Emerson Copeland Stream 4MF-13X User manual

Copeland™ Semi-Hermetic Compressor
Stream for refrigeration applications
User Manual

Emerson Climate Technologies is the world’s leading provider of heating, ventilation, air-conditioning and refrigeration
solutions for residential, commercial, and industrial applications, supporting the industry with advanced technology,
technical support and training services.
For more than 80 years, we have been introducing innovative technology to the market, from the rst semi-hermetic
and hermetic compressors in the 1940s and 1950s, the high efciency Discus™ semi-hermetic and the digital scroll
compressor technology of today.
Based on this, we have developed an unequalled range of solutions for the refrigeration and air conditioning markets.
In recent years, we have become a major solutions provider to the air conditioning and refrigeration industry. Our
range of Copeland™ brand products addresses the diverse needs of all of these markets. With scrolls and semi-hermetic
compressors available for all main refrigerants, equipped with smart electronics and capable of modulation, Emerson
Climate Technologies has taken compressor technology to new heights.
Emerson Climate Technologies, With Our Partners,
Will Provide Global Solutions To Improve Human Comfort,
Safeguard Food And Protect The Environment.
Our Vision:
Pioneering Technologies For Best-In-Class Products

Table of Contents
Safety Information 4
Product Description 5
Design Features 6
Nomenclature 7
Operating Envelopes 8
Nameplate Information 11
Application Range 11
Installation Guidelines 12
Electrical Connection 15
Wiring Diagrams 16
Start-up Leak Checking, Evacuation and Charging 20
Maintenance 22
Appendices
Appendix 1 24
Appendix 2 26
Appendix 3 27
Appendix 4 29
Notes 33
General Information 35
Contact List 36

4
5
Safety Information
• 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 EC Machines directive. They may be put to service only if
they have been installed in these systems according to instructions and conforming with the corresponding provisions of legislation.
For relevant standards, please refer to Manufacturers Declaration, available on request.
• These instructions should be retained throughout the lifetime of the compressor.
You are strongly advised to follow these safety instructions.
Icon Definition
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.
This word indicates a recommendation for easier
operation.
Explosion hazard
This icon indicates operations with a danger of explosion.
About this Manual
• This manual is intended to enable users to ensure the safe installation, starting, operation, and maintenance of semi-hermetic
compressors. This manual is not intended to replace the system expertise available from system manufacturers.
Safety Statements
• Refrigerant compressors must be employed only for their intended use.
• Only quali ed and authorized HVAC or refrigeration personnel are permitted to install, commission, and maintain this equipment.
• Electrical connections must be made by quali ed electrical personnel.
• All valid standards for connecting electrical and refrigeration equipment must be observed.
Use Personal Safety Equipment
• The new compressor contains oil and dry air under a pressure of 2.0bar. While releasing pressure before installation, the oil drain
plug may pop out under pressure and oil could spurt out.
• Safety gloves, protective clothing, safety boots, and protective eyewear should be worn where necessary.
General Instructions
WARNING
System breakdown! Personal injuries! Never install a system in the  eld 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 body 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.
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, e.g., PVC/CPVC and polycarbonate.
IMPORTANT
Transit damage! Compressor malfunction! Use original packaging. Avoid collisions and tilting.

5
Product Description
Technical Data
Compressor 4MU-25X 4MK-35X 6MM-30X 6MI-40X 6MT-35X 6MJ-45X 6MU-40X 6MK-50X
Number of Cylinders 4 4 6 6 6 6 6 6
Displacement
(m3/hr)
50 Hz 99.4 99.4 120.5 120.5 135.1 135.1 153.2 153.2
60 Hz 120 120 145.4 145.4 163 163 184.9 184.9
Bore/Stroke (mm) 80.6/56.0 80.6/56.0 71.5/57.5 71.5/57.5 75.7/57.5 75.7/57.5 80.6/57.5 80.6/57.5
Nominal Horse Power (HP) 25 35 30 40 35 45 40 50
Motor Speed
(RPM)
50 Hz 1450 1450 1450 1450 1450 1450 1450 1450
60 Hz 1740 1740 1740 1740 1740 1740 1740 1740
Discharge Service Valve Size 1 3/8” 1 3/8” 1 3/8” 1 3/8” 1 5/8” 1 5/8” 1 5/8” 1 5/8”
Suction Service Valve Size 2 1/8” 2 1/8” 2 1/8” 2 1/8” 2 1/8” 2 1/8” 2 5/8” 2 5/8”
Base mounting (mm) 381X305 381X305 381X305 381X305 381X305 381X305 381X305 381X305
Oil Charge (liter) 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3
Net Weight (kg)
Net 186 202 215 219 221 223 225 230
Gross 211 227 240 244 246 248 250 255
Table 1: Stream compressor range and performance
Semi-hermetic Stream 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 efcient refrigeration system.
Therefore the information in this manual relates to all semi-hermetic Stream compressors with standard equipment and
accessories only.
Compressor 4MF-13X 4MA-22X 4ML-15X 4MH-25X 4MM-20X 4MI-30X 4MT-22X 4MJ-33X
Number of Cylinders 4 4 4 4 4 4 4 4
Displacement
(m3/hr)
50 Hz 61.7 61.7 71.4 71.4 78.2 78.2 87.7 87.7
60 Hz 74.5 74.5 86.2 86.2 94.4 94.4 105.9 105.9
Bore/Stroke (mm) 63.5/56.0 63.5/56.0 68.3/56.0 68.3/56.0 71.5/56.0 71.5/56.0 75.7/56.0 75.7/56.0
Nominal Horse Power (HP) 13 22 15 25 20 30 22 33
Motor Speed
(RPM)
50 Hz 1450 1450 1450 1450 1450 1450 1450 1450
60 Hz 1740 1740 1740 1740 1740 1740 1740 1740
Discharge Service Valve Size 1 1/8” 1 1/8” 1 1/8” 1 1/8” 1 1/8” 1 1/8” 1 3/8” 1 3/8”
Suction Service Valve Size 1 5/8” 1 5/8” 1 5/8” 2 1/8” 2 1/8” 2 1/8” 2 1/8” 2 1/8”
Base mounting (mm) 381X305 381X305 381X305 381X305 381X305 381X305 381X305 381X305
Oil Charge (liter) 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3
Net Weight (kg)
Net 177 177 180 187 182 188 183 190
Gross 202 202 205 212 207 213 208 215

6 7
Capacity Control
For 4M* and 6M* compressors, a mechanical capacity control is available. The system used is blocked suction. Be aware that unloaded
operation changes the application range of the compressor.
NOTE: For the application range of the compressors with capacity control, refer to Technical Information D7.21.2
“Stream semi-hermetic compressor capacity control”.
Oil Pumps
The oil pumps used for Stream compressors are independent of their rotating direction. Stream compressors are delivered with
CoreSense™ Diagnostics. The oil pump integrates the electronic switch for integrating oil pressure safety functionality.
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-tting instead of plug on the compressor crankcase) or the suction service valve.
During irregular operating condition, e.g., a blockage of the suction lter, 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.
Compressor Cooling
Compressor motors must always be cooled, while cylinder head cooling may also be needed at certain operating conditions.
All Stream 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 (70W vertical air ow fan) may be required depending upon the operation conditions. Please see
Operating Envelopes.
Demand Cooling
“Demand Cooling”, as the term implies, means liquid refrigerant injection on demand. If a low-temperature R22 or R407F installation is
needed, the following compressors can be equipped with demand cooling. Models without demand cooling are also available from Asia.
Please contact the representative sales manager in your region for more information.
For Demand Cooling installation, refer to the installation manual in accessory kit. Please see Operating Envelopes.
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. 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.
4MF-13 4ML-15 4MM-20 4MT-22 4MU-25
6MM-30 6MT-35 6MU-40
Design Features
Compressor Structure
Each cylinder head has 2 plugged 1/8” - 27NPTF tapped holes 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 has exceeded.
The complete cylinder head is under discharge pressure.
Figure 1
All compressors are tted with Stream 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.

7
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.
Four-cylinder compressors have one crankcase ventilating valve on the left cylinder bank, whereas, six-cylinder compressors have two
ventilating valves on the left and right cylinder banks.
Oil level
All compressors are delivered with sufcient oil for normal operation (see Table 2). The optimum oil level should be checked by operat-
ing the compressor until the system is stable and then comparing the sight glass reading with the appropriate diagram below. Oil level
should be min 1/4 and max 3/4 of sight glass.
For service compressors when an oil regulator is used the oil level should be min 1/4 and max 3/4 of sight glass. The level can also be
checked within 10 seconds of compressor shut-down.
For 4M* and 6M* 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 2: 4M* and 6M* compressors
Stream
3/4
1/4
Nomenclature
Bill of Material
Number
of Cylinders
Bore Denomination
Design Revision Motor Code
Motor Size
25 = 25HP
Oil Type
X - Ester Oil
0 - Mineral Oil
Family
M - Copeland Stream
4 M H D 1 - 25X - AWM/D - D000
D - Digital

8 9
Operating Envelopes
4MF1-13X, 4ML1-15X, 4MM1-20X, 4MT1-22X
6MM1-30X, 6MT1-35X, 6MU1-40X
4MU1-25X
4MA1-22X, 4MH1-25X, 4MI1-30X, 4MJ1-33X, 4MK1-35X
6MI1-40X, 6MJ1-45X, 6MK1-50X
50
60
40
30
20
10
0
50
60
40
30
20
10
0
-50 -45 -40 -35 -30 -25 -20 -15 -10 0
R404A
Condesnsing Temperature °C
Evaporating Temperature °C
-5 -45 -40 -35 -30 -25 -20 -15 -10 -5 0510
Condesnsing Temperature °C
R404A
Evaporating Temperature °C
50
60
40
30
20
10
0
-50 -45 -40 -35 -30 -25 -20 -15 -10 0
R404A
Condesnsing Temperature °C
Evaporating Temperature °C
-5
20K Suction Superheat
20K Suction Superheat
0°C Return Gas Temperature
0°C Return Gas Temperature
20°C Return Gas Temperature
20°C Return Gas Temperature
0°C Return Gas Temperature
20°C Return Gas Temperature

8 9
Evaporating Temperature °C
Condensing Temperature °C
-20 -15 -10 -5 0510 15
10
20
30
40
50
R134a
60
4MA1-22X, 4MH1-25X
4MI1-30X, 4MJ1-33X, 4MK1-35X
6MI1-40X, 6MJ1-45X, 6MK1-50X
25°C Return Gas Temperature
Evaporating Temperature °C
Condensing Temperature °C
-20 -15 -10 -5 0510 25
10
20
30
40
50
60
80
R134a
70
15 20
4MF1-13X, 4ML1-15X
4MM1-20X, 4MT1-22X, 4MU1-25X
6MM1-30X, 6MT1-35X, 6MU1-40X
20K Suction Superheat

10 11
Evaporating Temperature °C
Condensing Temperature °C
-25 -20 -15 -10 -5 0510 15
10
20
30
40
50
60
R22
Evaporating Temperature °C
Condensing Temperature °C
-25 -20 -15 -10 -5 0510 15
10
20
30
40
50
60
R22
4MK1-350, 6MI1-400, 6MJ1-450 6MK1-500
20K Suction Superheat
20°C Return Gas Temperature
20K Suction Superheat
20°C Return Gas Temperature
Evaporating Temperature °C
Condensing Temperature °C
-25 -20 -15 -5-10 010515
10
20
30
40
60
50
R22
10
20
30
40
50
60
R22
-55-50 -45-40 -35-30 -25-20 -15-10 -5 0
4MA1-220, 4MH1-250, 4MI1-300, 4MJ1-330
4MF1-130, 4ML1-150, 4MM1-200, 4MT1-220,
4MU1-250, 6MM1-300, 6MT1-350, 6MU1-400
20°C Suction Gas Return+Fan+Liquid Injection 20°C Return Gas Temperature+Fan+Demand Cooling
20K Suction Superheat+Fan
20K Suction Superheat
20°C Return Gas Temperature
Evaporating Temperature °C
Condensing Temperature °C

11
Nameplate Information
All important information for identication 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 date of production indicates the year and week of production. The year and month of production are also part of the serial number
(Jan. = A, Feb. = B, ... Dec. = L).
Qualified Refrigerants and Oils
Application Range
Figure 3
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 Selection Software on www.EmersonClimateAsia.com
Qualified Refrigerants R404A, R407A, R407C, R407F, R134a, R507 R22
Copeland™ Brand Products
Standard Oil Emkarate RL 32 3MAF Karamay 32BYMO
Servicing Oil Emkarate RL 32 3MAF
Mobil EAL Arctic 22 CC
Karamay 32BYMO, Suniso 3GS
Shell 22-12, Texaco Capella WF32
Table 2: Qualied 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 around the system).
To Top up:
During commissioning, planned maintenance or servicing, add oil so that the compressor oil level is correct.
20K Suction Superheat
20°C Return Gas Temperature

12 13
Installation Guidelines
Compressor Handling
Delivery
Please check whether the delivery is correct and complete. Any deciency should be reported immediately in writing.
Transport and Storage
WARNING
High pressure! Injury to skin and eyes, possible! Be careful when opening connections on a pressurized item.
WARNING
Risk of collapse! Personal injuries! Move compressors only with appropriate mechanical or handling equipment according to
weight. Keep in the upright position. Stack and transit as shown below. Keep the packaging dry at all times.
• Suction and discharge shut-off valves
• Oil charge, oil sight glass
• Mounting kit
• CoreSense™ Diagnostics module
• Holding charge up to 2.5 bar(g) (dry air)
Compressors are delivered on pallets. Cooling fans are delivered in separate cartons. Accessories may be mounted or delivered loose.
Solenoid valves are never mounted.
Figure 4
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.
Positioning and Securing
If possible, the compressor should be kept vertical during handling. For safety reasons, two lifting eyes should be tted before moving a
compressor (½” - 13 UNC). Otherwise refer to drawings on Figure 5 to see how to apply other lifting methods.
In order to avoid refrigerant leaks or other damage the compressors should not be lifted by the service valves or other accessories.
4M*
max. 220 kg
6M*
max. 260 kg
Figure 5
STOCK
3
TRANSIT
2

13
Installation Location
Ensure the compressors are installed on a solid level base.
Mounting Parts
To minimize vibration and start/stop impulses, exible mounting should be used. For this purpose, one set of spring mounting parts for
each of the Stream models is delivered with each 4M* and 6M* compressor.
Due to differences in weight (cylinder/motor side), different springs have to be used on both sides. Springs have different colours for
easier identication: violet on motor side and orange on cylinder side.
When Stream compressors are mounted in racks, rubber mounting parts should be used. A compressor may be rigidly mounted, i.e.,
without springs. In this case, more shock and vibration loading will be transmitted to the frame, so atness of mounting location is very
important. If the installation requires a very high level of vibration absorption, additional vibration absorbers - available on the market -
can be tted between the rails and the foundation.
Figure 6
Transport position
Transport clamp
Operational position
34
44
2
TWIN compressors are tted to U mounting rails using rubber pads.
Rubber mounting parts can be delivered as a variation instead of the spring mounting parts, or as a separate kit.
Unevenness in the mounting surface will have to be taken by 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 atness of the mounting
location is essential. In addition, both vibration/shock and mechanical stress to compressor can be avoided by using rubber mounting
parts.
NOTE: For rigid mounting on rack with rubber mounting parts, the nuts should be tightened to the rubber surface without
rubber deformation to keep efficient operation of the rubber. The maximum applicable torque without rubber deformation is
50Nm.
Rubber pads
Spacer
Figure 7

14 15
Pressure Safety Controls
High-pressure Control
A high-pressure control with a maximum cut-out setting of 28 bar(g) is required. The high-pressure cut-out should have a manual reset
feature for the highest level of system protection.
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.
Maximum Operating Pressures
Maximum operating pressures according to EN 12693 shown on the compressor nameplate are obligatory and must not be exceeded.
NOTE: The compressor operating range may be restricted for various reasons. Check the application range limitations in
Copeland®brand products Selection Software on www.EmersonClimateAsia.com.
Brazing Procedure
IMPORTANT
Blockage! Compressor breakdown! Maintain a ow 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 minimizes any
entry of contaminants and moisture.
• The copper-coated steel tubes on Stream 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 tting 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 ame to
area 2.
Figure 8: Suction tube brazing
• 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 ow braze material around the
circumference.
• After the braze material ows 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 nal 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 tting.
To Reconnect:
Recommended brazing materials: Silfos with minimum 5% silver or silver braze used on other compressors.
• High-pressure side (HP): 28.0 bar
• Low-pressure side (LP): 22.5 bar

15
Screens
CAUTION
Screen blocking! Compressor breakdown! Use screens with at least 0.6 mm openings.
The use of screens ner than 30 x 30 mesh (0.6 mm openings) anywhere in the system should be avoided with these compressors. Field
experience has shown that ner 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 ow of either oil or refrigerant to the compressor. Such
blockage can result in compressor failure.
Electrical Connection
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.
Electrical Installation
Three-phase Motors
All compressors can be started direct-on-line.
The necessary position of bridges for direct-on-line start (depending on type of motor and/or mains voltage) is shown in page 16, Wiring
Diagrams.
Star / Delta Motors (Y/Δ) – Code E
With the help of bridges, this motor is interchangeable for star (Y) or delta (Δ) operation. It is suitable for two voltages, eg, 230V in delta,
400V in star connection. If the supply voltage and the nominal voltage of the motor in Δ-connection are identical, the star connection
motor can also be used for starting (remove the bridges!).
Part winding Motors (YY/Y) – Code A
PWS 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 the motor is only suitable for one voltage.
The rst part winding, i.e., 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, i.e., the 1/3 winding on terminals 7-8-9, must be brought on line.

16 17
Wiring Diagrams
The position of the jumpers in the terminal box and the recommended wiring diagrams are shown in Figures 9 and 10.
Wiring Diagram for Part Winding Motors (AW---)
Part winding motors can be connected direct-on-line or part-winding start.
Part-winding motor:
Y - Y
Code A
Direct-on-line start
Y - Y
Part-winding start
First start step 1-2-3
Y - Y
L1 L2 L3
1(U) 2(V) 3(W)
7(Z) 8(X) 9(Y)
L1 L2 L3
L3L2L1
1(U) 2(V) 3(W)
7(Z) 8(X) 9(Y)
Figure 9
A4 ........ Sensor module K1 ............ Contactor M1
A5 ........ Terminal box compressor K4 ............ Contactor M1 for second part winding
CCH ...... Crankcase heater M2 ........... Fan motor/condenser
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 M2 Y22 .... Solenoid valve capacity control 2
21 2928272625242322 30
in A5
M21 F10 Y21Y22
N/BU
L/BN
-/BK
WH WH
K1 K4
L1 L2 L3
F6 F7 F8
MODULE COMM
R2
CCH
POWER
24 VAC
INPUT
A4
A5
PE
1(U) 2(V) 3(W)
7(Z) 8(X) 9(Y)
S1 S2
BLACK
WHITE
WHITE
CURRENT
SENSOR
COMPRESSOR
WIRING
HARNESS

17
Wiring diagram for Star / Delta motors (EW---)
Star / Delta motors can be connected direct-on-line or Star / Delta start.
Star / Delta
motor
Y - Δ
Code E
Direct-on-line start
Δ
Direct-on-line start
Y
Star / Delta start
Y - Δ
L1 L2 L3
1(U) 2(V) 3(W)
7(Z) 8(X) 9(Y)
L1 L2 L3
1(U) 2(V) 3(W)
7(Z) 8(X) 9(Y)
Figure 10
L1 L2 L3
L3L2L1
1(U) 2(V) 3(W)
7(Z) 8(X) 9(Y)
A4 ........ Sensor module K2 ............ Y - Contactor M1
A5 ........ Terminal box compressor K3 ............ Contactor M1
CCH ...... Crankcase heater M2 ........... Fan motor/condenser
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 Y22 .......... Solenoid valve capacity control 2
K1 ........ Contactor M1
21 2928272625242322 30
in A5
A-M21 F10 Y21 Y22
N/BU
L/BN
-/BK
WH WH
R2
CCH
POWER
24 VAC
INPUT
A4
MODULE COMM
K1
L1 L2 L3
F6 F7 F8
A5
PE
1(U) 2(V) 3(W)
7(Z) 8(X) 9(Y)
S1 S2
CURRENT
SENSOR
K3 K2
COMPRESSOR
WIRING
HARNESS
K2 U.K3 FOR Y/ START ONLY
L1
BLACK
WHITE
WHITE

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Figure 11: CoreSense™Diagnostics Module
Protection Devices
Independently from the internal motor protection, fuses must be installed before the compressor. The selection of fuses has to be carried
out according to VDE 0635, DIN 57635, IEC 269-1or EN 60-269-1.
CoreSense™ Diagnostics
CoreSense™ Diagnostics for all 4M* and 6M* Stream semi-hermetic compressors combines oil and motor protection into one module,
replacing OPS1/2 and the electronic module INT69TM. In addition, it provides advanced protection such as high discharge temperature,
locked rotor, single/missing phase, voltage imbalance and low voltage protection. The module is capable of communication via
Modbus® protocol. An external overload protection is not necessary.
Discharge
Temp Sensor Sensor Module Current Sensor
CoreSense™
Control Module
Oil Pressure Sensor Motor Temp Sensor (PTC)

19
For the electrical connection of the CoreSense™ Diagnostics module, please refer to wiring diagram below:
Figure 12: CoreSense™Wiring Diagram
NOTE: For more information, please refer to Technical Information D7.8.4 “CoreSense™ Diagnostics for Stream refrigeration
compressors”.
Crankcase Heaters
• A crankcase heater is used to prevent refrigerant migrating into the body during standstill periods. Heaters for 4M* and 6M*
compressors are screwed into a sleeve (see Figure 13).
• The crankcase heater is available in 230V.
• The operation of crankcase heater is controlled by the CoreSense™ Diagnostics module.
Figure 13: 100 Watt crankcase heater element
IMPORTANT
Oil dilution! Bearing malfunction! Turn the crankcase heater on 12 hours before starting the compressor.
2
M
L
A
C
CoreSense Terminal Strip
HP LP T Stat
Contactor
Coil
Alarm
Indicator
120v
240v
NL

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Start-up Leak Checking, Evacuation, and Charging
Leak Test
The suction shut-off valve and discharge shut-off valve on the compressor must remain closed during pressure testing to prevent air
and moisture from entering the compressor. The test pressure (dried nitrogen) must not exceed 20.5 bar, provided no other system
component’s pressure is lower. In this case, the lower pressure is the test pressure.
System Evacuation
Before the installation is put into commission, remove the holding charge then evacuate with a vacuum pump. Proper evacuation
reduces residual moisture to 50 ppm. The installation of adequately sized access valves at the furthest point from the compressor in the
suction and liquid lines is advisable. To achieve undisturbed operation, the compressor valves are closed and the system is evacuated
down to 0.3 mbar / 0.225 Torr. Pressure must be measured using a vacuum pressure (Torr) gauge on the access valves and not on the
vacuum pump. This serves to avoid incorrect measurements resulting from the pressure gradient along the connecting lines to the
pump. Then, the compressor must be evacuated.
Due to the factory holding charge of dry air, the compressor is under pressure (about 1 to 2.5 bar). This is to indicate the compressor
does not leak.
When plugs are removed from the compressor in order to connect a pressure gauge or to ll in oil, the plug may pop out under pressure
and oil can spurt out.
Preliminary Checks - Pre-starting
Discuss details of the installation with the installer. If possible, obtain drawings, wiring diagrams, etc. It is ideal to use a check-list but
always check the following:
• Visual check of the electrics, wiring, fuses etc.
• Visual check of the plant for leaks, loose ttings such as TVX bulbs, etc.
• Compressor oil level
• Calibration of HP and LP switches and any pressure actuated valves
• Check setting and operation of all safety features and protection devices
• All valves in the correct running position
• Pressure and compound gauges tted
• Correctly charged with refrigerant
• Compressor electrical isolator location and position
Charging Procedure
The system should be liquid-charged through the liquid-receiver shut-off valve or through a valve in the liquid line. The use of a lter drier
in the charging line is highly recommended. The majority of the charge should be placed in the high side of the system to prevent bearing
washout during rst-time start on the assembly line.
WARNING
Diesel effect! Compressor destruction! The mixture of air and oil at high temperature can lead to an explosion. Avoid operating
with air.
CAUTION
Low suction pressure operation! Compressor Damage! Do not operate with a restricted suction. Do not operate with the
low-pressure cut-out bridged.