Application Guidelines

About these guidelines

These application guidelines provide guidance for the application of Copeland™ Stream Digital semi-hermetic compressors (4M*D and 6M*D). They address questions related to designing, assembling, and operating systems with these products. The instructions are critical for proper and safe compressor functioning. Misuse or non-adherence to these guidelines may impact product performance and reliability. These guidelines cover stationary applications only; for mobile applications, contact Application Engineering.

1 Safety instructions

Copeland™ semi-hermetic compressors adhere to the latest European safety standards, with a strong emphasis on user safety. They are intended for installation in systems compliant with the Machinery Directive MD 2006/42/EC. Installation must follow instructions and conform to relevant legislation. Refer to the Manufacturer's Declaration at www.climate.emerson.com/en-gb for standards. These instructions must be retained throughout the compressor's lifetime. Adherence to these safety instructions is strongly advised.

1.1 Icon explanation

• ⚠️ WARNING: Indicates instructions to avoid personal injury and material damage.
• ⚠️ CAUTION: Indicates instructions to avoid property damage and possible personal injury.
• ⚡ High voltage: Indicates operations with a danger of electric shock.
• IMPORTANT: Indicates instructions to avoid compressor malfunction.
• ?❄️ Danger of burning or frost burn: Indicates operations with a danger of burning or frost burn.
• NOTE: Indicates a recommendation for easier operation.
• ? Explosion hazard: Indicates operations with a danger of explosion.

1.2 Safety statements

• Refrigerant compressors must be used only for their intended purpose.
• Only qualified and authorized HVAC or refrigeration personnel may install, commission, and maintain this equipment.
• Electrical connections must be made by qualified electrical personnel.
• All applicable standards for connecting electrical and refrigeration equipment must be observed.
• National legislation and regulations regarding personnel protection must be observed.
• Use personal safety equipment: safety goggles, gloves, protective clothing, safety boots, and hard hats should be worn as necessary.

1.3 General instructions

• WARNING System breakdown! Personal injuries! Never install a system and leave it unattended without charge, a holding charge, or with service valves closed without electrical lockout.
• WARNING System breakdown! Personal injuries! Only approved refrigerants and refrigeration oils must be used.
• WARNING High shell temperature! Burning! Do not touch the compressor until it has cooled down. Ensure other materials do not contact it. Lock and mark accessible sections.
• CAUTION Overheating! Bearing damage! Do not operate the compressor without a refrigerant charge or without it being connected to the system.
• CAUTION Contact with POE! Material damage! Handle POE lubricant carefully with proper protective equipment. Avoid contact with surfaces or materials it might damage, including certain polymers like PVC/CPVC and polycarbonate.
• IMPORTANT Transit damage! Compressor malfunction! Use original packaging. Avoid collisions and tilting.

2 Product description

2.1 General information about Copeland™ Stream Digital semi-hermetic compressors

These guidelines cover Copeland™ Stream Digital semi-hermetic compressors, part of a reciprocating compressor family ranging from 13 hp to 50 hp. The table below provides performance data at full load.

1) R448A / R449A: evaporating -10 °C, condensing 45 °C, suction gas temperature 20 °C, subcooling 0 K

R134a: evaporating -10 °C, condensing 45 °C, suction superheat 20 K, subcooling 0 K

2) R448A / R449A: evaporating -35 °C, condensing 40 °C, suction gas temperature 0 °C, subcooling 0 K

Stream Digital compressors are suitable for single compressors, condensing units, or multi-compressor systems.

NOTE: The compressor is one component of a functional refrigeration system. This manual pertains to Copeland Stream semi-hermetic compressors with standard equipment and accessories only.

2.2 Nomenclature

The model designation provides technical information about Stream compressors, including cylinder count, bore, design revision, oil type (X=Ester, 0=Mineral), CoreSense™™ Diagnostics (D), CoreSense™™ Protection (P), or NextGen CoreSense™™ (N), digital (D) or stream (M) designation, service (S), motor size, motor code, and special BOM or blank.

2.3 Nameplate information

Key identification information is printed on the nameplate below the oil pump. The installer should stamp the refrigerant type used on the nameplate. The serial number indicates the year and month of production (e.g., Jan = A, Feb = B).

2.4 Application range

2.4.1 Qualified refrigerants and oils

WARNING Use of R450A and R513A refrigerants may cause compressor damage due to low oil viscosity if refrigerant migration occurs. Strict adherence to requirements is critical:

• Maintain adequate superheat (minimum 8-10K).
• Prevent liquid refrigerant migration at all times, including during standstill, defrost, or heat pump reverse mode.
• Pumpdown is recommended.
• Crankcase heater is mandatory.
• Retrofitting to R450A and R513A is only permitted for approved compressors. Contact Application Engineering for details.

IMPORTANT Carefully consider the glide of refrigerant blends (e.g., R407C) when adjusting pressure and superheat controls.

Oil recharge values are available from Copeland™™ brand products Select software at www.climate.emerson.com/en-gb.

2.4.2 Application limits

Refer to Copeland brand products Select software at www.climate.emerson.com/en-gb for application envelopes.

2.5 Design features

2.5.1 Compressor construction

Stream Digital compressors feature non-dismantlable valve plates. Use the correct valve-plate-to-body gasket for exchanges. The digital head is on the cylinder bank near the terminal box. 6M*D compressors have standard capacity control on the central cylinder bank. Each cylinder head has a plugged 1/8"-27 NPTF hole for high-pressure switches, which must be calibrated and tested to stop the compressor if pressure is exceeded. The cylinder head is under discharge pressure.

The factory delivery includes a standard bank, a Digital modulated bank, and for 6M*D, a capacity-controlled bank (blocked suction). To upgrade 6M* to 6M*D, Emerson recommends using the central cylinder bank.

2.5.2 Digital theory of operation

Digital technology enables 50-100% capacity modulation on 4M*D compressors (one bank) and 33-100% on 6M*D compressors (with blocked suction bank). Control is achieved via an internal unloading method that blocks gas to the valve plate suction area, regulated by a solenoid valve controlling an unloader piston mechanism.

2.5.3 Digital control

Capacity modulation occurs by energizing/de-energizing the solenoid valve. De-energized = 100% capacity; energized = 0% capacity. Average capacity is time-averaged. For example, 16 seconds de-energized and 4 seconds energized in a 20-second cycle yields 80% capacity.

For 4M*D, one bank is at 100% load, while the Digital bank modulates 0-100% (50-100% total capacity). For 6M*D with blocked suction, the blocked bank unloads below 67% demand and loads above it. The Digital bank provides continuous capacity from 33-100%.

2.5.4 Recommended application settings for modulation on Stream Digital compressors

The recommended digital modulation cycle time is 20 seconds. Consult Emerson Application Engineering for other values. The load/unload times determine the operating range. Minimum capacity is 50% for 4M*D and 33% or 67% for 6M*D.

2.5.5 Digital solenoid valve / Gaskets

Only Emerson solenoid valves and gaskets are permitted due to high life cycle requirements and warranty voidance. Solenoid coils are sold separately and are available for 24 V, 120 V, and 240 V. Special head and valve plate gaskets ensure proper digital modulation gas flow.

2.5.6 Compressor cooling

Compressor motors and cylinder heads require cooling. Stream Digital compressors are suction gas-cooled, with refrigerant gas cooling the motor. An additional fan may be needed depending on operating conditions; consult Select software.

2.5.7 Unloaded start

Direct starting involves switching the motor directly to the mains. This results in high breakaway starting current, potentially causing voltage dips. Compressors with current limitation require starting load reduction, especially at voltages below 85% of the nameplate value.

2.5.8 Oil pumps

Oil pumps are independent of rotation direction. Compressors with CoreSense™™ (-N) or CoreSense™™ Diagnostics (-D) have an integrated electronic switch for oil pressure safety. CoreSense™™ Protection (-P) compressors accommodate fittings for an OPS2 (oil sensor) or a mechanical oil safety device.

2.5.9 Oil pressure

Normal oil pressure is 1.05 to 4.2 bar above crankcase pressure. Net oil pressure is measured by comparing readings from gauges connected to the oil pump and the crankcase or suction service valve. Pressure drops due to conditions like suction filter blockage must be avoided.

2.5.10 Oil circulation

Oil returns via suction gases, a strainer, and the motor chamber, then to the crankcase via a relief valve. A crankcase ventilating valve equalizes pressure between the crankcase and suction side, ensuring smooth oil foam transfer to the oil pump. Both 4M*D and 6M*D compressors have one crankcase ventilating valve.

2.5.11 Oil level

Compressors are delivered with sufficient oil. Check the oil level via the sight glass when the system is stable (min ¼ to max ½). For service compressors with an oil regulator, the level is min ¼ to max ¾. The level can be checked within 10 seconds of shutdown. A higher oil level may be acceptable with an oil regulator on 4M*D and 6M*D compressors.

2.5.12 Multiple-compressor applications

For optimal suction pressure control and smooth modulation, select Stream Digital and fixed-capacity compressors based on capacity rules (F1 < D, F2 < D+F1, etc.). The Stream Digital compressor should have the smallest capacity to cover gaps efficiently. For example, a 4M*D (50-100% capacity) requires an associated fixed-capacity compressor of 50-100% of its load. For best results, the Stream Digital compressor must be the lead compressor (first on, last off).

3 Installation

WARNING High pressure! Injury to skin and eyes possible! Be careful when opening connections on a pressurized item.

3.1 Compressor handling

3.1.1 Delivery

Verify delivery is correct and complete. Report any deficiencies in writing.

Standard delivery includes: suction and discharge shut-off valves, oil charge, oil sight glass, mounting kit, digital solenoid valve (factory-mounted), CoreSense™™ module, and a holding charge up to 2.5 bar(g) (dry air).

3.1.2 Transport and storage

WARNING Risk of collapse! Personal injuries! Move compressors using appropriate equipment, keep upright, and respect stacking loads (Figure 8). Check tilting stability and keep packaging dry.

Maximum stacking: Transport n=1, Storage n=1.

3.1.3 Positioning and securing

IMPORTANT Handling damage! Compressor malfunction! Use only lifting eyes for positioning. Using discharge or suction connections can cause damage or leaks. Keep the compressor horizontal during handling.

Use two lifting eyes (" - 13 UNC) before moving. Refer to Figure 9 for other lifting methods. Max weight: 4M*D: 220 kg, 6M*D: 260 kg.

Do not lift by service valves or other accessories to avoid refrigerant leaks or damage.

3.1.4 Installation location

Ensure compressors are installed on a solid, level base.

3.1.5 Mounting parts

Use flexible mounting (spring parts included) to minimize vibration and start/stop impulses. Different springs (violet for motor side, orange for cylinder side) are used due to weight differences. Rubber mounting parts are recommended for rack installations. Rigid mounting transmits more vibration. Ensure the mounting surface is flat to avoid mechanical stress. Additional vibration absorbers can be used for high vibration absorption.

3.2 Pressure safety controls

3.2.1 High-pressure control

A high-pressure control with a maximum cut-out setting of 28.8 bar(g) is required, featuring a manual reset for system protection.

3.2.2 Low-pressure control

The normal minimum cut-out setting is 0.1 bar(g) for R404A, requiring a manual reset for system protection.

3.2.3 Maximum allowable pressures

Maximum allowable pressures (EN 12693) on the nameplate must not be exceeded: High-pressure side (HP): 28.0 bar (g) (up to S/N 14K46143M), 32.5 bar (g) (from S/N 14K46144M onwards). Low-pressure side (LP): 22.5 bar.

3.3 Brazing procedure

IMPORTANT Blockage! Compressor breakdown! Maintain a flow of oxygen-free nitrogen at low pressure during brazing to prevent copper oxide formation, which can block system components. Contamination or moisture! Bearing failure! Do not remove plugs until the compressor is set into the unit.

Refer to Figure 11 for brazing suction and discharge lines. Use silfos material, preferably with 5% silver. Ensure tube fittings are clean. Apply heat sequentially to areas 1, 2, and 3. Overheating can be detrimental. To disconnect, heat areas 2 and 3 until the material softens. To reconnect, use silfos with minimum 5% silver or silver braze.

3.4 Screens

CAUTION Screen blocking! Compressor breakdown! Use screens with at least 0.6 mm openings. Avoid screens finer than 30x30 mesh, as they can become plugged, blocking refrigerant or oil flow and causing compressor failure.

4 Electrical connection

4.1 General recommendations

Check the wiring diagram inside the terminal box cover. Ensure supply voltage, phases, and frequency match nameplate data. Remove knockouts carefully using a twist driller before installing electrical glands.

4.2 Electrical installation

All compressors can be started Direct-On-Line. Refer to section 4.2.3 for jumper positions for Direct-On-Line or part-winding start.

4.2.1 Part-winding motors (YY/Y) – Code A

These motors have two windings (2/3 + 1/3) connected in star and operated in parallel. Voltage cannot be changed by electrical connections. For part-winding start, remove bridges; the second winding (1/3) on terminals 7-8-9 must be connected after a 1 ± 0.1 second delay.

4.2.2 Star / Delta motors (Y/Δ) – Code E

These motors are interchangeable for star (Y) or delta (Δ) operation via bridges and support two voltages (e.g., 230V delta, 400V star). If supply voltage matches the delta connection voltage, the star connection can be used for starting.

4.2.3 Terminal box isolators and jumper position

Diagrams illustrate direct-on-line and part-winding start for part-winding motors (Code A), and direct-on-line and star/delta start for star/delta motors (Code E).

4.3 Wiring diagrams

Wiring diagrams are provided for compressors with Next Generation CoreSense module (basic protection, part-winding motors, star/delta motors), CoreSense Protection module (part-winding motors, star/delta motors), and CoreSense Diagnostics module (part-winding motors, star/delta motors).

4.4 Protection devices

Fuses must be installed before the compressor, selected according to relevant standards (VDE 0635, DIN 57635, IEC 269-1, EN 60-269-1).

4.5 Next Generation CoreSense™

Next Gen CoreSense is standard on 4M*D and 6M*D compressors, offering active protection, advanced algorithms, fault history, and LED indicators for quicker diagnostics and reduced downtime. It features a compact design with a base board and optional plug-in modules. It provides protection against faults like high discharge temperature, locked rotor, phase issues, and voltage imbalance. External overload protection is not required. Communication is possible via Modbus and Bluetooth.

4.5.1 Next Gen CoreSense specifications

The module is prewired in the terminal box. Power supply is 115 VAC or 230 VAC. Operating ambient temperature: -30 °C to 70 °C. Storage temperature: -30 °C to 80 °C. Voltage requirements: 115-230 VAC - 50/60Hz. Protection class: IP00.

4.5.2 Next Gen CoreSense features

Next Gen CoreSense is modular, allowing customers to select individual protection and control levels to enhance compressor lifetime.

4.6 CoreSense™ Protection

4.6.1 Motor protection

IMPORTANT Use the same potential for power supply (L) and switch contact (11-14) to prevent module malfunction.

Compressors with "-P" designation have CoreSense Protection using thermistors (PTC-resistance) embedded in motor windings to sense temperature. The module switches a control relay based on thermistor resistance. Maximum test voltage for thermistors is 3 V. Total resistance of cold thermistor chains should be ≤ 1800Ω. Module protection class: IP20.

4.6.2 Oil pressure control

The oil pressure switch breaks the control circuit if the pressure difference between the oil pump outlet and crankcase is too low. It must be properly adjusted and tamper-proof. A drop below the minimum acceptable value stops the compressor after a 120-second delay; manual reset is required. Proper oil pressure safety control is a warranty condition.

Available switches: Electronic oil pressure switch OPS2, Mechanical oil pressure switch Alco FD-113ZU.

4.6.2.1 Electronic oil pressure switch – OPS2

Specifications: Differential pressure: 0.95 ± 0.15 bar. Time delay: 120 ± 15 sec. A 7-wire cable is recommended for full features. Refer to Technical Information D7.8.3 for wiring diagrams.

4.6.2.2 Mechanical oil pressure switch – Alco FD-113ZU (A22 - 057)

Specifications: Cut-out pressure: 0.63 ± 0.14 bar. Cut-in pressure: 0.9 ± 0.1 bar. Time delay: 120 ± 15 sec. Protection class: IP30.

4.7 CoreSense™ Diagnostics (until December 2019 included)

CoreSense™ Diagnostics was fitted on 4M*D and 6M*D compressors until December 2019. It combines oil and motor protection, replacing OPS1/2 and INT69TM. It offers advanced protection against faults and communicates via Modbus protocol. External overload protection is not necessary.

4.8 Crankcase heaters

IMPORTANT Oil dilution! Bearing malfunction! Turn the crankcase heater on 12 hours before starting the compressor.

Crankcase heaters prevent refrigerant migration into the shell during standstill periods. They are available for 120 V, 230 V, and 480 V. 115 V and 230 V heaters can be controlled by Next Gen CoreSense; 480 V heaters cannot.

5 Start-up & operation

WARNING Diesel effect! Compressor destruction! Mixture of air and oil at high temperature can cause an explosion. Avoid operating with air.

5.1 Leak test

Keep suction and discharge shut-off valves closed during pressure testing (dried nitrogen) up to 20.5 bar (or lower if system components have lower pressure limits) to prevent air and moisture entry.

5.2 System evacuation

Remove holding charge and evacuate with a vacuum pump to reduce residual moisture to 50 ppm. Use adequately sized access valves. Evacuate the system to 0.3 mbar / 0.225 Torr. Measure pressure at access valves, not the pump. The factory dry air charge (1-2.5 bar) indicates no leaks. Removing plugs may cause oil spurt.

5.3 Preliminary checks – Pre-starting

Discuss installation details with the installer. Obtain drawings and wiring diagrams. Perform checks including:

• Visual check of electrics, wiring, fuses.
• Visual check for plant leaks, loose fittings.
• Compressor oil level.
• Calibration of HP & LP switches and pressure-actuated valves.
• Setting and operation of safety features and protection devices.
• Valve positions.
• Pressure and compound gauges.
• Refrigerant charge.
• Electrical isolator location.

5.4 Charging procedure

CAUTION Low suction pressure operation! Compressor Damage! Do not operate with restricted suction or bridged low-pressure cut-out.

Liquid-charge through the liquid-receiver shut-off valve or liquid line. Use a filter drier. Place most of the charge in the high side to prevent bearing washout.

5.5 Initial start-up

CAUTION Oil dilution! Bearing malfunction! Ensure new compressors are not subjected to liquid abuse. Turn crankcase heater on 12 hours prior to start.

CAUTION High discharge pressure operation! Compressor damage! Do not use the compressor to test the high-pressure cut-out set point.

Equip the compressor per technical documentation before start-up. Use 30% silver alloy rod for brazing dissimilar/ferric metals. Bolt torque settings are in Appendix 2. Oil gaskets and O-rings before fitting, except for rubber-coated ones. Never operate the compressor outside its approved range or perform high-potential testing under vacuum.

5.6 Minimum run time

Emerson recommends a maximum of 10 starts per hour. Minimum run time is critical for oil return after start-up.

5.7 Pump-down

For systems requiring pump-down, pay attention to the Digital unloader coil control logic. To avoid extended pump-down cycles, de-energize the Digital solenoid when initiating pump-down, forcing the compressor to run at 100% capacity.

6 Maintenance & repair

6.1 Provisions of legislation & leak check requirements

Systems with over 3 kg refrigerant charge require annual tightness inspection (EN 378-4). Maintain a logbook of all maintenance and repair works. The F-gas Regulation (EU) No 517/2014 mandates leak checks based on refrigerant GWP and system charge (CO2e). Leak check frequency varies from annually to quarterly based on CO2e tonnage. Permanent leak detection systems can halve this frequency.

The F-gas Regulation includes additional requirements and training for alternative refrigerants. HFO refrigerants are covered for reporting purposes.

6.2 Exchanging the refrigerant

Refer to Chapter 2.4.1 for qualified refrigerants and oils. Replace refrigerant only if contamination is suspected, verifying composition via chemical analysis. Compare refrigerant temperature and pressure during shutdown for verification. Recover refrigerant using a suitable unit. If R22 with mineral oil is replaced by an HFC refrigerant, the oil must also be changed. Refer to Technical Information CC7.26.1 and CC7.26.3 for changeover details.

6.3 Replacing a compressor

CAUTION Inadequate lubrication! Bearing destruction! Replace the accumulator after a burned-out motor to prevent oil starvation in the new compressor. Contaminated oil is removed via filter driers. A 100% activated alumina suction line filter drier is recommended (remove after 72 hours). Replace the suction accumulator if plugged. If a major portion of oil remains in the system, it may increase rotor drag and power usage.

6.4 Lubrication and oil removal

CAUTION Chemical reaction! Compressor destruction! Do not mix ester oils with mineral oil or alkyl benzene for chlorine-free (HFC) refrigerants.

The compressor is supplied with initial oil charge. Standard oil is polyolester (POE) lubricant Emkarate RL 32 3MAF for most refrigerants, and mineral oil Suniso 3GS for R22. POE is more hygroscopic than mineral oil; brief exposure to air can absorb moisture. Properly sized filter-driers are recommended for POE systems to maintain moisture below 50 ppm. Use POE with moisture content no higher than 50 ppm for charging.

Figure 31 compares moisture absorption of ester oil versus mineral oil. High moisture content can cause corrosion and copper plating. Evacuate systems to 0.3 mbar or lower. Test oil samples for moisture if uncertain.

6.5 Oil additives

Emerson does not recommend additives for reducing compressor bearing losses or for any other purpose due to complex chemical stability issues and potential for malfunction or warranty voidance.

6.6 Unbrazing system components

WARNING Explosive flame! Fire hazard! Oil-refrigerant mixtures are highly flammable. Remove all refrigerant before opening the system. Avoid unshielded flames in charged systems.

Remove all refrigerant before unbrazing. Applying a brazing torch to a pressurized system can ignite the mixture. Check both sides with manifold gauges before unbrazing. If compressor removal is necessary, cut it out rather than unbrazing.

7 Dismantling & disposal

Remove oil and refrigerant without dispersing them into the environment, using correct equipment and methods. Dispose of oil, refrigerant, and the compressor in compliance with national legislation and regulations.

Appendix 1: Connections of Stream Digital compressors

4M*D

6M*D

Appendix 2: Tightening torques in Nm

* In case of replacement of the piston con-rod assemblies, clean the Torx screws and apply Loctite 2701.

Torque values are assembly torques. Torque after joint relaxation must be within 15% of minimum assembly torque unless re-torque is specified, and not exceed 10% of maximum assembly torque.

Disclaimer

1. This publication is for informational purposes only and does not constitute warranties or guarantees.
2. Emerson Climate Technologies reserves the right to modify product designs and specifications without prior notice.
3. Emerson is not responsible for product selection, use, or maintenance; this remains the purchaser's responsibility.
4. Emerson is not liable for possible typographic errors.