Emerson Copeland Discus Series Instruction Manual

Application Guidelines
Semi-Hermetic Compressors
Discus, K, L & S-Series

D6.3.4/0715-0716/E
1Safety instructions............................................................................................ 1
1.1 Icon explanation.................................................................................................................1
1.2 Safety statements ..............................................................................................................1
1.3 General instructions...........................................................................................................2
2Product description .......................................................................................... 3
2.1 Common information about Copeland™semi-hermetic compressors..............................3
2.2 About these guidelines.......................................................................................................3
2.3 Nomenclature.....................................................................................................................3
2.3.1 Air- or water-cooled compressors ..........................................................................3
2.3.2 Suction gas-cooled compressors...........................................................................4
2.4 Nameplate information.......................................................................................................5
2.4.1 DWM Copeland designation (old models)..............................................................5
2.4.2 Copeland brand designation (present models)......................................................6
2.5 Application range ...............................................................................................................6
2.5.1 Qualified refrigerants and oils ................................................................................6
2.5.2 Application limits.....................................................................................................6
2.6 Design features..................................................................................................................7
2.6.1 Construction ...........................................................................................................7
2.6.2 Compressor cooling ...............................................................................................8
2.6.3 Unloaded start........................................................................................................8
2.6.4 Capacity control......................................................................................................9
2.6.5 Demand Cooling.....................................................................................................9
2.6.6 Discharge Temperature Control valve (DTC).........................................................9
2.6.7Running gear lubrication ........................................................................................9
2.6.8 Oil pumps –Suction gas-cooled compressors.....................................................10
2.6.9 Oil pressure..........................................................................................................10
2.6.10 Oil circulation........................................................................................................10
2.6.11 Oil level.................................................................................................................11
2.6.12 Oil separation & management for booster applications .......................................11
2.6.13 R22 Low temperature applications using D2SA–450/X Air & D2SC–550/X Air
compressors......................................................................................................................11
3Installation....................................................................................................... 12
3.1 Compressor handling.......................................................................................................12
3.1.1 Delivery.................................................................................................................12
3.1.2 Transport and storage..........................................................................................12
3.1.3 Positioning and securing......................................................................................12
3.1.4 Installation location...............................................................................................13
3.1.5 Mounting parts......................................................................................................13
3.2 Pressure safety controls ..................................................................................................14
3.2.1 High-pressure control...........................................................................................14

D6.3.4/0715-0716/E
3.2.2 Low-pressure control............................................................................................14
3.2.3 Internal pressure relief valve................................................................................14
3.2.4 Oil pressure switch...............................................................................................14
3.2.5 Maximum allowable pressures.............................................................................15
3.3 Brazing procedure............................................................................................................15
3.4 Screens............................................................................................................................15
4Electrical connection ...................................................................................... 16
4.1 General recommendations...............................................................................................16
4.2 Electrical installation ........................................................................................................16
4.2.1 Single-phase motors –Code C............................................................................16
4.2.2 Three-phase motors.............................................................................................17
4.2.3 Direct-on-line start motors –Code T....................................................................17
4.2.4 Star-delta motor (Y/∆) – Code E ..........................................................................17
4.2.5 Part-winding motor (YY/Y) –Code A ...................................................................17
4.3 Wiring diagrams...............................................................................................................17
4.4 Protection devices............................................................................................................17
4.5 Motor protection...............................................................................................................18
4.5.1 Over-current thermal protection switch for single-phase motors –System A......18
4.5.2 Thermistor protection –System W.......................................................................18
4.6 Discharge temperature protection ...................................................................................19
4.7 Demand Cooling ..............................................................................................................20
4.8 Oil pressure control..........................................................................................................20
4.8.1 Oil pressure switch (OPS2)..................................................................................20
4.8.2 SENTRONIC Oil pressure control........................................................................21
4.8.3 Oil pressure switch –ALCO FD 113 ZU (A22 - 057) ...........................................21
4.8.4 Crankcase heaters ...............................................................................................22
5Starting up & operation................................................................................... 23
5.1 Leak test...........................................................................................................................23
5.2 System evacuation...........................................................................................................23
5.3 Preliminary checks –Pre-starting....................................................................................23
5.4 Charging procedure .........................................................................................................23
5.5 Initial start-up ...................................................................................................................24
5.6 Minimum run time ............................................................................................................24
5.7 Recommended inverter range .........................................................................................24
6Maintenance & repair...................................................................................... 25
6.1 Exchanging the refrigerant...............................................................................................25
6.2 Refrigerant retrofit from HFC to HFO/HFC blends ..........................................................25
6.3 Shut-off valves .................................................................................................................25
6.4 Compressor replacement.................................................................................................25
6.5 Lubrication and oil removal..............................................................................................25

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6.6 Oil additives .....................................................................................................................26
6.7 Unbrazing system components .......................................................................................26
7Troubleshooting.............................................................................................. 27
7.1 Lubrication problems........................................................................................................27
7.2 Oil dilution ........................................................................................................................27
7.3 Refrigerant migration .......................................................................................................27
7.4 Inadequate suction superheat .........................................................................................27
7.5 Acid formation..................................................................................................................28
7.6 Inadequate compressor cooling.......................................................................................28
7.7 High discharge temperatures...........................................................................................28
7.8 Motor burnout due to undersized contactors ...................................................................28
7.9 Motor burnout due to by-passed or disconnected protectors..........................................28
8Dismantling & disposal................................................................................... 28
Appendix 1 –Compressor connections.................................................................... 29
Standard compressor connections..........................................................................................29
Discus compressor connections..............................................................................................35
Appendix 2 - Tightening torques (Nm)...................................................................... 38
Disclaimer ................................................................................................................... 39

D6.3.4/0715-0716/E 1
1 Safety instructions
Copeland™semi-hermetic compressors are manufactured according to the latest European
safety standards. Particular emphasis has been placed on the user’s safety.
These compressors are intended for installation in systems according to the Machinery Directive
MD 2006/42/EC. They may be put to service only if they have been installed in these systems
according to instructions and conform to the corresponding provisions of legislation. For relevant
standards please refer to the Manufacturer’s Declaration, available on request.
These instructions should be retained throughout the lifetime of the compressor.
You are strongly advised to follow these safety instructions.
1.1 Icon explanation
WARNING
This icon indicates instructions to
avoid personal injury and material
damage.
CAUTION
This icon indicates instructions to
avoid property damage and possible
personal injury.
High voltage
This icon indicates operations with a
danger of electric shock.
IMPORTANT
This icon indicates instructions to
avoid malfunction of the compressor.
Danger of burning or frostbite
This icon indicates operations with a
danger of burning or frostbite.
NOTE
This word indicates a
recommendation for easier operation.
Explosion hazard
This icon indicates operations with a
danger of explosion.
1.2 Safety statements
Refrigerant compressors must be employed only for their intended use.
Only qualified and authorized HVAC or refrigeration personnel are permitted to
install commission and maintain this equipment.
Electrical connections must be made by qualified electrical personnel.
All valid standards for connecting electrical and refrigeration equipment must be
observed.
The 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
where necessary.
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2 D6.3.4/0715-0716/E
1.3 General instructions
WARNING
System breakdown! Personal injuries! Never install a system in the field
and leave it unattended when it has no charge, a holding charge, or with the
service valves closed without electrically locking out the system.
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 that other materials in the area of the compressor do
not get in touch with it. Lock and mark accessible sections.
CAUTION
Overheating! Bearing damage! Do not operate compressors without
refrigerant charge or without being connected to the system.
IMPORTANT
Transit damage! Compressor malfunction! Use original packaging. Avoid
collisions and tilting.

D6.3.4/0715-0716/E 3
2 Product description
2.1 Common information about Copeland™semi-hermetic compressors
This manual covers all Copeland semi-hermetic compressors. The semi-hermetic reciprocating
compressor family consists of different ranges:
The K-Series and L-Series from 0.5 hp to 4 hp are available as air-cooled or water-cooled
versions and use reed valve technology.
The S-Series includes models 2S, 3S, 4S, 6S and 8S. It is suction gas-cooled and ranges
from 5 hp to 70 hp. It uses reed valve technology and offers cost-effective solutions.
The Discus™series includes models 2D, 3D, 4D, 6D and 8D and ranges from 4 hp to 60 hp.
Its optimized Discus™valve plate design provides the highest energy efficiency.
Special applications are addressed with a selected range of 2-stage, Booster and tandem
compressors.
Copeland compressors are suitable for a wide range of applications either in the form of single
compressors, condensing units or as multi-compressor equipment.
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 manual relates
to all semi-hermetic compressors with standard equipment and accessories only.
2.2 About these guidelines
These guidelines are intended to enable users to ensure the safe installation, starting, operation
and maintenance of semi-hermetic compressors. They are not intended to replace the system
expertise available from system manufacturers.
2.3 Nomenclature
The leading character “D” traditionally used for compressors is no longer in
use in the black painted compressors that use the brand.
The model designation contains the following technical information about the standard and
Discus compressors:
2.3.1 Air- or water-cooled compressors
Copeland brand designation (present models)
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DWM Copeland designation (old models)
2.3.2 Suction gas-cooled compressors
Copeland brand designation (present models)

D6.3.4/0715-0716/E 5
DWM Copeland designation (old models)
NOTE: For more information, please refer to Technical Information D7.4.3 “Copeland™
semi-hermetic compressor model designation”.
2.4 Nameplate information
All important information for identification of the compressor is printed on the nameplate.
The type of refrigerant used should be stamped on the nameplate by the installer.
The date of production consists of the year and week of production. In addition the year and
month of production are shown as part of the serial number (Jan = A, Feb = B, … Dec = L).
The mutual nameplate on TWIN compressors only indicates the model and the year of
manufacturing. All other details should be taken from the individual compressor nameplates.
2.4.1 DWM Copeland designation (old models)
DK, DL, D2S D4S, D4D, D6S/T, D6D, D8S, D8D
D2D, D3D, D3S
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6 D6.3.4/0715-0716/E
2.4.2 Copeland brand designation (present models)
K, L 6T, 8D
2D, 3D
2.5 Application range
2.5.1 Qualified refrigerants and oils
IMPORTANT
It is essential that the glide of refrigerant blends (primarily R407C) is carefully
considered when adjusting pressure and superheat controls.
Oil recharge values can be taken from Copeland™brand products Select software available at
www.emersonclimate.eu.
Qualified refrigerants
R134a, R404A,
R407A*, R407C, R407F*,
R448A*, R449A*,
R450A, R507, R22
R22
Copeland brand
products standard oils
Emkarate RL 32 3MAF
Suniso 3 GS
Servicing oils
Emkarate RL 32 3MAF
Mobil EAL Arctic 22 CC
Shell 22-12
Suniso 3 GS
Fuchs Reniso KM 32
Capella WF 32
* Only valid for compressors 2D, 3D and 8D
Table 1: Qualified refrigerants and oils
2.5.2 Application limits
For application envelopes please refer to Copeland brand products Select software.

D6.3.4/0715-0716/E 7
2.6 Design features
2.6.1 Construction
Standard
Figure 1
All K-, L- and S-Series compressors are fitted with “Reed” valve plates.
Depending on the number of cylinders, the motor cooling and the kind of application, there are
three different compressor families:
Air- or water-cooled single-stage compressors, models K, L with 2 cylinders and a
displacement between 3.97 m³/hr and 22.5 m³/hr; model LH is air-cooled with a
displacement of 26.6 m³/hr.
Refrigerant-cooled single-stage compressors, models D2S, D3S, D4S, D6S and D8S with 2,
3, 4, 6 and 8 cylinders and a displacement between 22.4 m³/hr and 210 m³/hr.
Refrigerant-cooled two-stage compressors, model 6T with 6 cylinders and a displacement of
84.7 m³/hr.
NOTE: D2SA-450, D2SA-45X, D2SC-550 & D2SC-55X can be suction gas-cooled or air-
cooled compressors depending on the position of the suction service valve.
In addition, air- or water-cooled compressors have two different kinds of lubrication:
K & L compressors using mineral oil or semi-synthetic oil and R22 (HCFC) are equipped
with a centrifuge lubrication system.
K & L compressors using ester oil for chlorine-free HFC refrigerants like R404A are
equipped with an internal oil pump. The LHA compressor has an external oil pump.
Refrigerant-cooled compressors from D4S upwards are also available as TWIN (Tandem), ie,
two compressors of the same type coupled together via a common suction chamber.
Two-stage compressors are used when high pressure ratios are required with acceptable
discharge temperatures. On the low-pressure stage (LP, 4 cylinders on 6T) the suction gas is
compressed to the inter-stage pressure. The gas enters the motor housing and crankcase via
the intermediate pressure mixing line. On the high-pressure stage (HP, 2 cylinders on 6T), the
gas is compressed to the condensing pressure.
IMPORTANT
Pressures in two-stage compressors are different from those in single-stage
compressors, eg, motor compartment and crankcase are under inter-stage
pressure.
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Discus
Figure 2
This family consists of refrigerant-cooled single-stage compressors, models 2D, 3D, D4D, D6D
and 8D with 2, 3, 4, 6 and 8 cylinders and a displacement between 22.4 m³/hr and 181 m³/hr.
All compressors are fitted with Discus valve plates which cannot be dismantled. To maintain the
high capacity of these compressors the correct valve-plate-to-body gasket must always be
selected in case of exchange. The gasket thickness is indicated on the gasket tab.
Each cylinder head has a plugged 1/8”- 27 NPTF tapped hole for connecting high-pressure
switches. These high-pressure switches must be calibrated and tested before putting the
compressor into service. They must stop the compressor if the allowable pressure is exceeded.
The complete cylinder head is under discharge pressure.
2.6.2 Compressor cooling
Compressor motors must always be cooled, and cylinder head cooling may also be needed at
certain operating conditions.
K and L compressor motors can utilize air or water cooling. For air cooling, the airflow should be
at least 18.5 m³/hr. Note that the airflow also cools the cylinder heads. This airflow can come
from the fan of an air-cooled condenser or from a separate fan. Some high pressure ratio
conditions may require additional head cooling.
For water cooling, the water is led through a water coil wound round the motor section. Usually
the water coil is connected before the water-cooled condenser. With mains water, a single coil
“W” is used, and with cooling-tower connection a split coil “W2” is used. To improve heat
transmission, the water coil is embedded into thermocement on motors >0.75 HP but smaller
than 4 HP. If cylinder head cooling is also required, an additional fan must be installed with
water-cooled compressors.
All compressors starting with 2* until 8* are suction gas-cooled. With suction gas-cooled
compressors, the motor is cooled by refrigerant gas that is led over the motor. An additional fan
may be required depending upon the operating condition (see Copeland brand products Select
software).
NOTE: For additional fan cooler mounting instructions, please refer to Technical
Information D7.11.1 “Semi-hermetic compressors –Additional fans”.
NOTE: R22 is no longer allowed for new refrigeration systems in Europe.
2.6.3 Unloaded start
With direct starting the motor of a compressor is switched directly into the mains by means of a
switch. The resulting breakaway starting current amounts to multiple times the rated motor
current (operating maximum) without consideration being given to transient phenomena.
In the case of high-powered motors the breakaway starting currents become so large that they
lead to disruptive voltage dips in the mains. The compressors that are subject to current
limitation must therefore by all means be equipped with starting load reduction to guarantee

D6.3.4/0715-0716/E 9
perfect starting even when the voltages amount to less than approximately 85% of the voltage
on the nameplate.
Unloaded start is not available for Copeland brand 2-stage compressors and K/L.
NOTE: For more information please refer to Technical Information D7.10.2 “Starting
methods and unloaded start for semi-hermetic compressors”.
2.6.4 Capacity control
For 3, 4, 6 and 8 cylinder compressors a mechanical capacity control is available. Be aware that
unloaded operation changes the application range of the compressor.
NOTE: For more information please refer to Technical Information D7.21.1 “Semi-hermetic
compressors capacity control”.
2.6.5 Demand Cooling
“Demand cooling”,as the term implies, means liquid refrigerant injection on demand.
If a low-temperature R22 installation is required, the following compressors can be equipped with
a Demand Cooling accessory kit:
2DL* - 400 D4DF* - 1000
2DB* - 500 D4DL* - 1500
3DA* - 500 D4DT* - 2200
3DC* - 750 D6DL* - 2700
3DS* - 1000 D6DT* - 3000
* The fourth or fifth digit of the model designation must be ≥ 3 for D4D & D6D and ≥ 4 for 3D.
2.6.6 Discharge Temperature Control valve (DTC)
The Discharge Temperature Control valve liquid injection system is a low cost and reliable
solution for the D3SC-750/X, D3SS-1000/X, D4SL/T, D6SL/T and D6SU compressors to obtain
lower evaporating temperatures within an extended operating envelope.
The afore-mentioned compressors are equipped with a plugged injection port on the side of the
compressor wall close to the base of the cylinder block. The injection port can be retro-fitted with
the DTC valve. The temperature sensing element with 12” NPT thread fits on the D4SL/T,
D6SL/T and D6SU compressor body close to the discharge shut-off valve.
Please note that:
DTC is needed only in systems with R22 refrigerant.
The valve can be obtained as an optional extra.
It is recommended to use an additional fan with the DTC valve for performance values as
shown in Copeland brand products Select software.
The D4SL/T, D6SL/T and D6SU compressors with DTC valve and fan operate with a voltage
tolerance of ± 5% over the complete operating envelope.
NOTE: For more information please refer to Technical Information D7.19.1 “Assembling
the DTC valve for semi-hermetic R22 low temperature applications”.
2.6.7 Running gear lubrication
Air- or water-cooled compressors
Air- or water-cooled compressors that are filled with mineral oil have an oil centrifuge. The oil
supplied is drawn over a magnetic plug in order to separate even the smallest iron particles from
the oil.
Air- or water-cooled compressors that are lubricated with ester oil have an integral low-pressure
oil pump. These compressors, with pump and ester oil filling, are marked with “P” in compressor
nomenclature. An exception is the KSLP-200 which has an oil pump but is filled with mineral oil.
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10 D6.3.4/0715-0716/E
K & L compressor oil circulation
The oil returning from the evaporator reaches the crankcase via an oil separator chamber behind
the suction shut-off valve through a small connecting bore. Due to this connecting bore the
crankcase pressure will be decreased slowly when the compressor starts. Thus the foaming of
the oil and refrigerant mixture will be reduced.
Figure 3: K & L compressors lubrication
2.6.8 Oil pumps –Suction gas-cooled compressors
The oil pumps used for standard and Discus compressors are independent of their rotating
direction. They are designed to accommodate fittings for an OPS1, OPS2, SENTRONIC oil
safety system or a standard oil pressure switch.
2.6.9 Oil pressure
Normal oil pressure is between 1.05 and 4.2 bar higher than crankcase pressure. Net oil
pressure can be read by connecting two pressure gauges to the compressor and comparing the
readings. One gauge should be connected to the oil pump. The second gauge should be
connected to the crankcase (T-fitting instead of plug on the compressor crankcase) or the
suction service valve.
During irregular operating conditions, eg, a blockage of the suction filter, the pressure measured
at the suction shut-off valve of the compressor may differ widely from that measured at the
crankcase therefore pressure drops have to be avoided.
2.6.10 Oil circulation
Oil returns with the suction gases through a suction strainer and separates in the motor chamber
reaching the crankcase by way of a pressure relief valve in the partition between motor housing
and crankcase. This relief valve closes on compressor start-up due to the pressure difference
arising between motor side and crankcase, thus slowing down pressure decrease in the
crankcase over a certain period of time. It reduces the foaming of the oil/refrigerant mixture that
would occur if the pressure decreased rapidly.
The valve does not reopen until the pressure has been equalized by means of a crankcase
ventilating valve. This second valve connects the crankcase and suction side cylinder head. It
reduces the pressure difference by means of a very small bore in the plate of the valve so slowly
that oil foams less and only limited oil/refrigerant foam is transferred to the oil pump.

D6.3.4/0715-0716/E 11
2.6.11 Oil level
All compressors are delivered with sufficient oil for normal operation (see oil quantities in Select).
The optimum oil level should be checked by operating the compressor until the system is stable
and then comparing the sight glass reading with the appropriate diagram below. The level can
also be checked within 10 sec. of compressor shut-down. For 4- to 8-cylinder compressors a
higher oil level may be accepted when an oil regulator is in use because the oil separator will
reduce excessive oil circulation.
DK, DL D2, D3 D4, D6, D8
K, L 2D, 3D 8D
Figure 4
2.6.12 Oil separation & management for booster applications
In direct-stage refrigeration systems, oil carried over from each compressor may accumulate in
one of the compressors in series resulting in a lack of lubrication for the others. To ensure each
compressor has the correct amount of oil returned, Emerson Climate Technologies recommends
the use of a highly efficient cyclone or coalescent type oil separator with an oil management
system. The oil separator shall be installed in the discharge line of the high stage compressor. It
will separate the oil from the discharge gas and pass it to an oil reservoir. The oil will then pass
from the oil reservoir through the oil management system to each individual compressor
ensuring full lubrication and extended compressor life and reliability.
2.6.13 R22 Low temperature applications using D2SA–450/X Air & D2SC–550/X Air
compressors
R22 low temperature applications require suction superheat limitations for both the D2S and
D3S compressors (refer to the operating envelope in Copeland brand products Select software
for details). With the D2S range this is achieved by repositioning the suction valve, moving it
from the motor cover end to the compressor body. This changes the compressor from a suction
gas-cooled model to an air-cooled model. We now have the “D2SA–45X Air”, “D2SA–450 Air”,
“D2SC–55X Air” and “D2SC–550 Air” air-cooled compressors. The D2SK–65X and D2SK–650
models cannot be run at low temperatures using R22. The smallest D3SC model should be used
for these applications (almost the same capacity at low temperature as the D2SK).
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12 D6.3.4/0715-0716/E
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
Please check whether the delivery is correct and complete. Deficiencies should be reported
immediately in writing.
Standard delivery:
Suction and discharge shut-off valves
Oil charge, oil sight glass
Mounting kit
Motor protector
Holding charge up to 2.5 bar(g) (dry air)
3.1.2 Transport and storage
WARNING
Risk of collapse! Personal injuries! Move compressors only with
appropriate mechanical or handling equipment according to weight. Keep in
the upright position. Stack pallets on top of each other when not exceeding
300 kg. Stacking higher than the recommended maximum can cause
accidents. Do not stack single boxes on top of each other. Keep the
packaging dry at all times.
Compressors are individually packed and may be delivered on pallets depending on quantity and
size. Cooling fans are delivered in separate cartons. Accessories may be mounted or delivered
loose. Solenoid valves are never mounted.
Figure 5: Transport Figure 6: Storage
3.1.3 Positioning and securing
IMPORTANT
Handling damage! Compressor malfunction! Only use the lifting eyes
whenever the compressor requires positioning. Using discharge or suction
connections for lifting may cause damage or leaks.
If possible, the compressor should be kept vertical during handling.

D6.3.4/0715-0716/E 13
DK, K DL, L D2D, D2S, 2D D3D, D3S, 3D
max. 45kg max. 90kg max. 140 kg max. 175 kg
D4D, D4S D6D, D6S, D6T, 6T D8D, D8S, 8D Lifting eye
max. 220kg max. 260kg max. 350 kg ½” – 13 UNC
Figure 7
3.1.4 Installation location
Ensure the compressors are installed on a solid level base.
3.1.5 Mounting parts
To minimize vibration and start/stop impulses flexible mounting should be used. For this purpose
coloured springs are delivered with each compressor. These springs should be mounted
according to the prescriptions given in Technical Information D7.11.2 “Mounting parts for semi-
hermetic compressors”.
A compressor may be rigidly mounted, ie, without springs. In this case more shock and vibration
loading will be transmitted to the frame.
If the installation requires a very high level of vibration absorption, additional vibration absorbers
(available on the market) can be fitted between the rails and the foundation.
To ensure proper lubrication of moving parts, the compressor should be installed horizontally on
both axes. TWIN compressors are fitted to mounting rails using rubber pads.
Transport clamp Transport position Operational position Grommets for twin
compressors
Figure 8
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14 D6.3.4/0715-0716/E
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.
The high-pressure cut-out should have a manual reset feature for the highest level of system
protection.
3.2.2 Low-pressure control
The normal minimum is 0.1 bar(g) for R404A.
The low-pressure cut-out should have a manual reset feature for the highest level of system
protection.
3.2.3 Internal pressure relief valve
Single-stage compressors (50 Hz) with a displacement ≥50m3/hr are equipped with an internal
pressure relief valve placed between suction chamber and discharge chamber. This valve
protects the compressor against bursting if the discharge shut-off valve is accidentally fully
closed.
On two-stage compressors this valve is placed between inter-stage and low-pressure side and
opens at ≈ 15 bar (see Figure 9).
NOTE: The valve will not protect the installation against dangerous system pressures!
Before operating the compressors the pressure switches and other safety devices must be
installed correctly. Maximum allowable pressures must not be exceeded.
For connecting a high-pressure switch there is a tapped hole with plug in 1/8” – 27 NPTF on
each cylinder head.
Figure 9 Figure 10
3.2.4 Oil pressure switch
The oil pressure switch breaks the control circuit when the pressure difference between the oil
pump outlet and the crankcase is too low. The switch must be properly adjusted and tamper
proof. If the oil differential pressure drops below the minimum acceptable value the compressor
will be stopped after a 120-second delay. After having solved the problem the control has to be
reset manually.
NOTE: Proper oil pressure safety control with an approved switch is a condition of
warranty!
Specifications for electro-mechanical oil pressure switches are as follows:
Cut-out pressure: 0.63 ± 0.14 bar
Cut-in pressure: 0.9 ± 0.1 bar
Time delay: 120 ± 15 sec.
The Alco Control FD-113-ZU mechanical oil pressure switch operates with the above set points.

D6.3.4/0715-0716/E 15
Figure 11: Brazing areas
3.2.5 Maximum allowable pressures
The maximum allowable pressures (according to EN 12693) shown on the compressor
nameplate are obligatory and must not be exceeded.
High pressure side (HP): 28.0 bar(g) (up to S/N 14K46143M & 14K031872M)
32.5 bar(g) (from S/N 14K46144M & 14K031873M onwards)
Low pressure side (LP): 22.5 bar
NOTE: The compressor operating range may be restricted for various reasons. Check the
application range limitations in Copeland brand products Select software and on
www.emersonclimate.eu.
3.3 Brazing procedure
IMPORTANT
Blockage! Compressor breakdown! Maintain a flow of oxygen-free
nitrogen through the system at very low pressure during brazing. Nitrogen
displaces the air and prevents the formation of copper oxides in the system.
If allowed to form, the copper oxide material can later be swept through the
system and block screens such as those protecting capillary tubes, thermal
expansion valves, and accumulator oil return holes.
Contamination or moisture! Bearing failure! Do not remove the plugs until
the compressor is set into the unit. This minimises any entry of contaminants
and moisture.
Figure 11 shows the proper procedure for brazing the
suction and discharge shut-off valves.
The shut-off valves of the compressors can be
brazed in approximately the same manner as any copper
tube.
Recommended brazing materials: any silfos material
is recommended, preferably with a minimum of 5% silver.
However, 0% silver is acceptable.
Be sure tube fitting inner diameter and tube outer
diameter are clean prior to assembly.
Using a double-tipped torch, apply heat in area 1.
As the tube approaches brazing temperature, move the torch flame to area 2.
Heat area 2 until braze temperature is attained, moving the torch up and down and rotating
around the tube as necessary to heat the tube evenly. Add braze material to the joint while
moving the torch around the joint to flow braze material around the circumference.
After the braze material flows around the joint, move the 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 result.
To disconnect:
Heat joint areas 2 and 3 slowly and uniformly until the braze material softens and the tube
can be pulled out of the fitting.
To reconnect:
Recommended brazing materials: Silfos with minimum 5% silver or silver braze used on
other compressors. Due to the different thermal properties of steel and copper, brazing
procedures may have to be changed from those commonly used.
3.4 Screens
CAUTION
Screen blocking! Compressor breakdown! Use screens with at least
0.6 mm openings.
The use of screens finer than 30 x 30 meshes (0.6 mm openings) anywhere in the system
should be avoided with these compressors. Field experience has shown that finer mesh screens
used to protect thermal expansion valves, capillary tubes or accumulators can become
temporarily or permanently plugged with normal system debris and block the flow of either oil or
refrigerant to the compressor. Such blockage can result in compressor failure.
Safety
instructions
Product
description
Installation
Electrical
connection
Starting up &
operation
Maintenance &
repair
Trouble-
shooting
Dismantling &
disposal