Emerson Copeland Stream Digital 4MFD-13X Instruction Manual

Application Guidelines
Copeland Stream Digital™ Semi-Hermetic Compressors
4MFD-13X to 4MKD-35X
6MMD-30X to 6MKD-50X

C6.3.2/0416-0716/E
1Safety instructions............................................................................................ 1
1.1 Icon explanation.................................................................................................................1
1.2 Safety statements ..............................................................................................................1
1.3 General instructions...........................................................................................................1
2Product description .......................................................................................... 3
2.1 Common information about Copeland Stream Digital™semi-hermetic compressors......3
2.2 About these guidelines.......................................................................................................3
2.3Nomenclature.....................................................................................................................3
2.4 Nameplate information.......................................................................................................4
2.5 Application range ...............................................................................................................4
2.5.1 Qualified refrigerants and oils ................................................................................4
2.5.2 Application limits.....................................................................................................5
2.6 Design features..................................................................................................................5
2.6.1 Compressor construction .......................................................................................5
2.6.2 Digital theory of operation ......................................................................................5
2.6.3 Digital control..........................................................................................................7
2.6.4 Recommended application settings for modulation on Stream Digital
compressors........................................................................................................................7
2.6.5 Digital solenoid valve / Gaskets .............................................................................7
2.6.6 Compressor cooling ...............................................................................................7
2.6.7Unloaded start........................................................................................................7
2.6.8 Oil pumps ...............................................................................................................8
2.6.9 Oil pressure............................................................................................................8
2.6.10 Oil circulation..........................................................................................................8
2.6.11 Oil level...................................................................................................................8
2.6.12 Multiple compressor application.............................................................................9
3Installation....................................................................................................... 10
3.1 Compressor handling.......................................................................................................10
3.1.1Delivery.................................................................................................................10
3.1.2 Transport and storage..........................................................................................10
3.1.3 Positioning and securing......................................................................................10
3.1.4 Installation location...............................................................................................11
3.1.5 Mounting parts......................................................................................................11
3.2 Pressure safety controls ..................................................................................................11
3.2.1 High-pressure control...........................................................................................11
3.2.2 Low-pressure control............................................................................................11
3.2.3 Maximum allowable pressures.............................................................................11
3.3 Brazing procedure............................................................................................................12
3.4 Screens............................................................................................................................12
4Electrical connection ...................................................................................... 13

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4.1 General recommendations...............................................................................................13
4.2 Electrical installation ........................................................................................................13
4.2.1 Part-winding motors (YY/Y) –Code A..................................................................13
4.2.2 Star / Delta motors (Y/∆) – Code E......................................................................13
4.3 Wiring diagrams...............................................................................................................13
4.3.1 Wiring diagrams for part winding motors (AW…).................................................14
4.3.2 Wiring diagrams for Star / Delta motors (EW…) ..................................................16
4.4 Protection devices............................................................................................................17
4.5 CoreSense™ Diagnostics................................................................................................17
4.6 CoreSense™Protection..................................................................................................19
4.6.1 Motor protection ...................................................................................................19
4.6.2 Oil pressure control..............................................................................................19
4.7Crankcase heater.............................................................................................................21
5Starting up & operation................................................................................... 22
5.1 Leak test...........................................................................................................................22
5.2 System evacuation...........................................................................................................22
5.3 Preliminary checks –Pre-starting....................................................................................22
5.4 Charging procedure .........................................................................................................22
5.5 Initial start-up ...................................................................................................................23
5.6 Minimum run time ............................................................................................................23
5.7 Pump-down......................................................................................................................23
6Maintenance & repair...................................................................................... 24
6.1 Exchanging the refrigerant...............................................................................................24
6.2 Replacing a compressor..................................................................................................24
6.3 Lubrication and oil removal..............................................................................................24
6.4 Oil additives .....................................................................................................................25
6.5 Unbrazing system components .......................................................................................25
7Dismantling & disposal................................................................................... 25
Appendix 1: Stream Digital compressor connections ............................................. 26
Appendix 2: Tightening torques in Nm ..................................................................... 27
Disclaimer ................................................................................................................... 27

C6.3.2/0416-0716/E 1
1 Safety instructions
Copeland™brand products 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.
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.
Safety
instructions
Product
description
Installation
Electrical
connection
Starting up &
operation
Maintenance &
repair
Dismantling &
disposal

2 C6.3.2/0416-0716/E
CAUTION
Contact with POE! Material damage! POE lubricant must be handled
carefully and the proper protective equipment (gloves, eye protection, etc.)
must be used at all times. POE must not come into contact with any surface
or material that it might damage, including without limitation, certain
polymers, eg, PVC/CPVC and polycarbonate.
IMPORTANT
Transit damage! Compressor malfunction! Use original packaging. Avoid
collisions and tilting.

C6.3.2/0416-0716/E 3
2 Product description
2.1 Common information about Copeland Stream Digital™semi-hermetic
compressors
These guidelines cover Copeland Stream Digital™semi-hermetic compressors. The semi-
hermetic reciprocating compressor family consists of different ranges. The Stream Digital series
of 4M*D and 6M*D models ranges from 13 hp to 50 hp.
Cooling
capacity
(kW)
COP
R404A R134a R404A R134a R404A R404A
4MFD-13X 13 31.30 18.25 2.36 2.40 9.52 1.28 177
4MAD-22X 22 32.40 18.95 2.27 2.48 9.33 1.28 178
4MLD-15X 15 38.00 22.10 2.34 2.46 12.05 1.33 180
4MHD-25X 25 38.10 21.80 2.29 2.40 11.05 1.29 187
4MMD-20X 20 41.60 24.40 2.35 2.46 13.70 1.36 182
4MID-30X 30 42.30 24.10 2.29 2.44 13.00 1.33 188
4MTD-22X 22 47.20 27.80 2.29 2.46 15.40 1.35 183
4MJD-33X 33 47.10 27.00 2.35 2.43 14.60 1.35 190
4MUD-25X 25 52.50 30.60 2.29 2.39 16.85 1.31 186
4MKD-35X 35 53.00 30.30 2.25 2.40 16.45 1.31 202
6MMD-30X 30 63.60 36.90 2.32 2.41 20.60 1.31 215
6MID-40X 40 64.00 35.50 2.27 2.32 19.70 1.30 219
6MTD-35X 35 71.70 41.60 2.27 2.41 23.20 1.33 221
6MJD-45X 45 71.70 40.40 2.29 2.40 21.90 1.30 223
6MUD-40X 40 80.50 45.60 2.27 2.36 25.70 1.30 225
6MKD-50X 50 80.10 43.30 2.27 2.22 24.50 1.26 230
135
153
62
71
78
88
99
120
381 x305
Cooling
capacity
(kW)
COP
Medium temperature 1)
Low temperature 2)
Model
Nominal
horsepower
(hp)
Displacement
m3/h
Net
weight
(kg)
Footprint
mm
1) R404A evaporating -10°C, condensing 45°C, suction gas temperature 20°C, subcooling 0K
R134a evaporating -10°C, condensing 45°C, superheat 20K, subcooling 0K
2) R404A evaporating -35°C, condensing 40°C, suction gas temperature 0°C, subcooling 0K
Table 1: Stream Digital compressors range and performance for full load (100%)
Semi-hermetic Stream Digital compressors are suitable for a wide range of applications in the
form of either 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 Stream Digital 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 Stream Digital semi-hermetic compressors. They are not intended to
replace the system expertise available from system manufacturers.
2.3 Nomenclature
The model designation contains the following technical information about Stream Digital
compressors:
Safety
instructions
Product
description
Installation
Electrical
connection
Starting up &
operation
Maintenance &
repair
Dismantling &
disposal

4 C6.3.2/0416-0716/E
2.4 Nameplate information
All important information for identification of the compressor is printed on the nameplate located
below the compressor oil pump.
The type of refrigerant used should be stamped on the nameplate by the installer.
The year and month of production are shown as a part of the serial number (Jan. = A, Feb. = B,
… Dec. = L).
Figure 1: Nameplate position
2.5 Application range
2.5.1 Qualified refrigerants and oils
WARNING
Use of R450A and R513A refrigerants! Risk of compressor damage!
Refrigerant migration of R450A or R513A into the compressor crankcase
could cause low oil viscosity, which could lead to compressor damage. When
using R450A or R513A it is critical to meet the following requirements:
maintain adequate superheat settings with a minimum superheat of 8-10K;
no liquid refrigerant migration into the compressor at any time, especially
during standstill, during or after defrost, or after reverse mode for example
in heat pumps;
pumpdown is recommended;
the use of a crankcase heater is mandatory;
retrofit to R450A and R513A is only allowed for compressors which are
approved for these refrigerants.
Contact Application Engineering for any further information.
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, R513A
R22
Copeland brand products
standard oils
Emkarate RL 32 3MAF
Suniso 3 GS
Servicing oils
Emkarate RL 32 3MAF
Mobil EAL Arctic 22 CC
Suniso 3 GS, Shell 22-12
Fuchs Reniso KM 32, Capella WF 32
Table 2: Qualified refrigerants and oils for recharging and topping up
To recharge:
When the compressor is completely empty of oil, the amount of oil to be "recharged" is
typically 0.12 litre less than the original oil charge (oil will already be present in the system).
To top up:
During commissioning, planned maintenance or servicing, add oil so that the compressor oil
level is correct.

C6.3.2/0416-0716/E 5
2.5.2 Application limits
For application envelopes please refer to Copeland brand products Select software available at
www.emersonclimate.eu.
2.6 Design features
2.6.1 Compressor construction
All compressors are fitted with Discus valve plates which cannot be dismantled. To maintain the
high capacity of these compressors in case of exchange, the correct valve-plate-to-body gasket
must always be selected.
The 4M*D and 6M*D Digital head is fitted on the terminal box side cylinder bank.
All 6M*D compressors are equipped with a standard capacity control on the central cylinder
bank.
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.
Figure 2: Exploded view of the Digital mechanism
Factory-delivered 4M*D and 6M*D compressors include as standard configuration:
one standard bank;
one Digital modulated bank;
one capacity-controlled bank (blocked suction std) only for 6M*D.
NOTE: To upgrade 6M* compressors to 6M*D, Emerson Climate Technologies
recommends to use the central cylinder bank.
2.6.2 Digital theory of operation
Digital technology is now available on the 4M*D and 6M*D Stream compressors. Applied to one
bank on a 4M*D compressor it provides 50 to 100% capacity modulation. When combined with a
blocked suction bank on a 6M*D compressor, it provides 33 to 100%.
Digital capacity control is achieved by using a proven internal unloading method, based on
blocking gas to the valve plate suction area. Capacity control can be achieved by varying the
percentage of duty cycle when the compressor is loaded and unloaded. The unloader piston
mechanism that controls the flow of suction gas into the cylinders is driven by a solenoid valve.
Safety
instructions
Product
description
Installation
Electrical
connection
Starting up &
operation
Maintenance &
repair
Dismantling &
disposal

6 C6.3.2/0416-0716/E
1. Gas enters the compressor
2. passes through the body
3. Unloader mechanism blocks gas
before entering the valve plate
Figure 3: Digital modulation components
Loaded Unloaded
Figure 4: Gas flow
Loaded –Valve de-energized (100% capacity) Unloaded –Valve energized (0% capacity)
1= Solenoid valve 2= Cylinder head 3= Valve plate 4 & 5 = Unloading piston
Figure 5: Cutaway view of the Digital cylinder head loaded and unloaded
1. Gas enters the compressor
2. passes through the body
3. into the valve plate
4. Compressed gas
5. exits the compressor
Bolts / studs
Solenoid valve
Solenoid valve gasket
Cylinder head
1
2
5
4
3
2

C6.3.2/0416-0716/E 7
2.6.3 Digital control
Capacity modulation is achieved by energizing and de-energizing the solenoid valve. When the
solenoid valve is de-energized, the Digital bank capacity is 100%. When the solenoid valve is
energized, the Digital bank capacity is zero. Therefore, the capacity achieved is the time average
capacity.
Example: In a 20-second cycle, if the solenoid is de-energized for 16 seconds, and then
energized for 4 seconds, the resulting capacity will be approximately 80%.
For 4M*D Stream compressors, one bank of the compressor remains loaded 100% while the
Digital bank will modulate 0 to 100% to provide the additional capacity. The capacity is 50 to
100% as one bank is modulating.
On a 6M*D Stream compressor with blocked suction, the blocked suction bank will unload when
demand capacity is less than 67% and load when the demand capacity is higher than 67%. The
Digital bank will continue to load and unload providing continuous capacity across the 33 to
100% range.
2.6.4 Recommended application settings for modulation on Stream Digital compressors
The Digital modulation recommended cycle time is 20 seconds. For other values, check with
Application Engineering.
Figure 6: The digital signal from the controller activates the unloading
The load and unload times will give the compressor an operating range during a 20-second
cycle. Minimum percent capacity would be 50% for 4M*D and 33% or 67% for 6M*D, depending
on compressor configuration. The compressor can also operate at a 100% load for the full
modulation sequence.
2.6.5 Digital solenoid valve / Gaskets
Due to the high life cycle requirements in a hot gas environment, a special valve has been
developed. Due to reliability requirements, only Emerson solenoid valves may be used. All
compressor warranties are null and void if the Emerson valve is not used. Solenoid coils will be
sold separately for all Stream Digital compressors.
The solenoid coil is available for several voltages: 24V, 120V and 240V.
Stream Digital compressors use special head and valve plate gaskets which have modifications
to ensure gas flow for proper Digital modulation. Only Emerson gaskets may be used. All
compressor warranties are null and void if the Emerson gaskets are not used.
2.6.6 Compressor cooling
Compressor motors must always be cooled, and cylinder head cooling may also be needed at
certain operating conditions.
All Stream Digital compressors 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 operation conditions (see Select software at
www.emersonclimate.eu).
2.6.7 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.
Safety
instructions
Product
description
Installation
Electrical
connection
Starting up &
operation
Maintenance &
repair
Dismantling &
disposal

8 C6.3.2/0416-0716/E
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
perfect starting even when the voltages amount to less than approximately 85% of the voltage
on the nameplate.
2.6.8 Oil pumps
The oil pumps used for Stream Digital compressors are independent of their rotating direction.
In compressors delivered with CoreSense™Diagnostics (-D), the oil pump integrates the
electronic switch for integrating oil pressure safety functionality.
Compressors delivered with CoreSense™Protection (-P) are designed to accommodate fittings
for an OPS2 (oil sensor included in the oil pump). A mechanical oil safety device like the Alco
Control FD-113ZU can also be used.
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 oil return 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.
Both four- and six-cylinder compressors have one crankcase ventilating valve on the left cylinder
bank.
2.6.11 Oil level
All compressors are delivered with sufficient oil for normal operation (see Table 2). 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 oil level should be
min ¼ and max ¾ of the sight glass.
For service compressors when an oil regulator is used the oil level should be min ¼ and max ¾
of the sight glass. The level can also be checked within 10 seconds of compressor shut-down.
For 4M*D and 6M*D compressors a higher oil level may be accepted when an oil regulator is in
use because the oil separator will reduce excessive oil circulation.
Figure 7: Sight glass reading on 4M*D and 6M*D compressors

C6.3.2/0416-0716/E 9
2.6.12 Multiple compressor application
To ensure smooth and continuous modulation, ie, for optimum suction pressure control, the
selection of the Stream Digital and Stream fixed-capacity compressors should be made
according to the following rule:
- F1 < D
- F2 < D+F1
- F3 < D+F1+F2
- ……
- FN < D+F1+F2+....FN-1
Where D= Capacity of the Stream Digital compressor and F1 --- FN = Capacity of the Stream
compressors.
The Stream Digital compressor selected should have the smallest capacity to cover all the gaps
between steps to ensure the most efficient system control.
For example, a 4M*D has a continuous capacity from 50 to 100%. Therefore, when a 4M*D
Stream Digital compressor is selected, the associated fixed-capacity compressor should have 50
to 100% of the full load of the Stream Digital compressor.
NOTE: For best results, the Stream Digital compressor must be the lead compressor. It
must be the first compressor "On" and the last compressor "Off" in multiple compressor
applications.
Safety
instructions
Product
description
Installation
Electrical
connection
Starting up &
operation
Maintenance &
repair
Dismantling &
disposal

10 C6.3.2/0416-0716/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. Any deficiency should be reported
immediately in writing.
Standard delivery:
Suction and discharge shut-off valves
Oil charge, oil sight glass
Mounting kit
CoreSense™Diagnostics or CoreSense™Protection module
Holding charge up to 2.5 bar(g) (dry air)
Digital solenoid valve (delivered mounted)
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. Do not stack pallets on top of each other. Keep the
packaging dry at all times.
Figure 8
Compressors are delivered on pallets. Cooling fans are delivered in separate boxes.
Accessories may be mounted or delivered loose. Solenoid valves are never mounted, except the
Digital head solenoid valve.
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 horizontal during handling.
For safety reasons two lifting eyes should be fitted before moving a compressor (½" - 13 UNC).
Otherwise refer to drawings on Figure 9 to see how to apply other lifting methods.
4M*D 6M*D
max. 220 kg max. 260 kg
Figure 9
1
4M*D, 6M*D

C6.3.2/0416-0716/E 11
In order to avoid refrigerant leaks or other damage the compressors should not be lifted by the
service valves or other accessories.
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
one set of spring mounting parts for each of the Stream models is delivered with each 4M*D and
6M*D compressor.
Due to differences in weight (cylinder/motor side) different springs have to be used on both
sides. Springs have different colours for easier identification: violet on motor side and orange on
cylinder side.
Operational position Transport position
Figure 10: Position of vibration dampers during transport and operation
When Stream Digital compressors are mounted in racks, rubber mounting parts should be used.
A compressor may be rigidly mounted, ie, without springs. In this case more shock and vibration
will be transmitted to the frame.
Unevenness in the mounting surface will affect the rack and/or the compressor bottom plate/feet.
Excessive unevenness can result in too high mechanical stress to the system and could damage
the compressor or rack. Therefore, the flatness of the mounting location is essential. In addition,
both vibration/shock and mechanical stress to compressor can be avoided by using rubber
mounting parts.
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.
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 cut-out setting 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 Maximum allowable pressures
The maximum allowable pressures according to EN 12693 shown on the compressor nameplate
are obligatory and must not be exceeded.
Safety
instructions
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description
Installation
Electrical
connection
Starting up &
operation
Maintenance &
repair
Dismantling &
disposal
Transport clamp

12 C6.3.2/0416-0716/E
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
NOTE: The compressor operating range may be restricted for various reasons. Check the
application range limitations in Copeland brand products Select software at
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.
Refer to Figure 11 and procedure below for the brazing of the suction and discharge lines:
The copper-coated steel tubes on Stream Digital
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.
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 mesh (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.
Figure 11: Suction tube brazing areas

C6.3.2/0416-0716/E 13
4 Electrical connection
4.1 General recommendations
The compressor terminal box has a wiring diagram on the inside of its cover. Before connecting
the compressor, ensure the supply voltage, the phases and the frequency match the nameplate
data.
The knockouts have to be removed before the electrical glands can be installed. First make sure
that the terminal box is closed with the terminal box cover. We recommend to use a subland
twist driller to avoid any damage to the box while removing the knockouts.
Figure 12
4.2 Electrical installation
All compressors can be started Direct-on-line.
The position of bridges required for Direct-on-line start (depending on type of motor and/or mains
voltage) is shown in Chapter 4.3 "Wiring diagrams".
4.2.1 Part-winding motors (YY/Y) –Code A
Part-winding motors contain two separate windings (2/3 + 1/3) which are internally connected in
star and operated in parallel. You cannot change the voltage by changing the electrical
connections as these motors are only suitable for one voltage.
The first part winding, ie, the 2/3 winding on terminals 1-2-3, can be used for part-winding start
(remove the bridges!). After a time delay of 1 ± 0.1 seconds the second part winding, ie, the 1/3
winding on terminals 7-8-9, must be brought on line.
4.2.2 Star / Delta motors (Y/∆) – Code E
Star / Delta motors are interchangeable for star (Y) or delta (∆) operation by means of bridges.
They are suitable for two voltages, eg, 230V in delta, 400V in star connection. If the supply
voltage and the nominal voltage of the motor in ∆-connection are identical, the star connection
motor can also be used for starting (remove the bridges!).
4.3 Wiring diagrams
The position of the jumpers in the terminal box and the recommended wiring diagrams are
shown in Figures 13 to 16.
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Twist driller

14 C6.3.2/0416-0716/E
4.3.1 Wiring diagrams for part winding motors (AW…)
Part-winding motors can be connected Direct-on-line or part-winding start.
NOTE: The sensor module inside the terminal box requires a separate 24V AC power
supply.
Part-winding motor:
Y –Y
Code A
Direct-on-line start
Y –Y
Part-winding start
First start step 1-2-3
Y –Y
4.3.1.1 Compressors with CoreSense Diagnostics module
Legend
A4 ....... Sensor module K1 .......Contactor M1
A5 ....... Compressor terminal box K4 .......Contactor M1 for second part-winding
CCH.... Crankcase heater M21.....Fan motor / condenser
F6 ....... Fuse for control circuit R2.......Crankcase heater
F7 ....... Fuse for control circuit Y21 .....Solenoid valve capacity control 1
F8 ....... Fuse for control circuit Y22 .....Solenoid valve capacity control 2
F10 ..... Thermal protection switch M21
Figure 13

C6.3.2/0416-0716/E 15
4.3.1.2 Compressors with CoreSense Protection module
Legend
A1 ....... CoreSense Protection module K4 .......Contactor M1 for second part-winding
A2 ....... OPS2 Oil pressure switch M21.....Fan motor / condenser
A5 ....... Compressor terminal box R2.......Crankcase heater
F6 ....... Fuse for control circuit Y7 .......Solenoid valve Digital
F7 ....... Fuse for control circuit Y21 .....Solenoid valve capacity control 1
F8 ....... Fuse for control circuit Y22 .....Solenoid valve capacity control 2
F10 ..... Thermal protection switch M21 Y3 .......Solenoid valve unloaded start
K1 ....... Contactor M1
Figure 14
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16 C6.3.2/0416-0716/E
4.3.2 Wiring diagrams for Star / Delta motors (EW…)
Star / Delta motors can be connected Direct-on-line or Star / Delta start.
NOTE: The sensor module inside the terminal box requires a separate 24V AC power
supply.
Star / Delta motor:
Y - ∆
Code E
Direct-on-line start
∆
Direct-on-line start
Y
Star / Delta start
Y - ∆
4.3.2.1 Compressors with CoreSense Diagnostics module
Legend
A4 ....... Sensor module K1 .......Contactor M1
A5 ....... Compressor terminal box K2 .......Contactor M1 Y-connection
CCH.... Crankcase heater K3 .......Contactor M1 Δ-connection
F6 ....... Fuse for control circuit M21.....Fan motor / condenser
F7 ....... Fuse for control circuit R2.......Crankcase heater
F8 ....... Fuse for control circuit Y21 .....Solenoid valve capacity control 1
F10 ..... Thermal protection switch M21 Y22 .....Solenoid valve capacity control 2
Figure 15

C6.3.2/0416-0716/E 17
4.3.2.2 Compressors with CoreSense Protection module
Legend
A1 ....... CoreSense Protection module K2 .......Contactor M1 Y-connection
A2 ....... OPS2 Oil pressure switch K3 .......Contactor M1 Δ-connection
A5 ....... Compressor terminal box M21.....Fan motor / condenser
F6 ....... Fuse for control circuit R2.......Crankcase heater
F7 ....... Fuse for control circuit Y7 .......Solenoid valve Digital
F8 ....... Fuse for control circuit Y21 .....Solenoid valve capacity control 1
F10 ..... Thermal protection switch M21 Y22 .....Solenoid valve capacity control 2
K1 ....... Contactor M1 Y3 .......Solenoid valve unloaded start
Figure 16
4.4 Protection devices
Independently from the internal motor protection, fuses must be installed before compressor
start-up. The selection of fuses has to be carried out according to VDE 0635, DIN 57635,
IEC 269-1 or EN 60-269-1.
4.5 CoreSense™ Diagnostics
CoreSense™Diagnostics can be used for all 4M*D and 6M*D Stream Digital compressors. It
combines oil and motor protection into one module, replacing OPS1/2 and the electronic module
INT69TM. In addition to diagnostics, it provides advanced protection against faults such as high
discharge temperature, locked rotor, single/missing phase, voltage imbalance, low voltage. The
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