variable frequency drives.

Dismantling & disposal

Removing oil and refrigerant

Safe methods for oil and refrigerant removal and disposal in compliance with regulations.

Maintenance & repair

Qualification of workers

Specifies training and qualification requirements for personnel working on A2L systems.

Preparation and work procedure

Guidelines for planning and executing service tasks safely, including fire safety.

Unbrazing system components

Safety precautions and procedures for removing brazed connections.

Disassembling system components

Steps for safely taking apart system components, including oil recovery.

Exchanging the refrigerant

Procedures for safely handling refrigerant exchange and contamination checks.

Replacing a compressor

Steps for replacing a compressor, including oil handling and motor burnout issues.

Lubrication and oil removal

Procedures for handling oil during maintenance, disposal, and chemical compatibility.

Appendix 1: Compressor connections

2D* Compressor connections

Detailed connection points, sizes, and part numbers for 2D* models.

3D* Compressor connections

Detailed connection points, sizes, and part numbers for 3D* models.

8D* Compressor connections

Detailed connection points, sizes, and part numbers for 8D* models.

Appendix 2: Tightening torques (Nm)

2D* and 3D* Tightening torques

Torque specifications for various components on 2D* and 3D* compressor models.

8D* Tightening torques

Torque specifications for various components on 8D* compressor models.

Other torque specifications

Torque values for magnetic plugs, cylinder heads, mounting feet, and terminal studs.

Troubleshooting

Lubrication issues

Common lubrication problems, causes, and symptoms like oil pump-out and low gas velocity.

Oil dilution problems

Causes and prevention of oil dilution, including foaming and bearing failure.

Inadequate suction superheat

Diagnosing and resolving issues related to low suction superheat causing component damage.

Acid formation causes

Causes and remedies for acid formation from moisture, oxygen, and high temperatures.

Inadequate compressor cooling

Identifying and addressing issues with compressor cooling leading to high discharge temperatures.

High discharge temperatures

Symptoms and causes of excessive discharge temperatures, like dirty condensers.

Motor burnout (undersized contactors)

How undersized contactors can lead to motor burnout despite protection systems.

Motor burnout (bypassed protectors)

Consequences of bypassing or disconnecting motor protection devices leading to burnout.

Disclaimer

Publication content and usage

Information on publication scope, product modifications, and user responsibility for selection and use.

Emerson's liability

Disclaimer regarding liability for product specifications, errors, and warranties.

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