Emerson COPELAND Stream Z9-4MA-22X User manual

ZX Condensing Unit
User Manual
Stream Condensing Unit
User Manual

Table of Contents
Introduction, Scope, Disclaimer 2
Safety Information 3
Nomenclature 5
Features &Benefits 5
CDU Layout 6
Bill of Materials 6
NextGen CoreSense 7
Electrical Connections 15
CDU Performance/Technical Data 19
21
Installation &Start-up
Commissioning Report 28
Page

Introduction
Emerson Stream Condensing Unit comes with state-of-the-art Stream semi-hermetic
compressors equipped with Discus valve technology and New Generation CoreSense
module.
This document is designed to help the contractor and customer for the installation,
commissioning & operation of Emerson’s Stream Condensing Unit.
Scope of supply – Check page number 9 of this manual for detailed scope of supply.
Disclaimer
Thank you for purchasing the Emerson™ Stream Condensing Unit. We hope that this
product meets your intended refrigeration requirement. Please read through this opera-
tion manual to familiarize yourself with the installation, commissioning and operation of
this product. Please do read the following information in this page before proceeding
with the rest of the manual.
The Emerson™ Stream semi-hermetic refrigeration condensing units should only be
installed by suitably qualified and experienced refrigeration technicians. No responsibilty
can be accepted for damage caused by inexperienced or inadequately trained site techni-
cians or improper system design. All instructions and procedures described in this
manual are based on good refrigeration trade practices as applicable to this particular
product. The installation contractor may prefer to use variations to these recommenda-
tions. However, the methods described in this manual represent the minimum require-
ments to avoid any subsequent warranty claims for this equipment and its components.
These instructions do not cover the fundamentals of good electrical or refrigeration
practice and are therefore intended for use only by qualified and/or experienced person-
nel or technicians.
For any additional query, please consult your local sales office, quoting unit model and
serial number as shown on the nameplate. In case of ambiguity, the wiring diagram
supplied with each unit takes precedence over the diagram in this manual.
2

1. Safety Information
1.1 Installation and commissioning work on CDU shall be carried out only by qualified,
refrigeration personnel who have been trained and instructed.
1.2 Stream condensing unit is manufactured according to the latest safety standards.
Emphasis has been placed on the user’s safety. For relevant standards please refer to the
manufacturer’s declaration, available on request. You are strongly advised to follow
these safety instructions.
1.3 Icon explanation
1.4 Safety Statements
a. Only qualified and authorized refrigeration personnel are permitted to install,
commission and maintain this equipment.
b. Electrical connections must be made by qualified electrical personnel.
c. All valid standards for connecting electrical and refrigeration equipment must be
observed.
d. 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
WARNING
This icon indicates instructio
ns 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.
3

1.5 General Instructions
1.6 Safety Refrigerants/Lubricant
a. Please use correct refrigerant as designed to work in safe operating envelope.
b. Compressor is supplied with an initial oil charge. The standard oil charge for use
with HFC refrigerant is polyol ester (POE) lubricant Emkarate RL 32 3MAF.
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.
CAUTION
Compressors contain oil & refrigerant under pressure. Release pressure
from both high & low side of compressor before servicing.
CAUTION
Tube brazing & compressor operation can produce hot surfaces. To avoid
burns, allow surfaces to cool.
4

4 M A 1 - 2 2 X - E W K - N
2. Nomenclature
3. Features and Benefits
X - POE Oil
Design
Revision
Motor Size
22 - 22 HP
NextGen
CoreSense
No. of Cylinders EW* Star/Delta
AW* Part Winding
Bore
Denomination
Displacement
M - StreaM
Features Benefits
Stream semi -hermetic
compressor with CoreSense™
Diagnostics
Stream’s unique Discus valve technology makes it more efficient
than other equivalent compressor and therefore helps reduce the
carbon footprint and running cost of any installation.
CoreSense Module offers advanced protection and diagnostics
benefits for excellent system reliability, reduced service costs and
increased equipment uptime.
Stream range provides best in class performance for today’s
commonly used HFCs and future low GWP refrigerants. This results
in significantly lower cost of operation and reduced environmental
impact compared to competing products.
Condenser Generously sized for high ambient operation
Accessories
Liquid Receiver
Alco PS2 HP/LP Cut-out for safety
Hermetic Moisture Indicator (optional)
Filter Drier (optional)
Oil Separator (optional)
Accumulator (optional)
5

4. Condensing Unit Layout
5. Bill of Materials
Item Description
1Service/Shut-off Valve
2Filter Drier (Optional)
3Liquid Receiver
4HP/LP Cut-out
5Base -frame
6Stream Compressor
7CoreSense Diagnostic Module
8Fans
9Condenser
10 Junction Box
Nomenclature Option
F00 Standard
F01
Filter drier and hermetic moisture indicator fitted on the liquid
line
F02
Filter drier, hermetic moisture indicator and oil separator fitted on
the liquid line
F03
Filter drier, hermetic moisture indicator and oil separator fitted on
the liquid line including suction accumulator
1
23
4
5
1Hermetic moisture
indicator
Most sensitive indicator
with wide angle viewing
2Filter drier
High moisture and
acid removal capacity
3Suction
accumulator
Protects the
compressor
condition
4Stream
compressor
Semi-hermetic piston technology, CoreSense™
handling capability, capacity modulation and
lower sound compared to other compressors.
5Oil separator
Guards
compressor
from short-
term oil return
condition
6
8
10
4
3
7
1
2
5
9
6

a. Stream Compressors
- All Stream compressors are suction gas cooled. (motor is cooled by refrigerant gas
that is led over the motor).
- All compressors are fitted with discus valve plates.
- Each cylinder head has 2 plugged 1/8" - 27 NPTF tapped holes for connecting high
pressure switches.
- Copeland Stream compressors is fitted with CoreSense module as a standard.
b. Liquid Receiver
- Emerson CDUs are equipped with liquid receivers
- Rotalock service valve is provided at the receiver outlet
- Sight glass mounted on liquid receivers to help to not exceed maximum liquid level
c. HP/LP Cut-out
- Dual HP/LP, auto reset, safety switch
- Pressure switches used for control/protective functions
- Control functions – compressor cycling, pump down
- Protective functions – pressure limiting and cut-out against excessive pressures,
against loss of charge or freeze protection
- Display scales are printed in relative pressure units – “bar” and “psi”
d. Z9/Z12 Condenser
- Condenser is constructed with copper tubes and aluminum fins, steel-sheet housing
with a fan opening.
- Number of fans: 4
e. Fan
- Z9 CDU is equipped with single phase fans and dual rated for 50/60 Hz operation.
- Fan is made of an external rotor motor with fan blades permanently fixed to rotor.
- Fan guard has 4 mounting feet.
- Fan is positioned in order to blow air from condenser to the compressor.
7

f. Mounting Parts
To minimize vibration and start/stop impulses flexible mounting should be used. Each
Stream compressor is delivered with four colored mounting springs that are installed
between the feet and the condensing unit base plate. These are clamped to avoid
transport damage. It is necessary to remove the transport clamps and to adjust the
mounting spring height before starting up the condensing unit. The adjustment is
described in the picture below.
Due to differences in weight (cylinder / motor side) different springs have been used on
both sides. Springs have different colours for easier identification: violet on motor side
and orange on cylinder side.
g. Packaging
Condensing units are individually packed on a baseboard and a carton is fitted over.
Accessories are mounted. In the unlikely event that the packaging box is damaged, the
condenser might be damaged.
Condensing units can be stacked two high. It is recommended to keep the
unit packaged until final installation. The condensing unit, when boxed, can
be handled by a forklift or pallet truck. The condensing unit without the
packaging must be handled by a forklift.
6. NextGen CoreSense
CoreSense™ is an ingredient brand name for compressor electronics associated with
Copeland™ branded compressors. The CoreSense technology uses the compressor as a
sensor to unlock information from within the compressor, providing value-added
features such as advanced motor protection, diagnostics, power consumption measure-
ment and communication.
Operational position Transport position
Transport clamp
8

6.2 Oil pressure protection
The Next Gen CoreSense module receives an input from the oil
pressure differential sensor (OPS3) located in the oil pump. The
module will issue a warning when the oil pressure differential
falls below 0.95 bar for 4 seconds. Once the oil pressure differen-
tial falls below 0.95 bar for more than 2 minutes, the module will
trip the compressor and a "low oil pressure lockout" will be
reported. Before using the reset button, troubleshooting needs
to be done to understand the failure. The compressor will switch
ON once the CoreSense is manually reset.
6.1 Warnings, trips and lockouts
Next Gen CoreSense module provides 3 different protection levels. Each of them has its
own LED colour.
- Warning alarms: Compressor will continue to run.
- Trip alarms: Compressor turns off for defined time with automatic reset. If the
compressor was stopped due to a fault condition, the compressor will restart
when the fault condition is cleared and the defined off time has elapsed.
- Lockout alarms: Compressor turns off, manual reset is necessary. If the compressor
was stopped due to a fault condition, the compressor will restart when the fault
condition is cleared and a manual reset using the reset button is pressed. If a
Modbus extension module is mounted, the reset can be done via Modbus.
Basic features
Motor Overheat protection
High discharge temperature protection
Insufficient oil pressure protection
Oil level protection (OM3) –Not used
Current protection
Phase failure protection
Power consumption measurement
Under/over voltage protection
Crankcase heater control
Part winding protection
Switching frequency overstepping protection
Connection with computer
LEDs on terminal box cover
Reset button for manual reset
9

6.4 High discharge temperature protection
Discharge temperature protection is provided using a PT1000 sensor in the compressor
cylinder head.
The sensor is pre-installed at the factory and connected to the Next Gen CoreSense
module. The module will protect the compressor from high discharge temperature
conditions. If the temperature sensor detects a discharge temperature higher than 154
°C, the module will shut off the compressor until the temperature cools down to an
acceptable level (20 K below setpoint).
The configurable range of trip settings is 108 °C to 154 °C and the reset value is 83 °C to
134 °C.
• Trip value ≥ 154 °C for 0.5 sec
• Trip alarm: automatic reset after 2 minutes; discharge temp < 130 °C
PT1000 sensor technical data:
• Measuring range: -40°C to 155°C, 170°C for
30 minutes max
• Tightening torque: 15 Nm
• Protection class: IP65
6.3 Motor overheat protection
By using Positive Temperature Coefficient (PTC) thermistors on 4M* and 6M* Stream
compressor models, Next Gen CoreSense provides motor overheating protection.
Two chains of three thermistors each connected in series are embedded in the motor
windings.
- Static overheat protection
The Next Gen CoreSense module will trip the compressor if the motor windings are
getting too hot.
• Standard condition:
Total resistance of the thermistor chains @ 25 °C ≤ 1.8 kΩ
• Alarm condition:
Trip condition: PTC resistance > 4.5 kΩ;
Reset condition: PTC resistance < 2.75 kΩ; 5 min time delay.
• Trip due to sensor failure:
Short circuit: PTC resistance < 20 Ω; Open circuit: PTC resistance > 20kΩ. 5
- Dynamic overheat protection
If the motor winding temperature increases in a short period (>240Ω/400ms), the
module will trip the compressor. The compressor will restart after 5 minutes.
10

6.5 Current Protection
A current sensor is located in the terminal box.
One power supply wire (2 from the same phase in case of part-winding) is
going through this sensor. The direction of the leads has to be respected
6.6 Locked rotor protection
If, 2.5 seconds after compressor start, the current is 150% of the MOC value, an alarm is
triggered and the compressor trips. The alarm is reset after 5 minutes.
After 10 trips a lockout is activated and the Next Gen CoreSense module must be reset
manually using the reset button (no automatic reset).
6.7 MOC protection
The MOC value of a compressor is stored into the Next Gen CoreSense module. The
compressor trips if the measured current is higher than the MOC for more than 2
seconds.
This function starts 4.5 seconds after compressor start and resets automatically 5 min-
utes after tripping.
6.8 Switching frequency overstepping protection
The number of compressors starts is monitored over a defined period of time. If the
compressor reaches the maximum number of starts in a time shorter than the defined
one, an alarm is triggered.
Default setting is 10 starts in 1 hour and trip generation.
The reset time is calculated as the difference between the defined time period (1 hour)
and the actual time it took for the defined maximum number of starts (10) to occur.
Example:
• 10 starts occurred in 35 minutes
• Alarm is triggered at 35 minutes
• Automatic reset will be done after 25 minutes
It is possible to choose between a warning or compressor trip.
• MOC detection at first start
Most compressors have two sets of nominal voltages and frequencies:
1) 50 Hz or 60 Hz value for part-winding motors (AW…)
2) Different voltages for ∆/Y start motors (EW...)
11

At first start and at every power reset, the Next Gen CoreSense module automatically
detects the compressor power supply (voltage and frequency) and will automatically
select the corresponding MOC and undervoltage/overvoltage protection setpoints.
If the measured voltage and/or frequency is different from the one defined on the
nameplate, the module will generate a warning.
For example, if an AWM/D (400 V / 50 Hz or 460 V / 60 Hz) motor is connected to a 230
V power line, the green LED will flash.
6.9 Phase / voltage monitoring
There are 6 voltage sensor circuits to measure the 3 phases. Thanks to the 6 sensors
the part-winding motors can also be protected. The status of each phase in direct
on-line and part-winding is monitored for undervoltage, overvoltage and phase asym-
metry.
Missing phase protection / Phase failure protection
A comparison is made between the voltage of each phase and their average. If any of
the 3 power phases is missing after compressor start, a single-phasing condition exists.
Any voltage imbalance above 60 % is a condition for phase-loss trip.
Alarm conditions: occurs in case of missing phase conditions.
Trip time: 5 minutes with automatic reset.
A missing phase can be detected during start-up and when the compressor is running.
Undervoltage Protection
Occurs when the compressor voltage is lower than the nominal supply voltage.
Low voltage warning condition: voltage < 85 % of the nominal line voltage for 2
seconds.
Low voltage trip conditions: voltage < 75 % of the nominal line voltage 2 seconds.
Trip time: 2 minutes.
Overvoltage Protection
Occurs when the compressor voltage is higher than the nominal supply voltage.
High voltage warning condition: voltage > 115 % of the nominal line voltage for 2
seconds. High voltage trip conditions: voltage > 125 % of the nominal line voltage for 2
seconds. Trip time: 2 minutes.
12

Voltage Imbalance Protection
The purpose of this feature is to protect the compressor against a voltage imbalance
that could lead to motor overheating.
A configurable setting (default = 5 %) for voltage imbalance is used to determine the
operating limit of the compressor. The voltage imbalance setting is configurable in
the range of 2 to 8 % using the Next Gen CoreSense module app.
Alarm conditions:
• Warning: when the voltage imbalance > 3 % (configurable).
• Trip: when the voltage imbalance > 5 % (configurable).
• Reset: automatic reset after 5 min; voltage imbalance < 5 %.
6.10 Part-winding Protection
The two winding supply cables should go through the current sensor in the same direc-
tion. At first start or at power reset of the Next Gen CoreSense module, the voltage is
measured on both windings.
If the voltages are identical:
a. Compressor is connected in full winding, the protection is disabled.
b. If the voltages are different, the voltages are compared again after 1 second.
c. If the voltage on the second winding is the same as on the first winding, the comp
ressor is connected in part-winding - the protection is enabled.
d. If the voltage on the second winding is not the same as on the first winding, the
second winding is improperly connected and the compressor trips.
The user has the possibility to select between a warning or trip condition. After a trip, the
compressor will restart after 2 minutes. Default setting is trip.
6.11 LEDs on the terminal box cover
Status LEDs in 3 colours (green, orange and red) are visible on the top of the T-box
13

6.12 Compressor status codes
a. Steady green: An indication of normal operation. There are no faults or issues
with the compressor.
b. Flashing green: An indication that there is a warning condition. The compres
sor keeps running.
c. Steady orange: An indication that the compressor is in emergency mode.
d. Flashing orange: An indication that the compressor has tripped and will auto
matically restart after a defined time (auto reset).
e. Steady red: An indication that CoreSense is in parametrization mode.
f. Flashing red: An indication that the compressor is locked out. Manual reset is
needed for restart.
6.13 Failure alarms displayed by LEDs
Alarms are displayed via colored LEDs and flashing sequences. Every flash sequence is
interrupted by a 2-second pause.
Standard Settings
Chap.
Flash
code
Protection feature
Standard
delivery
Compressor keeps
running
Warning
Automatic reset
Trip
Manual reset
required
Lockout
Automatic reset after trip
5.1.1
1
Low oil pressure
(oil pump)
X< 0.95 bar
after 4 sec
< 0.95 bar
after 2 min
5.1.2 Oil level protection
(OM)
XSelection
possible Oil level below
25 %
Correct oil level
5.2.1
2
Static motor overheat
protection X
PTC resistance
> 4.5 kΩ
5 minutes and PTC resistance <
2.75 kΩ
5.2.2 Dynamic motor
overheat protection X
> 240 Ω/400 ms 5 minutes
5.3 3High discharge
temperature (DLT) X
154 °C
2 minutes and
< 130 °C
5.4.1
4
Locked rotor
protection X
150 %of MOC 10 X Trip 5 minutes
5.4.2 Maximum Operating
Current (MOC) X
MOC 5 minutes
5.4.3 Switching frequency
protection
XSelection
possible
10 starts/hour
When number of sta
rts/set time
period is lower than set value
5.4.4 MOC detection at first start XVoltage different
from nameplate
5.5.1
5
Missing phase
protection X
60 %of voltage
imbalance
5 minutes
5.5.2 Undervoltage
protection X< 85 %of nominal
voltage for 2 sec
< 75 %of nominal
voltage for 2 sec
2 minutes
5.5.3 Overvoltage
protection
X
> 115
%
of
nominal voltage for 2
sec
> 125
%
of
nominal voltage for 2
sec
2 minutes
5.5.4 Voltage imbalance
protection XImbalance > 3 %Imbalance > 5 %
5 minutes and min 2 %below
setpoint
5.5.5 Welded contactor
protection
XNo demand
signal/current on one
phase
Selection
possible
10 X Trip
5.5.6 Part-winding
protection XSelection
possible
Voltage difference
after 1 sec
Flashing explanation X= Disabled in standard delivery
14

6.14 Alarm history
The 20 most recent alarms are stored in the module memory and can be downloaded
with the Next Gen CoreSense module app.
6.15 Reset button
Pressing the reset button is needed after a compressor lockout. In addition, it can be
used for an immediate trip reset (no compressor waiting time to restart).
If the tripping condition is cleared, all tripping counters are set to zero, the compressor
can restart.
If the tripping condition is not cleared, the reset signal is ignored.
6.16 CoreSense location
The Next Gen CoreSense module is located in the compressor terminal box. It is prewired
to the oil pressure sensor (for compressors with oil pump), the motor thermistor chain
(PTC), the discharge temperature sensor and the current sensor.
7. Electrical Connections
Motor Connections
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
15

Compressor CoreSense/Control Wiring
Star / Delta motors can be connected direct-on-line or Star / Delta start
Star / Delta motor
Y - ∆
Code E
Direct-on-line start
∆
Direct-on-line start
Y
Star / Delta start
∆
16

The Next Gen CoreSense module is originally delivered with basic modules pre-connected.
*1-2 Power Supply, 19-20 Control circuit & 17-18 Welded contact alarm (optional)
Part Winding Motors (AW...) Star/Delta Motors (EW...)
17

Z9 CDU: Fan Wiring
Z12 CDU: Fan Wiring
18

8. CDU Performance/Technical Data
a. 50 Hz Medium Temperature
b. 50 Hz Low Temperature
*R404A, Evaporating -10°C, Ambient 46°C, Suction Gas Return 20°C, Subcooling 0K
*R404A, Evaporating -30°C, Ambient 46°C, Suction Superheat 10K, Subcooling 0K
CDU Model W9-4MF-13X W9-4ML-15X W9-4MM-20X Z9-4MT-22X Z9-4MU-25X Z9-6MM-30X Z12-6MU-40X
Comp Model 4MF-13X 4ML-15X 4MT-22X 4MU-25X 6MM-30X 6MU-40X
Capacity (kW) 7.62 9.48 10.30 13.20 14.05 16.60 21.60
Power Input (kW) 9.82 11.85 13.15 15.40 17.00 20.80 26.30
COP 0.78 0.80 0.78 0.86 0.83 0.80 0.82
Displacement (m³/hr) 61.70 71.40 78.00 87.50 99.50 120.50 153.00
Condenser Type/ Fan Qty W9/2 W9/2 W9/2 Z9/4 Z9/4 Z9/4 Z12/4
Air Flow (m³/sec) 3.33 3.33 3.33 5.41 5.41 5.41 7.50
Gross Weight (kG) 434.00 434.00 434.00 554.00 557.00 575.00 720.00
Net Weight (kG) 320.00 320.00 320.00 389.00 392.00 410.00 513.00
Dimension in mm (W*D*H) 1600*1107*873 1600*1107*873 1600*1107*875 1600*1107*1263 1600*1107*1263 1600*1130*1263 2001*1180*1406
Suction Dia (") 1.63 1.63 2.13 2.13 2.13 2.13 2.13
Liquid Line (") 0.88 0.88 0.88 0.88 0.88 0.88 0.88
Receiver Capacity (L) 18.90 18.90 18.90 18.90 18.90 18.90 47.90
Condenser Fan Current (A) 1.85 1.85 1.85 1.85 1.85 1.85 1.35
Compressor MOC (A) 30.80 35.40 39.00 44.50 51.90 59.70 75.80
Compressor LRA 105.00 156.00 175.00 175.00 199.00 255.00 306.00
CDU Model Z9-4MA-22X Z9-4MH-25X Z9-4MI-30X Z9-4MJ-33X Z12-4MK-35X Z12-6MI-40X
Comp Model 4MA-22X 4MH-25X 4MI-30X 4MJ-33X 4MK-35X 6MI-40X
Capacity (kW) 26.6 30.2 32.8 35.3 41.9 49
Power Input (kW) 16.65 19.55 21.9 23.8 27.6 33.6
COP 1.597597598 1.544757033 1.497716895 1.483193277 1.518115942 1.458333333
Displacement (m³/hr) 61.7 71.4 78 87.5 99.5 120.5
Condenser Type/ Fan Qty Z9/4 Z9/4 Z9/4 Z9/4 Z12/4 Z12/4
Air Flow (m³/sec) 5.41 5.41 5.41 5.41 7.5 7.5
Gross Weight (kG) 548 554 581 581 697 714
Net Weight (kG) 383 389 416 416 490 507
Dimension in mm (W*D*H) 1600*1107*873 1600*1107*1263 1600*1107*1263 1600*1107*1263 2001*1180*1406 2001*1180*1406
Suction Dia (") 1.625 2.125 2.125 2.125 2.125 2.125
Liquid Line (") 0.875 0.875 0.875 0.875 0.875 0.875
Receiver Capacity (L) 18.9 18.9 18.9 18.9 47.9 47.9
Condenser Fan Current (A) 1.85 1.85 1.85 1.85 1.35 1.35
Compressor MOC (A) 36.3 41.6 46.6 52.9 61.1 71.4
Compressor LRA 175 199 230 230 272 321
19