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AE4-1396 R4

AE4-1396 R5

Application Guidelines for Copeland™ Semi-Hermetic Compressors for Transcritical CO2 Applications

January 2017

Safety ........................................................................ 2 Safety Instructions ................................................... 2 Safety Icon Explanation ........................................... 2 Instruction Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons ......................................... 3 Safety Statements ................................................... 3Introduction .............................................................. 4 Nomenclature ......................................................... 4 Application Range .................................................. 4 QualifiedRefrigerantsandOils ........................... 4 Application Limits ................................................ 4 Design Features ..................................................... 4 Compressor Construction ................................... 4 Compressor Cooling ........................................... 4 OilLubrication ..................................................... 5 OilLevel .............................................................. 5 OilLevelControl ................................................. 5Installation ................................................................ 5 CompressorHandling ............................................. 5 Delivery ............................................................... 5 TransportandStorage ........................................ 5 PositioningandSecuring .................................... 5 Installation Location ............................................ 6 Mounting Parts .................................................... 6 Pressure Safety Controls ........................................ 6 SafetyReliefValve/StandstillPressures ............. 6 MaximumOperatingPressures .......................... 6 ShutOffValveDesign ............................................. 6 Screens .................................................................. 7Electrical Connection .............................................. 7 GeneralRecommendations ....................................... 7 Electrical Installation .................................................. 7 Three Phase Motors ........................................... 7 Part-WindingMotor ............................................. 7 Wiring Diagrams ................................................. 7 Terminal Box Isolator .......................................... 7 Breaker ............................................................... 7 CoreSense Protection ............................................ 7 Crankcase Heaters ................................................. 8

Table of ContentsStartup and Operation ............................................. 8 Leak Test ................................................................ 8 SystemEvacuation ................................................. 8 Preliminary Checks (Pre-Start) ............................... 8 ChargingProcedure ............................................... 8 Initial Start-Up ......................................................... 9 Minimum Run Time ................................................. 9 RecommendedInverterRange .............................. 9Maintenance and Repair ......................................... 9 Exchanging the Refrigerant .................................... 9 Replacing a Compressor ........................................ 9 LubricationandOilRemoval ................................. 10 OilAdditives ........................................................... 10 UnbrazingSystemComponents ............................ 10Dismantling and Disposal ...................................... 10Figures and Tables ..................................................114MTLS Name Plate ...................................................11CO2Envelope .......................................................... 124MTLS Sight Glasses ............................................... 13SightGlassOilLevel ................................................ 13StackingConfiguration ............................................. 13Lifting Eyes ............................................................... 13Mounting Parts ......................................................... 14SafetyValveLocation ............................................... 14Pressure Connection Ports....................................... 15CompressorElectricalWiringConfig.–FSD/TSE.... 16CompressorElectricalWiringConfig.–FSC............ 17Terminal Box Isolator ................................................ 18Terminal Plate ........................................................... 18Crankcase Heater..................................................... 19OilDilutionGraph ..................................................... 19Electronics Locations................................................ 20Wiring Diagram for CoreSense................................. 20QualifiedRefrigerantsandOils................................. 21OilSensorKit............................................................ 214MTLSModelSelection ........................................... 21 Appendix 2: 4MTLS Tightening Torques ................. 23


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Safety InstructionsCopeland™compressorsaremanufacturedaccordingtothelatestU.S.andEuropeanSafetyStandards.Particularemphasishasbeenplacedontheuser'ssafety.Safetyiconsareexplainedbelowandsafetyinstructionsapplicabletotheproductsinthisbulletinaregroupedonpage3.Theseinstructionsshouldberetainedthroughoutthelifetimeofthecompressor.You are strongly advised to follow these safety instructions.

Safety Instructions Copeland Scroll™ compressors are manufactured according to the latest U.S. and European Safety Standards. Particular emphasis has been placed on the user's safety. Safey icons are explained below and safety instructions applicable to the products in this bulletin are grouped on Page 3. These instructions should be retained throughout the lifetime of the compessor. You are strongly advised to follow these safety instructions. Safety Icon Explanation

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

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.

DANGER

WARNING

CAUTION

NOTICE

CAUTION

FLAMMABLE


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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.

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.

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.

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.

Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons

WARNING

WARNING

WARNING

CAUTION


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INTRODUCTIONThis manual covers semi-hermetic Copeland™ CO2 compressors.The4MTLSmediumtemperaturemodelsrange from5hp to 30hpmodels.TheperformancelistedinTable 1attheendofthisdocumentcorrespondto60Hzoperation.

Thelineupoffourcylindersemi-hermeticcompressorsforCO2transcriticalapplicationsistheidealsolutionforthemediumtemperaturesectionoftheboostersystem.

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 medium temperature applications with standard equipment and accessories only.

Thisbulletinisintendedtoenableuserstoensurethesafeinstallation,starting,operationandmaintenanceof semi-hermetic compressors. It is not intended toreplace the system expertise available from systemmanufacturers.

NomenclatureThemodeldesignationcontainsthefollowingtechnicalinformation:

The Copeland 4MTLS compressor model numbersincludethenominalcapacityat60Hertz,at14°F/1305psia/32°F/95°F (evaporating temperature/dischargepressure/return gas temperature/gas cooler exittemperature)withR-744refrigerant.

Example:4MTLS82KE-FSD-C004=NumberofCylinders

MT=MediumTempApplication(Transcritical)

LS=ModelVariation

82K=NominalCapacity(kBtu/hr)

E,L=OilType(POE),Lessoil

FSC = 208-230 Volt Motor Version

FSD = 460 Volt Motor Version

TSE = 575 Volt Motor Version

C00=ProductVariation

Application RangeQualified Refrigerants and OilsCopeland4MTLSareonlyapplicable for transcriticalCO2 (R-744) applications. The approved oil is apolyolester (POE) lubricant, Emkarate RL68HB. OilchargeandrechargevaluesarelocatedinEmerson'sOnlineProductInformationatEmersonClimate.com. For other oil types, contact Emerson.Recommendedqualityforcarbondioxidepuritygradeis4.0[(≥99.99%)H2O≤10ppm,O2≤10ppm,N2≤50ppm]or higher.

Application Limits

CAUTIONOil dilution! Bearing malfunction! A minimum superheat of 9°F (5K) at the compressor inlet is required at all operating conditions to avoid oil dilution with CO2 (R-744). 18°F (10K) superheat is recommended.

The compressor superheat should be controlledat a balanced level to not only avoid oil dilution inthe compressor but also maintain a compressorhead discharge temperature below 310 °F (154°C),especiallyathighcompressionratios(highcondensingandlowevaporatingtemperatures).SeeFigure 2 for compressoroperatingenvelopes.

Design FeaturesCompressor ConstructionAll compressors are equipped with reed-style valveplates which cannot be dismantled. To maintain thehighcapacityof thesecompressors, thecorrectvalveplate-to-bodygasketmustalwaysbeselectedincaseof exchange.

Each cylinder head has a plugged 1/8" - 27 NPTFtappedholeforconnectinghigh-pressureswitches.High-pressureswitchesmustbecalibratedandtestedbeforeputtingthecompressorintoservice.Theymuststopthecompressorif1755psig(121bar)isexceeded.

Note: Copeland 4MTLS compressors come equipped with an external high side safety valve that opens at 1960 psi (135 bar). Refer to Safety Valves section.

Compressor CoolingAll4MTLSCO2compressorsaresuctiongas-cooled.With suction gas-cooled compressors, the motor iscooledbyrefrigerantgasthatflowsthroughthemotor.


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Depending on operating conditions, the maximumallowed suction gas superheat shall not exceed thevaluesshownintheenvelopes.

Oil Lubrication40Kto15McapacityratedCO2 compressors employ anoilimpellersystemtoensurelubricationatconstantandvariablespeedconditions.

Oil LevelAll 4MTLS CO2 compressors are equipped withthreesight glasses, twoof themon the sidesof thecompressorandoneonthefront.SeeFigure 3.

Theoptimumoillevelshouldbecheckedbyoperatingthe compressor until the system is stable and thencheckingthesightglassreadingwiththeappropriatediagram.

Oillevelonthesidesightglassesshouldbeaminimum1/4andmaximum3/4ofthesightglass.Thelevelcanalso be checked within 10 seconds of compressorshutdown.SeeFigure 4.

Thesightglassinthefrontofthecompressorservesasanoillevelcheckonly.Theoillevelduringoperationshouldbeatleast3/4ofthesightglassatalltimes.Iftheoillevelislessthanthisonthefrontofthecompressor,checktheoillevelsonthesidesightglasses.Oillevelcontrolscannotbemountedtothissightglass.

Sensorscanbeinstalledinthesightglassportonthesideofthecompressor.Thesightglassis1-1/8”–18UNEFwitha tightening torquespecificationof37-44lb-ft.

Oil Level Control40Kto15McapacityratedCO2 compressors are not assembledwithanoilpump,soanoilpressuresafetycontrol cannot be used to protect the compressoragainstlubricationproblemsforthesecompressors.

Afloat levelswitch foroilcanbeusedtoprotect thecompressoragainstoil loss.HBSO1isalevelswitchfor detecting common lubricating oils in refrigerationsystems.TheHBSO1oil level switch/sensor can beusedtosecureorcontrollubricationofcompressorsathighandlowpressureapplications.

Thesensordetectsoilwithoutdetectingrefrigerant.Itiscalibratedsothatitisunaffectedbyoilsprayandonlyallowsasmallamountoffoam.

Thesensorisconstructedsoastoresisthighpressureandtemperatures,soitissuitedforuseontranscriticalCO2 refrigeration systems.

FormoreinformationonapplyingtheHBS01referhttp://www.hbproducts.dk/en/products/oil-sensor/hbso1-oil-switch.

INSTALLATION

WARNINGHigh pressure! Injury to skin and eyes possible! Be carefulwhenopeningconnectionsonapressurizeditem.

Compressor HandlingDeliveryPlease check whether the delivery is correct andcomplete;deficienciesshouldbereportedimmediatelyinwriting.

StandardDelivery:• Suctionanddischargeshut-offvalves• Oilcharge,oilsightglass• Mountingkit(rubber)• CoreSenseProtectionmodule• Electrical terminals• Safetypressurereliefvalveondischarge• Holdingchargeuptoagaugepressureof2.5bar(36.25psig)(dryair)

Transport and Storage

WARNINGRisk of collapse! Personal injuries! Move compressors only with appropriate mechanical or handling equipment according to weight. Keep in the upright position. Do not stack pallets on top of each other. Keep the packaging dry at all times. See Figure 5.

Compressors are individually packed and may bedeliveredonpalletsdependingonquantityandsize.

Positioning and Securing

NOTICEHandling damage! Compressor malfunction!

Only use the lifting eyes whenever the compressor


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requires positioning. Using discharge or suctionconnectionsforliftingmaycausedamageorleaks.

Ifpossible,thecompressorshouldbekepthorizontalduring handling. For safety reasons two lifting eyesshouldbefittedbeforemovingacompressor(½"-13UNC). Refer to Figure 6.

Installation LocationEnsurethecompressorsareinstalledonasolidlevelbase.

Temperaturearoundthecompressorshouldnotexceed150°F in order to avoid suction gas temperatureincreaseandmalfunctioningofelectronics.

Mounting PartsTominimizevibrationandstart/stopimpulses,flexiblemountingshouldbeused.Forthispurposeonesetofrubbermountingpartsforeachofthe4MTLSmodelsisdeliveredwitheach4MTLScompressor.ThisKitcanbeusedforsingleandparalleloperation.SeeFigure 7.

When 4MTLS compressors are mounted in racks,rubbermountingpartsshouldbeused.

A compressor may be rigidly mounted (i.e., withoutrubbermountingorsprings).Inthiscasemoreshockandvibrationloadingwillbetransmittedtotheframe.Useonlythecompressormountingfeetforfixationandavoiddirectcontactofotherpartsof thecompressorhousingwithborderingcomponentsorbaseframe.

Iftheinstallationrequiresaveryhighlevelofvibrationabsorption,additionalvibrationabsorbers–availableonthemarket-canbefittedbetweentherailsandthefoundation.

Pressure Safety ControlsSafety Valves

WARNINGIn 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.

Safety Relief Valves/Standstill PressuresThecompressoremploysafactoryinstalledpressuresafety relief valve on the discharge side of thecompressor. The valve setting provides that if the

standstillpressuresof1960psi(135bar)areexceeded,thesafetyvalveopensandventsCO2 toambient topreventfurtherpressureincrease.

Emersonalsooffersa1305psi(90bar)lowpressuresafety relief valve thatmaybeemployed in thefieldonthesuctionorlowpressuresideofthecompressor.ThislowpressurevalveisnotrequiredbyULandisnotintendedtoreplacethehighpressurevalvebutratherserve as a means of added compressor protection.Typically, system controls will serve as a means ofprotectingthesuctionor lowpressureside.Withthisvalveemployed,standstillpressuresare1305psi(90bar) lowsideand1960psi (135bar)highside.SeeTable 2.

Note: The 1960 psi (135 bar) valve is M24 - LH thread and the 1305 psi (90 bar) valve is M24 - RH thread to prevent improper usage.

Maximum Operating PressuresMaximum operating pressures are defined by theoperatingenvelope,asseeninFigure 2.

It is recommended to connect the pressure cut-outdevices directly to the compressor housing. For ahigh-pressure cut-out switch, connection port 4maybeused.Forlow-pressurecut-outconnection,port6isrecommended.SeeFigure 9 to locate high pressure andlowpressureconnectionpositionsaswellastheportidentityonthecompressor.

Shut Off Valve Design 4MTLS compressors are factory equippedwith bothsuctionanddischargeshut-offvalves. Thestandardshut-off valves are flange valves with one flareconnection port (lockable) for service. The serviceconnectionport isa7/16”–20UNFwithablindcapSAE¼”(materialofblindcapisstainlesssteel1.4301).Valveconnectionmethodsmaybebrazing,buttwelding,orfilletwelding–seeTable 3forconnectionsizes.

Torquevaluesforthebolts,spindlecap,blindcapandglandsealmaybefoundinAppendix 2.Thespindleis front seated (closed to piping system) when thecompressorisdelivered.

Valvematerialisfinegrainedmildsteel(EN10025)withFe/Cu5Sn5platingmaterial.Forbrazingconnectionswhere dissimilar or ferricmetals are joined, a silveralloyrodwithaminimumof34%silvershouldbeused,eitherfluxcoatedorwithaseparateflux.Forwelding


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operations with stainless steel tubing, the weldingconsumablemustbeselectedfordissimilarmaterials(SStomildsteel).

OptionaldischargevalveswithcompressionfittingsareavailablethroughEmersonandinstalledinthefield.SeeTable 3 for offering.

Screens

CAUTION Screen blocking! Compressor breakdown! Use screens with at least 0.6 mm openings.

Theuseofscreensfinerthan30x30mesh(0.6mmopenings)anywhereinthesystemshouldbeavoidedwiththesecompressors.Fieldexperiencehasshownthat finer mesh screens used to protect thermalexpansion valves, capillary tubes, or accumulatorscanbecometemporarilyorpermanentlypluggedwithnormalsystemdebrisandblocktheflowofeitheroilorrefrigeranttothecompressor.Suchblockagecanresultin compressor failure.

Intheeventofareleasedchargethroughthesuctionsafety relief valve (if installed, not manditory),ensure that the suction screen does not need tobe replaced. If a replacement is required, refer to EmersonClimate.com

ELECTRICAL CONNECTIONGeneral RecommendationsThe compressor terminal box has a wiring diagramon the inside of its cover. Before connecting thecompressor,ensurethesupplyvoltage,thephasesandthefrequencymatchthenameplatedata.

Electrical InstallationThree Phase Motors AllcompressorscanbestartedDirect-On-Line.

Note: Pay special attention to the position of the voltage terminals. Refer to Figures 10 or 11.

Part-Winding Motor (YY/Y) – Code APart winding PWS motors contain two separatewindings which are internally connected in star andoperatedinparallel.Youcannotchangethevoltagebychanging the electrical connections, the motor is only suitableforonevoltage.

For40Kto64K,thefirstpartwinding,the1/2windingonterminals1-2-3,canbeusedforpartwindingstart.Afteratimedelayof1±0.1secondsthesecondpartwinding(1/2)mustbebroughtonline.

For82Kto15M,thefirstpartwinding,the2/3windingonterminals1-2-3,canbeusedforpartwindingstart.Afteratimedelayof1±0.1secondsthesecondpartwinding(1/3)mustbebroughtonline.

Wiring DiagramsThepositionofthejumpersintheterminalboxandtherecommendedwiringdiagramsareshowninFigures 10 or 11.

Terminal Box Isolator40Kto15MFSD(460v),40Kto15MTSE(575v)and40K to64KFSC(208/230v)compressormodelsareequippedwithtwoisolators.Oneisforacrossthelinestartandoneisforpartwindingstartapplicators.Referto Figure 12.82Kto15MFSC(208/230v)compressormodelsdonotincludeisolators.RefertoFigure 13.Note: It is recommended to use these isolators on above mentioned models including the terminal isolators in order to keep the terminals isolated.BreakerIndependentlyfromtheinternalmotorprotection,fusesmustbeinstalledbeforethecompressor.TheselectionoffuseshastobecarriedoutaccordingtoVDE0635,DIN 57635, IEC 269-1or EN 60-269-1.

CoreSense Protection CoreSense Protection provides motor protection for4MTLS compressors. The CoreSense Protection Module (CPM) will communicate a motor protectiontrip when the resistance caused by an increasingmotortemperaturehasrisenabove4.5KOhms.Thecompressorwillrestartoncetheresistancedropsbelow2.5KOhmsandfiveminuteshaselapsed.

CoreSense Protection for Copeland Discus 4MTLScompressors can also provide valuable dischargetemperature protection. By installing the temperature probeintotheheadoftheDiscus4MTLScompressorand connecting to the CPM, CoreSense will protectthe compressor from high discharge temperatureconditions. If the temperaturesensordetectsaheadtemperature greater than 310°F, CoreSense will trip


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thecompressoroffuntilthetemperaturecoolsdowntoanacceptablelevel(about267°F)andatwominuteofftimehasbeenachieved.Ahighdischargetemperaturelockoutcanalsobeenabled through theE2.Pleaserefer to AE8-1367 for more information about theCoreSense Protection and E2 setup screens. Themodule is capable of communication via MODBUSprotocol.

Because there is no oil pump, the low oil pressureprotection feature is disabled on the 4MTLScompressors.

The CoreSense Protection module comes factoryinstalled on each 4MTLS compressor. For electricalconnectionstothemodule,refertoAE8-1367.

Note: CoreSense Protection on 4MTLS compressors disables switch 6. Only switches 1 to 5 may be used for node address (32 combinations).

Crankcase HeatersNOTICE

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

Twovoltages(115Vand208V)forthe100wattheaterare available for use on the 4MTLS compressors.Please refer to Figure 14attheendofthisbulletin.

STARTUP AND OPERATION

WARNINGDiesel effect! Compressor destruction! The mixture of air and oil at high temperature can lead to an explosion. Avoid operating with air.

Leak TestThesuctionshut-offvalveanddischargeshut-offvalveonthecompressormustremainclosedduringpressuretesting topreventairandmoisture fromentering thecompressor. The test pressure (dry nitrogen) mustnotexceed870psi(60bar)providednoothersystemcomponent’spressureislower,inthiscasethelowerpressure is the test pressure. Systems should becheckedonceperyear (oras required).Check locallegislation for requirements.

System Evacuation Beforecommissioningthesystem,removetheholdingchargeandthenevacuatewithavacuumpump.Properevacuation reduces residual moisture to 50 ppm.Theinstallationofadequatelysizedaccessvalvesatthe furthest point from the compressor in the suction and liquid lines isadvisable.Toachieveundisturbedoperation,closethecompressorvalvesandevacuatethe system. Pressure must be measured using avacuumpressuregaugeontheaccessvalvesandnoton the vacuum pump; this serves to avoid incorrectmeasurements resulting from the pressure gradientalong the connecting lines to the pump. Then the compressormustbeevacuated.

Due to the factory holding charge of dry air thecompressorisunderpressureofabout14.5to36psi(1 to2.5bar), this is to indicate that thecompressordoesnotleak.

Whenplugsareremovedfromthecompressorinordertoconnectapressuregaugeortofillinoil,theplugmaypopoutunderpressureandoilresiduecanspurtout.

Preliminary Checks – Pre-starting Discussdetailsof the installationwith the installer. Ifpossible, obtain drawings,wiring diagrams, etc. It isidealtouseacheck-listbutalwayscheckthefollowing:

• Visualcheckoftheelectrics,wiring,fusesetc.• Visualcheckofthesystemforleaks,loosefittings• Compressoroillevel¼-¾sightglass(seeFigure4)• Calibrationofhighandlowpressureswitchesandanypressureactuatedvalves

• Checksettingandoperationofall safety featuresandprotectiondevices

• Allvalvesinthecorrectrunningposition• Pressureandcompoundgaugesfitted• Check that compressor is pre-charged with

refrigerant• Ensure compressor electrical isolator is correct

Charging Procedure

CAUTIONLow suction pressure operation! Compressor damage! Donotoperatewitharestrictedsuction.Donotoperatewiththelowpressurecut-outjumpered.


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Low moisture content! Corrosive impact on refrigeration systems!UseonlyhighlydriedCO2.

Do not operate compressor without enough systemcharge to maintain at least 73 psig (5 bar) suctionpressure.Allowingapressure todropbelow73psig(5bar)formorethanafewsecondsmightcauseCO2 solidification(dryice)andblockvalvesorpipes.

ChargethesystemwithvaporCO2 up to a minimum of 145psig(10bar)topreventformingofdryice.ThencontinuewithchargingliquidCO2.Thesystemshouldbechargedthroughtheliquid-receivershut-offvalveorthroughavalveintheliquidline.

Theuseofafilterdrier in thecharging line ishighlyrecommended.Becausetheremaybeseveralvalvesinthesystem,itisrecommendedtochargeonboththehighandlowsidessimultaneouslytoensuresufficientpressureispresentinthecompressorbeforeitruns.

Themajorityofthechargeshouldbeplacedinthehighsideofthesystemtopreventbearingwashoutduringfirst-timestart.

Initial Start-Up

CAUTIONOil 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.

Withtheexceptionofrubbercoatedmetallicgaskets.Allgasketsshouldbeoiledbeforefitting.O-ringsshouldalsobeoiled.Acompressorshouldneverbeoperatedbeyonditsapprovedapplicationrange.Toavoidmotordamage,thecompressormustnotbestartedorhighpotentialtestedundervacuum.

Minimum Run Time Emerson Climate Technologies recommends amaximum of 10 starts per hour. The most critical considerationistheminimumruntimerequiredtoreturnoil to the compressor after start-up.

Recommended Inverter Range4MTLS compressors can be applied with a variablefrequencydrive.Theapprovedoperatingrangeis25to60Hz.

Running the CO2 compressor with an inverter is areliable application. Resonances might occur in thelower frequency ranges. This phenomenon largelydepends on the operating conditions and systemdesign.

The following hardware variables have a significantimpactonpossibleresonances:

• Mountingparts:Therubbermountingpartssuppliedwith the 4MTLS compressor are suitable for thewholefrequencyrange.

• Pipingdesign:It isrecommendedtotakespecialcareforthedischargeline.Adischargepipeparallelto thecompressoraxisnormallygivesapositiveeffecttoreduceresonancesatlowfrequency

• Baseframedesign:Theframeworkstructureshouldbestiffenoughsothattheresonantfrequencyisabove 70 hz.A design with natural frequenciesbelowthe25hzspeedmayleadtohighvibrationsduringstart-up.

MAINTENANCE AND REPAIRExchanging the Refrigerant4MTLScompressorsareonlyreleasedforusagewithCO2 (R-744) as a refrigerant.

Forservicekitpartnumbers,refertotheOnlineProductInformation at EmersonClimate.com or contact your Emersonsalesrepresentative.

Replacing a Compressor

CAUTIONInadequate 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 ofcontaminatedoilwillberemovedwiththecompressor.Therestoftheoiliscleanedthroughtheuseofsuctionandliquidlinefilterdriers.A100%activatedalumnasuction line filter drier is recommended but mustbe removed after 72 hours. When a compressor isexchangedinthefield,itispossiblethatamajorportionoftheoilmaystillbeinthesystem.


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Lubrication and Oil Removal

WARNINGChemical reaction! Compressor destruction! Do not mixupesteroilswithmineraloiland/oralkylbenzene.

CAUTIONHandle 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 contact with any surface or material that might be harmed by POE, including certain polymers (e.g. PVC/CPVC and polycarbonate).

Compressorsthatarenotshipped"lessoil"aresuppliedwithaninitialoilcharge.ThestandardoilchargeforusewithrefrigerantsR744isapolyolester(POE)lubricantEmkarate RL 68 HB.

POE is far more hygroscopic than mineral oil (seeFigure 15). Only brief exposure to ambient air isneededforPOEtoabsorbsufficientmoisturetomakeit unacceptable for use in a refrigeration system.SincePOEholdsmoisturemorereadilythanmineraloil it ismoredifficult to remove it through theuseofvacuum.CompressorssuppliedbyEmersonClimateTechnologies contain oil with low moisture content,anditmayriseduringthesystemassemblingprocess.Thereforeitisrecommendedthataproperlysizedfilter-drierisinstalledinallPOEsystems.Thiswillmaintainthemoisturelevelintheoiltolessthan50ppm.Ifoilischargedintoasystem,itisrecommendedtousePOEwithamoisturecontentnohigherthan50ppm.

Figure 15 compares the hygroscopic characteristics of POEoilwithmineraloil(moistureabsorptioninPPMat25°Cand50%relativehumidity).

If the moisture content of the oil in a refrigeration system reachesunacceptablyhighlevels,corrosionandcopperplatingmayoccur.Thesystemshouldbeevacuateddowntoanabsolutepressureof225micronsorlower.If there is uncertainty as to the moisture content in thesystem,anoilsampleshouldbetakenandtestedformoisture.Sightglass/moistureindicatorscurrentlyavailablecanbeusedwith theHFCrefrigerantsandlubricants; however, the moisture indicator will justshowthemoisturecontentoftherefrigerant.TheactualmoisturelevelofPOEwouldbehigherthanthesightglassindicates.Thisisduetothehighhygroscopicityof

thePOEoil.Todeterminetheactualmoisturecontentofthelubricant,sampleshavetobetakenfromthesystemandanalyzed.

Oil AdditivesAlthough Emerson Climate Technologies cannot commentonanyspecificproduct,fromourowntestingandpastexperience,wedonot recommend theuseofanyadditivestoreducecompressorbearinglossesor for any other purpose. Furthermore, the long term chemical stability of any additive in the presence ofrefrigerant, lowandhightemperatures,andmaterialscommonly found in refrigeration systems is complexand difficult to evaluate without rigorously controlledchemicallaboratorytesting.Theuseofadditiveswithoutadequatetestingmayresultinmalfunctionorprematurefailure of components in the system and, in specificcases,invoidingthewarrantyonthecomponent.Referto AE17-1282foradditionalinformation.

Unbrazing System Components

WARNINGExplosive 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.

Beforeopeningupasystemitisimportanttoremoveallrefrigerantfromboththehighandlowsidesofthesystem. If a brazing torch is then applied to the lowsidewhile the lowsideshellandsuction linecontainpressure, the pressurized refrigerant and oil mixturecouldignitewhenitescapesandcontactsthebrazingflame. To prevent this occurrence, it is important tocheckboththehighandlowsideswithmanifoldgaugesbefore unbrazing. Instructions should be providedin appropriate product literature and assembly (linerepair) areas. If compressor removal is required, thecompressor should be cut out of system rather thanunbrazed.

Dismantling and DisposalRemovingoilandrefrigerant:

• Usethecorrectequipmentandmethodofremoval.• Disposeofoilandrefrigerantproperly.• Dispose of compressor properly.


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Figure 1 – 4MTLS Name Plate


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Figure 2 – CO2 Envelopes

30

40

50

60

70

80

90

100

110

120

130

Disc

harg

e Pr

essu

re

Evaporating Temperature

CO2 Operating Envelope4MTLS82K ; 4MTLS11M; 4MTLS15M

18F (10K) SUPERHEAT

36F (20K) SUPERHEAT

Evaporating Pressure

barpsig

R-744

23015.8

-25-13

-20-4

-155

-1014

-523

032

541

1050

1559

2068

1885

1740

1595

1450

1305

1160

1015

870

725

580

435

27118.7

31821.9

36925.4

42729.4

49133.9

56138.7

60942

63844

72550

81656.3

50 122

44 111

40 105

36 96

32 90

29 85

23 73

15 59

5 41

-4 24°C

°F

Cond

ensi

ng T

empe

ratu

re

Gas

Coo

ler O

utle

t Tem

pera

ture

30

40

50

60

70

80

90

100

110

120

130

Disc

harg

e Pr

essu

re

Evaporating Temperature

CO2 Operating Envelope4MTLS40K ; 4MTLS53K; 4MTLS64K

18F (10K) SUPERHEAT MAX

Evaporating Pressure

barpsig

R-744

23015.8

-25-13

-20-4

-155

-1014

-523

032

541

1050

1559

2068

1885

1740

1595

1450

1305

1160

1015

870

725

580

435

27118.7

31821.9

36925.4

42729.4

49133.9

56138.7

60942

63844

72550

81656.3

50 122

44 111

40 105

36 96

32 90

29 85

23 73

15 59

5 41

-4 24°C

°F

Cond

ensi

ng T

empe

ratu

re

Gas

Coo

ler O

utle

t Tem

pera

ture


AE4-1396 R4

Figure 5 – Stacking Configuration

Figure 6 – Lifting Eye Location

Figure 4 – Sight Glass Oil Level

Lifting Eyes

Figure 3 – 4MTLS Sight Glasses


AE4-1396 R4

Figure 8 – Safety Valve Location

Figure 7 – Compressor Mounting Parts


AE4-1396 R4

ID Description Size

SL

Suction ServiceValve

4MTLS40K4MTLS53K4MTLS64K

5/8"ID22mmOD

4MTLS82K4MTLS11M4MTLS15M

7/8"ID30mmOD

DL

Discharge ServiceValve

4MTLS40K4MTLS53K4MTLS64K

1/2"ID17.2mmOD

4MTLS82K4MTLS11M4MTLS15M

5/8"ID22mmOD

1 Base Mountings 22mmOD4 Plug High Pressure Connection 1/8"27NPTF5 Crankcase Heater 1/2"14NPTF6 PlugLowPressureConnection/OilRemovalPlug 1/4"18NPTF6 PlugLowPressureConnection 1/2"14NPTF

Figure 9 – Pressure Connection Ports


AE4-1396 R4

Figure 10 – Wiring Diagram A

Note: Wiringdiagramappliestothefollowingmodels:

4MTLS 40K 53K 64K 82K 11M 15M-FSC X X X-FSD X X X X X X-TSE X X X X X X

78

9

ACROSS THE LINE CONNECTED

MOTOR CODE LINE VOLTAGEFSD 50 HZ. 380-420FSC 50 HZ. 200-220

01 02 03

WHEN CHECKING MOTOR PROTECTION SYSTEM:MODULE POWER MUST BE DISCONNECTED BEFORE CHECKING MOTOR SENSORS.

USE OHMMETER ONLY TO CHECK SENSOR RESISTANCE. DO NOT SHORT ACROSS THE TERMINALS.

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 EUROPEANPUBLICATIONS GUIDELINE SH DISCUS COMPRESSORS DEC. 2001 AND US PUBLICATIONS AE BULLETIN #8-1367.

USE COPPER CONDUCTORS ONLY.

USE MINIMUM 75° C (167° F) WIRE FOR AMPACITY DETERMINATION.

USE THIS EQUIPMENT ON A GROUNDED SYSTEM ONLY.

PRIMARY SINGLE PHASE FAILURE PROTECTION IS PROVIDED.

OPTIONAL CRANKCASE HEATER, FAN OR CAPACITY CONTROL VALVE(S) MUST BE CONNECTED ONLY TO THEIR RATED VOLTAGE.

OVERCURRENT PROTECTION DEVICE RATING AND TYPE MUST BE IN ACCORDANCE WITH REGULATORY AGENCY END PRODUCT APPROVALS - SEE SYSTEM NAMEPLATE.


MOTOR WINDINGCONNECTIONS

052-

2753

-00

WIRING DIAGRAML7 L8 L9

CURRENTSENSOR

COMPRESSORWIRINGHARNESS

CURRENTSENSING

L1 L2 L3

CURRENTSENSOR

7 8BLACK

ORANGE

PART WINDING START CONNECTED

LINE VOLTAGE

01 02 03 01 02 03CONTROL CIRCUIT

VOLTAGE

C1

TD

C2TD

L 1 L 2 L 3

T 1 T 2 T 3

L 1 L 2 L 3

T 1 T 2 T 3

78

9

12

3

CONTROLS

91 2 3

C1C2

1(U) 3(W)

7(Z)8(X)

9(Y)

2(V)

UV

W

ZX

Y

1U

Z

2V

X

3W

Y

PART WINDING START

L M PROTECTOR MODULE

78

9

01 02 03CURRENTSENSOR

1U

Z

2V

X

3W

Y

MOTOR CODE LINE VOLTAGEFSD 60 HZ. 460TSE 60 HZ. 575FSC 60 HZ. 208-230


AE4-1396 R4

WHEN CHECKING MOTOR PROTECTION SYSTEM:MODULE POWER MUST BE DISCONNECTED BEFORE CHECKING MOTOR SENSORS.

USE OHMMETER ONLY TO CHECK SENSOR RESISTANCE. DO NOT SHORT ACROSS THE TERMINALS.

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 EUROPEANPUBLICATIONS GUIDELINE SH DISCUS COMPRESSORS DEC. 2001 AND US PUBLICATIONS AE BULLETIN #8-1367.

USE COPPER CONDUCTORS ONLY.

USE MINIMUM 75° C (167° F) WIRE FOR AMPACITY DETERMINATION.

USE THIS EQUIPMENT ON A GROUNDED SYSTEM ONLY.

PRIMARY SINGLE PHASE FAILURE PROTECTION IS PROVIDED.

OPTIONAL CRANKCASE HEATER, FAN OR CAPACITY CONTROL VALVE(S) MUST BE CONNECTED ONLY TO THEIR RATED VOLTAGE.

OVERCURRENT PROTECTION DEVICE RATING AND TYPE MUST BE IN ACCORDANCE WITH REGULATORY AGENCY END PRODUCT APPROVALS - SEE SYSTEM NAMEPLATE.

052-

3017

-00

L7 L8 L9

CURRENTSENSOR

COMPRESSORWIRINGHARNESS

CURRENTSENSING

L1 L2 L3

7 8BLACK

ORANGE

91 2 3

PART WINDING START

WIRING DIAGRAM

MOTOR WINDINGCONNECTIONS

7(Z) 8(X) 9(Y)

1(U) 3(W)2(V)

PART WINDING START CONNECTED

LINE VOLTAGE

01 02 03 01 02 03CONTROL CIRCUIT

VOLTAGE

C1

TD

C2TD

L 1 L 2 L 3

T 1 T 2 T 3

L 1 L 2 L 3

T 1 T 2 T 3

1 2 3

7 8 9

CONTROLS

C1C2

(Z) (X) (Y)

(U) (V) (W)

L M PROTECTOR MODULE

7 8 9


MOTOR CODE LINE VOLTAGEFSC 50 HZ. 200-220 60 HZ. 208-230

01 02 03CURRENTSENSOR

1(U)

(Z)

2(V)

(X)

3(W)

(Y)

Figure 11 – Wiring Diagram B

Note: Wiringdiagramappliestothefollowingmodels:

4MTLS 40K 53K 64K 82K 11M 15M-FSC X X X-FSD-TSE


AE4-1396 R4

Figure 12 – Terminal Box IsolatorNote: Terminalisolatorappliestothefollowingmodels:

4MTLS 40K 53K 64K 82K 11M 15M-FSC X X X-FSD X X X X X X-TSE X X X X X X

Figure 13 – 82K to 15M FSC Terminal PlateNote: Terminalplateappliestothefollowingmodels:

4MTLS 40K 53K 64K 82K 11M 15M-FSC X X X-FSD-TSE


AE4-1396 R4

Figure 14 – Crankcase Heater

Crankcase Heater Kit Part Number115V/100W 918-0003-00230V/100W 918-0003-01

Kit contents:1 crankcase heater1heat-conductivepastetube1 mounting ring

1. Slidethemountingring onto the heater

2. Spreadathicklayerofconductivepastearoundheater.

3. Removetheplugfromcompressor. Insert the heater in the hole.

4. Press the mounting ring into the hole.

Figure 15 – Oil Dilution GraphAbsorptionofmoistureinesteroilincomparisontomineraloilinppmbyweightat25Cand50%relativehumidity.


AE4-1396 R4

Figure 17 – Wiring Diagram for CoreSense

Figure 16 – Electronics Locations

CoreSenseControl Module

Current Sensor

Switch6disabledon4MTLSproduct


AE4-1396 R4

Table 1 – 4MTLS Model Selection

ModelDisplacement

CFH (m3/h)

Capacity kBtu/hr

(kW)

Max Oper. Pressure psig (bar)

Design Pressure psig (bar)

Burst Pressure psig (bar)

Net Weight lbs (kg)

Footprint in (mm) Motors

4MTLS40KE 195 (5.5) 40 (12)

1740/609(120/42)

1960/1305(135/90)

6090/4785(420/330)

271 (123)

14.5 x 10(368 x 256)

FSD 400V/3Ø/50Hz 460V/3Ø/60Hz

TSE 480V/3Ø/50Hz 575V/3Ø/60Hz

FSC 200-240V/3Ø/50Hz 208-230V/3Ø/60Hz

4MTLS53KE 263 (7.4) 53 (15) 273 (124)4MTLS64KE 314 (8.9) 64 (19) 278 (126)4MTLS82KE 406 (11.5) 82 (24) 375 )170)4MTLS11ME 530 (15.0) 108 (32) 375 (170)4MTLS15ME 764 (21.6) 155 (45) 386 (175)*Nomenclature based on rated capacity at 14°F evap, 95°F gas cooler, 18°F SH

Table 2 –

Application Valve Pressure Rating

Compressor Standstill Pressure Note:

MT (Transcritical) High-PressureSide(HP) 1960psig(135bar) 1960psig(135bar) HPvalveprotectswhole

compressor

MT (Transcritical)

High-PressureSide(HP) 1960psig(135bar)

1305psig(90bar)LPvalveprotectsLPsideof

compressor.HPvalveprotectsHPsideofcompressor.

Low-PressureSide(LP)1305psig(90bar)

(Optional–FieldInstalled)

Kit Description Part Number

OilSensorKit

GasketO-ringOildSensorAdapterOilControlSensor

998-0244-00

Figure 19 – Oil Sensor Kit

Qualified Refrigerants CO2 (R-744)

Copeland™ Standard Oil Emkarate RL 68 HB

Servicing Oil Emkarate RL 68 HB

Figure 18 – Qualified Refrigerants and OilsNote: Refer to form 93-11forthelatestapprovedrefrigerantsandlubricantsforCopelandproducts.


AE4-1396 R4

Table 3 –

Description Part Number CompressorFlange Pitch

(Mounting Footprint)

(mm)

Brazing (Valve ID)

d(in)

Butt Weld (Valve OD)

D(in)

Conn. Wall Thickness

z(in)

Weld Depth

a(in)

Tube Ins. Depth

h(in)

Discharge Service 510-0809-00 4MTLS40K

4MTLS53K

4MTLS64K

45 x 45 1/2 0.677 0.087 0.122 0.433

Suction Service 510-0823-00 45 x 45 5/8 0.866 0.116 0.164 0.433

Discharge Service 510-0842-00 4MTLS82K

4MTLS11M

4MTLS15M

52 x 52 5/8 0.866 0.116 0.164 0.433

Suction Service 510-0844-00 52 x 52 7/8 1.181 0.151 0.213 0.630

Additional Service Kit Offerings:

SwagelokDischarge Service

510-0865-00

4MTLS40K

4MTLS53K

4MTLS64K

45 x 451/2

SwagelokFitting

SwagelokDischarge Service

510-0866-00

4MTLS82K

4MTLS11M

4MTLS15M

52 x 52 mm5/8”

SwagelokFitting


AE4-1396 R4

Thecontentsofthispublicationarepresentedforinformationalpurposesonlyandarenottobeconstruedaswarrantiesorguarantees,expressorimplied,regardingtheproductsorservicesdescribedhereinortheiruseorapplicability.EmersonClimateTechnologies,Inc.and/oritsaffiliates(collectively"Emerson"),asapplicable,reservetherighttomodifythedesignorspecificationsofsuchproductsatanytimewithoutnotice.Emersondoesnotassumeresponsibilityfortheselection,useormaintenanceofanyproduct.Responsibilityforproperselection,useandmaintenanceofanyEmersonproductremainssolelywiththepurchaserorenduser.

Component Description Thread Type Torque (lb-ft)

Torque (Nm)

Torque - Final Customer

InstallationSuctionServiceValveMounting 3/8"-16UNC 26-32 36-44

SuctionServiceValvePressureTap 7/16"-20UNF 18-26 24-35

SuctionServiceValveCap 3/4"-16UNF-2A 4-Mar 5-Apr30-37lb-ft/40 - 50 N-m

DischargeServiceValveMounting 3/8"-16UNC 26-32 36-44DischargeServiceValvePressureTap 7/16"-20UNF 18-26 24 -35

DischargeServiceValveCap 3/4"-16UNF-2A 4-Mar 5-Apr30-37lb-ft/40 - 50 N-m

StatorCoverMounting 1/2"-13UNC 88-117 119-159HousingCoverMounting 1/2"-13UNC 88-117 119-159

CylinderHead 1/2"-13UNC 75-102 102-138HeadTemperatureProbe(CoreSense) 1/8"-27NPTF 25-26 35

Terminal Plate Mounting 3/8"-16UNC 26-32 36-44Stator Mounting M16 103-133 140-180OilSightGlass 1-1/8"-18UNEF 37-44 50-60OilDrainPlug 1/4"-18NPTF 22-30 30-40

Misc Plugs 1/4-18NPTF 22-30 30-40OilFlingerMounting M10 13-16 18-22

SafetyValves M24x1.5LH/RH 66-81 90-110Deflectormounting 32 UNF 8-Jul 11-SepOilSensorProbe 3/4"-14NPT 63-66 85-90

OilSensorProbeAdaptor 11/8"-18UNEF 66 90

Appendix 2: 4MTLS Tightening Torques

NOTE: Therangesoftorquevaluesgiveninthisspecificationareassemblytorque.Torqueafterjointrelaxationmustbewithin15%oftheminimumassemblytorqueunlessre-torqueiscalledforandmustnotbeabove10%ofthemaximumassemblytorque.

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