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Emerson Copeland Discus Series User Manual

Emerson Copeland Discus Series
45 pages
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Application Guidelines
Semi-Hermetic Compressors
Discus, K, L & S-Series

Table of Contents

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Emerson Copeland Discus Series Specifications

General IconGeneral
Frequency50/60 Hz
RefrigerantR-22, R-407C, R-134a, R-404A, R-507
ApplicationAir Conditioning, Refrigeration
StagesSingle Stage
Cooling MethodAir Cooled, Water Cooled
DisplacementVaries with model
Voltage575
Sound LevelVaries with model
WeightVaries with model

Summary

Safety Instructions

Icon Explanation

Explains safety icons used in the manual for hazard communication.

Safety Statements

Lists essential safety rules for personnel, equipment, and intended use.

General Instructions

Provides general safety warnings and instructions for handling and operation.

Product Description

Common Information about Copeland Semi-Hermetic Compressors

Overview of compressor families, types, and applications.

About These Guidelines

Explains the purpose and scope of the application guidelines document.

Nomenclature

Details the model designation system for compressors.

Air- or Water-Cooled Compressors

Details the model designation system for air/water-cooled compressors.

Suction Gas-Cooled Compressors

Details the model designation system for suction gas-cooled compressors.

Nameplate Information

Explains how to interpret compressor nameplate data.

DWM Copeland Designation (Old Models)

Explains nameplate designations for older DWM Copeland compressor models.

Copeland Brand Designation (Present Models)

Explains nameplate designations for current Copeland brand compressors.

Application Range

Covers the scope of applications for the compressors.

Qualified Refrigerants and Oils

Lists compatible refrigerants and oils for compressor operation.

Application Limits

Refers to software for detailed compressor application limits.

Design Features

Details the various design aspects of the compressors.

Construction

Describes the internal and external construction of compressor series.

Compressor Cooling

Details methods of compressor and cylinder head cooling systems.

Unloaded Start

Explains the concept and benefits of unloaded compressor starts for reduced stress.

Capacity Control

Describes mechanical capacity control options available for compressors.

Demand Cooling

Explains the Demand Cooling accessory kit for low-temperature applications.

Discharge Temperature Control Valve (DTC)

Details the DTC valve for low-temperature R22 applications.

Running Gear Lubrication

Explains lubrication systems for air/water-cooled compressors.

Oil Pumps – Suction Gas-Cooled Compressors

Describes oil pumps used in suction gas-cooled compressors.

Oil Pressure

Explains how to measure and interpret oil pressure readings.

Oil Circulation

Details the oil circulation process within the compressor.

Oil Level

Instructions on how to check and maintain the correct oil level.

Oil Separation & Management for Booster Applications

Recommends oil separators for booster systems.

R22 Low Temperature Applications

Specifics for R22 low-temp apps with certain models.

Installation

Compressor Handling

Guidelines for safely handling and moving compressors.

Delivery

Procedures for checking compressor delivery for correctness and completeness.

Transport and Storage

Safety precautions for transporting and storing compressors to prevent damage.

Positioning and Securing

Instructions for correctly positioning and securing compressors.

Installation Location

Recommendations for selecting a suitable installation location for compressors.

Mounting Parts

Details on mounting parts for vibration reduction and shock absorption.

Pressure Safety Controls

Details pressure safety controls for compressor protection.

High-Pressure Control

Specifies requirements for high-pressure cut-out devices.

Low-Pressure Control

Specifies requirements for low-pressure cut-out devices.

Internal Pressure Relief Valve

Explains the function of internal pressure relief valves.

Oil Pressure Switch

Details the function and specifications of oil pressure switches.

Maximum Allowable Pressures

Lists the maximum permitted operating pressures for compressors.

Brazing Procedure

Provides essential guidelines for proper brazing techniques to prevent contamination.

Screens

Advises on the use and minimum opening size of system screens.

Electrical Connection

General Recommendations

General advice before making electrical connections to the compressor.

Electrical Installation

Guides on wiring single-phase and three-phase motors.

Single-Phase Motors – Code C

Specifics for single-phase motor electrical connections and components.

Three-Phase Motors

General information on three-phase motor connections.

Direct-on-Line Start Motors – Code T

Details for direct-on-line start motor connections.

Star-Delta Motor (Y/Δ) – Code E

Explains star-delta motor wiring and voltage interchangeability.

Part-Winding Motor (YY/Y) – Code A

Details for part-winding motor connections and start sequence.

Wiring Diagrams

Refers to external wiring diagrams for recommended power and control circuits.

Protection Devices

Advises on installing external protection devices like fuses before the compressor.

Motor Protection

Details motor protection systems for compressors.

Over-Current Thermal Protection Switch for Single-Phase Motors – System A

Explains thermal protection for single-phase motors.

Thermistor Protection – System W

Details thermistor protection for three-phase motors.

Discharge Temperature Protection

Covers protection against high discharge temperatures.

Demand Cooling

Explains the Demand Cooling system for low-temperature applications.

Oil Pressure Control

Details oil pressure monitoring and control systems.

Oil Pressure Switch (OPS2)

Explains the function and wiring of the OPS2 oil pressure switch.

SENTRONIC Oil Pressure Control

Describes the SENTRONIC oil pressure control system.

Oil Pressure Switch – ALCO FD 113 ZU (A22 - 057)

Details the ALCO FD 113 ZU oil pressure switch.

Crankcase Heaters

Explains the purpose and types of crankcase heaters.

Starting Up & Operation

Leak Test

Procedures for performing a leak test on the refrigeration system.

System Evacuation

Steps for evacuating the refrigeration system to remove moisture.

Preliminary Checks – Pre-starting

Checklist for pre-start checks before system operation.

Charging Procedure

Guidelines for charging the system with refrigerant.

Initial Start-Up

Instructions for the initial startup of the compressor.

Minimum Run Time

Recommends minimum run time for oil return after start-up.

Recommended Inverter Range

Information on compatible inverters and frequency ranges for operation.

Maintenance & Repair

Exchanging the Refrigerant

Procedures for changing refrigerants in the system.

Refrigerant Retrofit from HFC to HFO/HFC Blends

Guidelines for retrofitting to new refrigerant blends.

Shut-off Valves

Advises on periodically re-torquing shut-off valves for leak prevention.

Compressor Replacement

Steps and precautions for replacing a compressor, including accumulator.

Lubrication and Oil Removal

Details oil types and handling for HFC refrigerants.

Oil Additives

Disclaimer regarding the use of oil additives and potential warranty issues.

Unbrazing System Components

Safety warnings for unbrazing system components due to flammable mixtures.

Troubleshooting

Lubrication Problems

Common lubrication issues and their potential causes.

Oil Dilution

Explains oil dilution and its effects on compressor operation.

Refrigerant Migration

Discusses refrigerant migration and prevention methods.

Inadequate Suction Superheat

Identifies causes and effects of low suction superheat.

Acid Formation

Explains acid formation, its causes, and how to address it.

Inadequate Compressor Cooling

Discusses issues related to insufficient compressor cooling.

High Discharge Temperatures

Explains high discharge temperatures and their symptoms.

Motor Burnout due to Undersized Contactors

Causes of motor burnout from undersized contactors.

Motor Burnout due to By-passed or Disconnected Protectors

Explains motor burnout from bypassed protectors.

Dismantling & Disposal

Procedures for safe removal and disposal of compressor components.

Procedures for safely dismantling and disposing of compressors and their contents.

Appendix 1 – Compressor Connections

Standard Compressor Connections

Details on standard compressor connection types and sizes.

Appendix 2 - Tightening Torques (Nm)

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