COMPRESSORINSTALLATIONINSTRUCTIONSFOR EMBRACO EUROPEAN
ON-OFF COMPRESSORS

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SCOPE OF THE COMPRESSORS INSTALLATION INSTRUCTIONSThis Installation Instructions applies to the Embraco on-off compressors produced in Europe (the country oforigin is indicated on the compressor label).
It is addressed to professional users, refrigeration system manufacturers/installers and maintenancetechnicians and intends to provide instructions/recommendations on the proper use of Embraco compressors
regarding reliability, performance and safety aspects.
The information of this Installation Instructions is limited to the Embraco european on-off compressors and totheir installation/operation/service. They are not to be considered comprehensive or as a set of information
for training for technicians that need to be qualified by appropriated training nor to replace the instruction
manual of the final equipments provided by the manufacturers.
All the operation on systems, their production, installation use, repairing and disposal must be carried out
according to all the applicable International and National regulations and standards.

DISCLAIMER
All product, product specifications and data are subject to change without notice; thus customer should always
verify its latest updates on Embraco website ( www.embraco.com), catalogues before relying on them.
The information provided herein is correct to the best of Embraco’s knowledge of typical requirements thatare often requested to Embraco’s products. It is the customer’s responsibility, relying solely on its own testingand engineering work, to validate that a particular product with the properties described in Embraco’s productspecification is suitable for use in a particular application. Embraco makes no representation concerning thesuitability of its products for incorporation into or use with customer’s applications.
Parameters provided in datasheets and / or specifications may vary in different applications and performanceover time. Therefore Embraco’s statements related to all operating parameters, including typical parameters,
cannot be intended to replace the customer’s validation for each application by the customer’s technical experts.
Product specifications do not expand or otherwise modify Embraco’s terms and conditions of purchase, including
but not limited to the warranty expressed therein.
Embraco rejects any liability for damages and injures caused by its products and/or the applications they areembedded into being installed or repaired by untrained personnel and/or in discordance with these safety
instructions.

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GENERAL INDEX

1 			

SAFETY..................................................................................................... p.		 111.1 			

Safety notice............................................................................................ p.		 111.2 			

Safety advice............................................................................................ p.		 112 			COMPRESSOR APPLICABLE STANDARDS AND DIRECTIVES........ p.		 122.1 			PED Category II........................................................................................ p.		 122.1.1 			Compressor label for PED II.................................................................... p.		 12Figure 2.1.1

Compressor label for PED II.................................................................................... p.		 132.1.2 			Specification............................................................................................. p.		 133			EMBRACO COMPRESSOR RELEVANT DOCUMENTS....................... p.		 134 			COMPRESSOR RANGE........................................................................... p.		 134.1 			

Application description........................................................................... p.		 13Table 4.1

4.2 			Table 4.2

4.3 			Table 4.3

Applications.............................................................................................................. p.		 14Starting torque classification ................................................................ p.		 14Electrical motor starting torque classification..................................................... p.		 14Electrical motor types............................................................................. p.		 15Electrical motor types.............................................................................................. p.		 154.4 			

Electrical motor voltages and frequencies........................................... p.		 16Table 4.4			Compressor voltages & frequencies, operating voltage range
and minimum starting voltage .............................................................................. p.		 164.5			

Electrical components types.................................................................. p.		 17Table 4.5

4.6			
Table 4.6

Electrical components types................................................................................... p.		 17Compressor cooling types...................................................................... p.		 18Cooling types............................................................................................................ p.		 18

5 			
			

COMPRESSOR NAMEPLATES, MODEL, BILL OF MATERIALCODE,TEST CONDITIONS................................................................................. p.		 195.1 			

Compressor label .................................................................................... p.		 19Figure 5.1

5.2			

5.3

Compressor label..................................................................................................... p.		 19Compressor model code ........................................................................ p.		 20Figure 5.2.1

EM / NE / NT / NJ model code............................................................................... p.		 20Figure 5.2.2

EM model code......................................................................................................... p.		 20Figure 5.3

Compressor Bill of material code.......................................................... p.		 215.4			
Figure 5.4

5.5			
Table 5.5

Manufacturing date code........................................................................ p.		 21Date code.................................................................................................................. p.		 21Compressor test condition...................................................................... p.		 22Test condition........................................................................................................... p.		 226 			WIRING DIAGRAMS................................................................................ p.		 226.1 			

Electrical connections............................................................................. p.		 22

4Figure 6.1.aWiring diagrams key................................................................................................ p.		 23Figure 6.1.bWiring diagrams....................................................................................................... p.		 24

6.1.1 			Figure 6.1.1

6.2 			Figure 6.2.1

Notes on electrical components assembly .......................................... p.		 31Electrical box mounting position............................................................................ p.		 31Compressor pin position......................................................................... p.		 32EM / NE / NT / NJ models pin position................................................................. p.		 326.3 			

Screw clamping torque of supplied components................................. p.		 326.4 			

Screw final tightening............................................................................. p.		 326.5 			

Quick connection (faston)....................................................................... p.		 327 			COMPRESSOR SUPPLY CONDITIONS................................................. p.		 337.1			

Compressor performance....................................................................... p.		 337.2 			

Compressor external views..................................................................... p.		 337.3 			

Electrical insulation................................................................................. p.		 337.4 			

Compressor approvals by Safety Institutes.......................................... p.		 337.5 			“IP” degree of protection........................................................................ p.		 34Table 7.5

IP Degree................................................................................................................... p.		 34Figure 7.5.aNT with vertical terminal fence ............................................................................. p.		 34Figure 7.5.b

NT with horizontal terminal fence.......................................................................... p.		 34Figure 7.5.c

CSR box – IP34......................................................................................................... p.		 357.6 			

Compressor shell hydrostatic strength................................................. p.		 357.7 			

Dehydration ............................................................................................. p.		 35Table 7.7

Maximum level of residual humidity (H2O mg).................................................... p.		 357.8 			

Painting .................................................................................................... p.		 357.9 			

Compressor pressurization .................................................................... p.		 367.10 			Oil charge.................................................................................................. p.		 36Table 7.10

7.11 			Table 7.11

7.12 			Table 7.12

Lubricant oils approved for compressors.............................................................. p.		 36Minimum quantity of lubricant inside the compressor ...................... p.		 37Minimum quantity of lubricant............................................................................... p.		 37Special versions....................................................................................... p.		 37Special external version examples......................................................................... p.		 378 			COMPRESSOR PACKAGING.................................................................. p.		 388.1 			

Multiple packaging.................................................................................. p.		 38Table 8.1.1

Pallet packages composition.................................................................................. p.		 38Figures 8.1.1. a – f Compressor package type pictures............................................................... p.		 38Table 8.1.2

8.2 			

Characteristics of multiple wooden packaging ................................................... p.		 39Single packaging...................................................................................... p.		 39Figure 8.2.1

Carton box for single package................................................................................ p.		 39Figure 8.2.2

Single compressor palet package........................................................................... p.		 39Table 8.2

Characteristics of complete single package......................................................... p.		 408.3 			

Package for electrical components and accessories........................... p.		 408.4 			

Compressor identification marks........................................................... p.		 41Figure 8.4.1

Compressor identification label for multiple packaging...................................... p.		 41Figure 8.4.2

Compressor identification label for single packaging.......................................... p.		 41

59 			HANDLING, TRANSPORTING AND STORING.................................... p.		 429.1 			

Handling.................................................................................................... p.		 429.2 			

Transportation.......................................................................................... p.		 429.2.1 			Shipment by container............................................................................ p.		 42Table 9.2.1

9.2.2 			Table 9.2.2

9.3 			Table 9.3

Load characteristics for 20ft container................................................................. p.		 43Shipments by truck.................................................................................. p.		 44Characteristics of load by truck.............................................................................. p.		 44Acceptable compressor positions during transportation ................... p.		 44Acceptable compressor position during transportation of finished products .. p.		 459.4 			

Acceleration during transport and handling......................................... p.		 469.5 			

Compressor storage................................................................................ p.		 46Table 9.5.1

Compressor multiple package storage - maximum height................................. p.		 46Table 9.5.2

Compressor single package storage - maximum height..................................... p.		 479.6 			

Storage conditions................................................................................... p.		 4710 			INFORMATION ABOUT CORRECT COMPRESSOR INSTALLATION.....p.		 4810.1 			Compressor selection.............................................................................. p.		 4810.1.1

Characteristics of the hermetic compressor......................................... p.		 4810.1.2

Selecting the proper compressor........................................................... p.		 4810.1.3

Recommended guideline for the compressor selection...................... p.		 4910.1.3.1

Minimum / maximum evaporating temperature................................. p.		 4910.1.3.2

Appropriate cooling capacity.................................................................. p.		 4910.1.3.3

Refrigerant type....................................................................................... p.		 4910.1.3.4

Electric motor starting torque................................................................ p.		 4910.1.3.5

Supply voltages and frequencies........................................................... p.		 5010.1.3.6

Ambient temperature.............................................................................. p.		 5010.1.3.7

Compressor cooling type........................................................................ p.		 51		Table 10.1.3.7 Fan cooler characteristics....................................................................................... p.		 51Figure 10.1.3.7 Fan motor position.................................................................................................. p.		 5210.1.4

Noise and vibrations................................................................................ p.		 5210.1.5

Maximum continuous current................................................................. p.		 5310.1.6

Overload protector................................................................................... p.		 5310.1.7

Electrical supply line and cabinet supply cable................................... p.		 5410.2 			Compressor unpacking............................................................................ p.		 5410.3 			System components................................................................................ p.		 5510.3.1

Humidity and contaminants................................................................... p.		 55Table 10.3.1a Soluble, insoluble and solid residuals limits......................................................... p.		 55Table 10.3.1b Humidity limits......................................................................................................... p.		 5510.3.2

Piping basic principles............................................................................. p.		 5610.3.2aEvaporator and condenser...................................................................... p.		 5610.3.2b

Liquid lines - valid also for close coupled remote system.................. p.		 5610.3.2c

Suction lines - valid also for close coupled remote system................ p.		 57

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10.3.3

Expansion devices.................................................................................... p.		 5810.3.3aCapillary ................................................................................................... p.		 5810.3.3b

Thermostatic expansion valve (TXV)...................................................... p.		 5810.3.4Use of liquid separator and crankcase heater...................................... p.		 5810.3.5

Leak control.............................................................................................. p.		 5910.3.6

High pressure control.............................................................................. p.		 5910.3.7

Compressors with internal pressure relief valve (IPR)......................... p.		 5910.3.8Embraco compressors with oil equalization tube for Gemini (Twin).. p.		 60Figure 10.3.8.1 Gemini compressor with connection port.............................................................. p.		 61Figure 10.3.8.2 Compressor mounting and oil level indication..................................................... p.		 6210.4			

Liquid line filter dryer.............................................................................. p.		 63Table 10.4a

Suggested filter dryer molecular sieves: 3 or 4 Angstrom.................................. p.		 63Table 10.4b

Inconvenient caused by humidity in the system................................................... p.		 6410.5 			Brazing process........................................................................................ p.		 6410.6 			Refrigerant use guide.............................................................................. p.		 6510.6.1

Guide line for use of HFCs R134a, R404A and R407C........................ p.		 6510.6.1.1

HFCs R134a, R404A, R407C general information............................... p.		 65Table 10.6.1.1 R134a, R404A and R407C characteristics............................................................ p.		 6510.6.1.2

System components compatibility........................................................ p.		 6610.6.1.3

System evacuation ................................................................................. p.		 6610.6.1.4

Refrigerant charge .................................................................................. p.		 6710.6.1.5

Embraco compressor max refrigerant charge...................................... p.		 68Table 10.6.1.5 Max refrigerant charge admitted in the Embraco compressors......................... p.		 6810.6.1.6

Alternative refrigerants........................................................................... p.		 68Table 10.6.16 R452A, R449A, R448A, R513A and R450A characteristics................................ p.		 6810.6.1.6a

R404A....................................................................................................... p.		 6910.6.1.6b

R134a........................................................................................................ p.		 6910.6.2

Guide for the use of HCs refrigerants R600a and R290...................... p.		 6910.6.2.1

HCs R600a and R290 general information........................................... p.		 70Table 10.6.2.1 R600a and R290 characteristics............................................................................ p.		 7010.6.2.2

R600a and R290 purity........................................................................... p.		 7110.6.2.3

Embraco R600a and R290 identification and warning symbols........ p.		 71Figure 10.6.2.3 Warning symbol.................................................................................................... p.		 7110.6.2.4

Safety warnings........................................................................................ p.		 7110.6.2.5

System components compatibility........................................................ p.		 7210.6.2.6

Expansion devices.................................................................................... p.		 7210.6.2.7

Liquid and suction line tubes................................................................. p.		 7210.6.2.8

Evaporators and condensers.................................................................. p.		 7310.6.2.9

Water tray................................................................................................. p.		 7310.6.2.10

Filter dryer................................................................................................ p.		 7310.6.2.11

System components brazing.................................................................. p.		 7410.6.2.12

System evacuation.................................................................................. p.		 7410.6.2.13

Refrigerant charge................................................................................... p.		 74

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10.6.2.14

Maximum refrigerant charge.................................................................. p.		 7510.6.2.15

Leak control.............................................................................................. p.		 7510.7.

Capillary tubes size ................................................................................. p.		 7610.7.1

Suggested capillary for preliminary selection...................................... p.		 76Table 10.7.1a R600a LBP Applications.......................................................................................... p.		 76Table 10.7.1b R600a HBP applications ........................................................................................ p.		 77Table 10.7.1c R134a LBP applications.......................................................................................... p.		 77Table 10.7.1d R134a HBP Applications......................................................................................... p.		 78Table 10.7.1e R290 - R404A - R507A LBP applications.............................................................. p.		 78Table 10.7.1f R290 – R404A – R507A – R407C M/HBP application......................................... p.		 7910.8 		

Rubber grommets and sleeves............................................................... p.		 8010.8.1		

Rubber grommets assembly.................................................................. p.		 81Figure 10.8.1 Rubber grommets assembling scheme................................................................. p.		 8110.8.2
Table 10.8.2

Rubber grommets/sleeves dimension.................................................. p.		 81Rubber grommets/sleeves dimensions.................................................................. p.		 81Figure 10.8.2 Rubber grommets and sleeves............................................................................... p.		 8210.9 		

Rotolock valves........................................................................................ p.		 8310.9.1

Rotolock tightening torques................................................................... p.		 83Table 10.9.1

Recommended tightening torques......................................................................... p.		 83Figure 10.9.1 Rotolock valve types................................................................................................ p.		 8410.9.2

Valve system position............................................................................. p.		 84Figure 10.9.2 Valves position......................................................................................................... p.		 8410.10Electric supply.......................................................................................... p.		 8510.10.1

Supply voltage admitted limits.............................................................. p.		 8510.10.2

Preliminary selection of fuses................................................................ p.		 8511 			RUNNING DATA AND COMPRESSOR CHECKING PROCEDURES.. p.		 8611.1 			Minimum compressor temperature ...................................................... p.		 8611.2 			Maximum temperature of electric motor windings............................. p.		 8611.3 			Maximum discharge gas temperature................................................... p.		 8711.4 			Maximum discharge gas pressures and temperatures........................ p.		 88Table 11.4

Discharge gas maximum pressures/temperature................................................ p.		 8811.5 			Suction gas overheating......................................................................... p.		 8911.6 			Compressor operating fields................................................................... p.		 8911.6.1

Compressors admitted operating fields................................................ p.		 89Figure 11.6.1 Compressor approved operating fields.................................................................. p.		 9011.6.2Start conditions........................................................................................ p.		 91Table 11.6.2
			Temperature conditions corresponding to balanced
and unbalanced pressures....................................................................................... p.		 9111.6.2.1

Notes on starting pressures.................................................................... p.		 9211.6.3Use of transformer to raise the voltage................................................ p.		 9211.6.4Compressor cycling................................................................................. p.		 9311.6.5

Running time............................................................................................ p.		 9311.6.6

Hot gas defrost ....................................................................................... p.		 94

812			COMPRESSOR CONTROL PROCEDURES..................................... p.		 9412.1			

Troubleshooting and service chart ........................................................ p.		 95Table 12.1

Troubleshooting and service chart......................................................................... p.		 9613 			ELECTRIC CIRCUITS CONTROL................................................... p.		 9913.1.1		

Version RSIR - RSCR with PTC starting device..................................... p.		 9913.1.2

Version RSCR with TSD starting device................................................. p. 100

13.1.3

Version RSIR with terminal board and current relay starting device	��p.101

13.1.4

Version CSIR American version and current relay starting device.......p.102

13.1.5

Version CSIR Terminal board and current relay starting device...........p.103

13.1.6

Version CSR/CSIR box with external overload protector.......................p.104

13.1.7

Version CSR/CSIR box with internal overload protector.......................p.105

13.1.8

Version PSC with internal or external overload protector.....................p.106

13.1.9

Version 3-phase internal overload protector..........................................p.107

13.1.10

Version 3-phase internal + external overload protector.......................p.108

13.2			

Control procedures....................................................................................p.109

13.2.1		

Control of electric motor (stator) windings.............................................p.109

13.2.2		

Control of stator windings ohmic resistance..........................................p.109

13.2.3		

Control of start and run capacitors..........................................................p.109

14 			COMPRESSOR REMOVAL AND REPLACEMENT............................p.110

14.1 		

Compressor removal and replacement - HFCs models.........................p.110

14.1.1

Compressor removal procedure...............................................................p.110

14.1.2Compressor replacement procedure.......................................................p.112

14.2 		

Compressor removal and replacement - R600a and R290 models.....p.113

14.2.1Preventive actions to be adopted............................................................p.113

14.2.2

Failure diagnosis........................................................................................p.114

14.2.3Compressor removal ................................................................................p.114

Figure 14.2.3a HCs refrigerant venting........................................................................................... p. 115

14.2.4

System washing by OFDN procedure......................................................p.115

14.2.5

Installing a new compressor.....................................................................p.116

14.2.6

System vacuum, charging and sealing ...................................................p.116

14.2.7

Repaired cabinet verification....................................................................p.117

14.2.8Retrofitting.................................................................................................p.117

15

COMPRESSOR DISPOSAL....................................................................................... p.117

16

HOW TO RETURN SUPPLIED PRODUCTS TO EMBRACO EUROPE....................p.118

17

TESTS ON THE CUSTOMER APPLICATIONS.....................................................p.119
APPENDIX .....................................................................................................p.119
DIGITAL TOOLS................................................................................................................p. 123

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Revision 1 - May 2020
1. Chapter 6.1.1 : Notes on electrical components assembly
added note about position of electrical box in the appliance, distance from the appliance wall (safety note)
2. Chapter 10.6.1.5 : Embraco compressor max refrigerants charge
added technical limit of Hydrocarbons + note

ACRONYMS USED IN THE TEXT
AB: Alkyl Benzene

IPRV: Internal Pressure Relief Valve

ANSI: American National Standards Institute

LFL: Lower Flammability Limit

ASHRAE: American Society of Heating,
Refrigerating and Air Conditioning Engineers

LRA: Locked Rotor Amps

ATEL: Acute-toxicity Exposure Limit
AHRI: Air-Conditioning, Heating and Refrigeration
Institute (formerly)
ATEX: Atmosphères Explosibles (Directive 94/9/EC)
CSIR: Capacitive Start - Inductive Run
CSR (CSCR): Capacitive Start & Run (Capacitor
Start - Capacitor Run)

LST: Low Starting Torque
LVD: Low Voltage Directive
MBP: Medium Back Pressure
MCC: Maximum Continuous Current
MD: Machine Directive
MSDSs: Material Safety Data Sheets
NS: American National Thread-Special

DIN: Deutsches Institut für Normung

OD: Outside Diameter

ELCOM: Electrical Component

ODL: Oxygen Deprivation Limit

EN: European Standards

OFDN: Oxygen-Free-Dry-Nitrogen

EPA: Environmental Protection Agency

OLP: Overload Protector

Ex: Mark for ATEX certified electrical equipment
for explosive atmospheres

PED: Pressure Equipment Directive

F: Fan Cooling
FLA: Full Load Amps

PTC: Positive Temperature Coefficient
POE: Polyolester

GWP: Global Warming Potential

REACH: Regulation on Registration, Evaluation,
Authorization and Restriction of Chemicals

HBP: High Back Pressure

RLA: Rated Load Amperage

HC: Hydrocarbon

RSIR: Resistance Start - Inductive Run

HCFC: HydroCloroFluoroCarbon
HFC: HydroFluoroCarbon

RoHS: Restriction of Hazardous Substances
Directive

HGD: Hot Gas Defrost

RSCR: Resistance Start - Capacitive Run

HH: Household Application

S: Static Cooling

HST: High Starting Torque

SAE: Society for Automobile Engineer

ID: Internal Diameter

TXV: Thermostatic Expansion Valve

IP: International Protection (ratings)

UL: Underwriters Laboratories

ISO: International Organization of Standardization

3Ø: Three-phase

Terms and Definitions
For the refrigeration system terms used in this Installation Instructions, refer to EN 378-1
or similar standards.

10

1. SAFETY
1.1 SAFETY NOTICE
Embraco compressors are designed, manufactured and inspected according to the latest International
applicable standards, with particular care on the user’s safety.
Embraco compressors are designed as refrigerant pumping elements on refrigeration machines. Only if they
are used for this purpose and installed according to the instructions of this Installation Instructions and to
the applicable regulations and standards can be put in service, as indicated on the Embraco Manufacturers
Declaration of Incorporation according the 2006/42/EC Machinery Directive.
For details contact Embraco Technical support team.
Only qualified/certified and authorized refrigeration technicians are allowed to perform installation andmaintenance of the Embraco compressors; the electrical connections must be made by qualified electrical
technicians.
Technicians are strongly advised to follow all the applicable International and National laws and regulation
as well as the instructions of this Installation Instructions.

1.2 SAFETY ADVICEWARNINGCAUTION

IMPORTANTWARNING: Indicates Instructions that may result in personal injury or death andproperty damage if not carefully followed.

CAUTION: indicates instructions that may results in property damage and possible
personal injury if not carefully followed.

IMPORTANT: indicates instruction to avoid damages/malfunction of thecompressors.

11

2. COMPRESSOR APPLICABLE STANDARDS AND
REGULATIONSASTM B117:

Standard Practice for Operating Salt Spray (Fog) Apparatus

ANSI/ASHRAE 34 (*): Designation and Safety Classification of Refrigerants
ISO817 (*):

Refrigerants - Designation and safety classification

EN 378-1 (*):

Refrigerating systems and heat pumps. Safety and environmental requirements

EN 378-4 (*) :Refrigerating systems and heat pumps. Safety and environmental requirements

EN 60079-15:

Explosive atmospheres. Electrical installations inspection and maintenance

EN 60999-1 (*):

Connecting devices - Electrical copper conductors - Safety

EN 60335-1 :Household and similar electrical appliances. Safety. General requirements

EN 60335-2-34:

Household and similar electrical appliances. Safety. Particular requirements formotor-compressors

EN 60335-2-89(*): Household and similar electrical appliances. Safety. Particular requirements forcommercial refrigerating appliances with an incorporated or remote refrigerant unit
or compressor
EN 60529 (*):

Degrees of protection provided by enclosures (IP Code)UL 60335-1:

Safety of Household and Similar Appliances, General Requirements

UL 60335-2-34:

Safety of Household and Similar Electrical Appliances. Particular Requirements forMotor-Compressor• Low Voltage Directive 2014/35/EU• Machinery Directive 2006/42/EC• Pressure Equipment Directive (PED) 2014/68/UE• RoHS II Directive 2011/65/EU• REACH Regulation (EC) 1907/2006(Refer to the latest publication dates)(*) Standars marked with this symbol are used as a reference during product development or as a reference forcustomers to check additional information.

2.1 PED CATEGORY II
2.1.1 COMPRESSOR LABEL FOR PED II
NJX compressor models with R290 (propane) refrigerant are approved for PED category II according to
Pressure Equipment Directive (PED) 2014/68/EU. Label intended for PED category II contains following
additional information:

12

Figure 2.1.1 Compressor label for PED II
A
B
F
C

A

Maximum allowable operatingpressure (refer to note 1)

E

Embraco website

B

Proof test pressure
Pt:1,1xPs (refer to note 2)

F

Registration number ofthe notified bodyC

Minimum/Maximum temperature(refer to note 3)

G

Registered trade nameD

Manufactoring and test date

DGE

All the other fields remain the same as for another labels described in Chapter 5.

2.1.2 SPECIFICATION
The maximum internal free volume of the NJX propane compressors models is 4,4 liters.
The oil charge is considered as part of free volume.
Note 1: NJX housing of the hermetic compressor is subjected to low pressure side of the refrigeration system.
Note 2: Embraco is checking the compressor housing and its components for any indication of leaks(hermetic sealing test after the peripheral welding) applying a test pressure (Pt = 1,1×Ps), which is inaccordance with PED II requirements, according to standard EN 14276-1. For verification of the strengthof the hermetic compressor housing after peripheral welding, additional burst tests (hydrostatic tests) are
performed regularly.
Note 3: Compressor housing shall not be exposed to the temperatures below -35°C as material mechanicalcharacteristics are not guaranteed below this temperature. Embraco compressors are designed to operate
at maximum ambient temperature of +43°C.

3. EMBRACO COMPRESSOR RELEVANT DOCUMENTS
1.

Embraco Product catalogue on www.embraco.com

2.

Installation Instructions

Check available documents on the www.embraco.com, or contact Embraco Technical support team.

4. COMPRESSOR RANGE
The available models for the different applications and refrigerants, cooling capacity, energy
consumption and the approved electrical components, are listed in the Embraco Product catalogue
on www.embraco.com

4.1 APPLICATION DESCRIPTIONWARNING

Each model of motor-compressor is intended for specific refrigerant and application.
Their use in different application and/or with different refrigerant may result insignificant impact to motor-compressor performance, life expectancy or even may
result in personal injury and damages.
13

Table 4.1 Applications
COMPRESSORTYPEULBP (*)

DESCRIPTION(Ultra Low Back Pressure)
Models for very low evaporating temperatures, suitable for applications with working
evaporating temperatures between -95°C to -65°C; for instance: medical appliances.
(Low Back Pressure)

LBP (*)

Models for low evaporating temperatures, suitable for applications with working
evaporating temperatures lower than - 20°C; for instance: chest freezers, frozen foodcabinets, frozen food display cases, upright freezers, etc.
(Low/Medium Back Pressure)

L/MBP (*)

Models for low/medium evaporating temperatures, suitable for applications with working
evaporating temperatures between - 35°C and 0°C; for instance: professional kitchen coolers,
ice cream freezers, bottle coolers, chest freezers, etc.
(Medium Back Pressure)

MBP (*)

Models for medium evaporating temperatures, suitable for applications with working
evaporating temperatures higher than -20°C; such as fresh food cabinets, drink dispenser,
bottle coolers, ice makers, etc.
(High Back Pressure)

HBP (*)

Models for high evaporating temperatures, suitable for applications with working
evaporating temperatures higher than -15°C; such as fresh food cabinets, drink coolers,
ice makers, dehumidifiers, dryers, etc.
(Air Conditioning)AC

Models for air conditioning, suitable for applications with positive working evaporating
temperatures, such as air conditioners, heat pumps and dehumidifiers.

(*) See Figure 11.6.1 - Compressor admitted operating fields
See the available compressor models in the Embraco Product catalogue on www.embraco.com

4.2 STARTING TORQUE CLASSIFICATION
Table 4.2 Electrical motor starting torque classification
TYPE

DESCRIPTION(Low Starting Torque compressors)

LST (*)

These compressors adopt low starting torque electric motor types RSIR – RSCR - PSC andare suitable for systems with balanced pressures at the compressor start up (capillary
tube or other expansion devices that allow balanced pressure during off cycle).
(High Starting Torque compressors)

HST (*)

These compressors adopt high starting torque motor type CSIR - CSCR (start capacitor
is mandatory) and are suitable for systems with expansion valve or capillary, with
unbalanced pressures at the compressor start up (as well as for systems with balanced
pressure at the start up).
(*) See Table 4.4 - Minimum starting voltage and Chapter 11.6.2 - Start conditions.

144.3 ELECTRICAL MOTOR TYPESCAUTION

Each compressor model has specific electrical components, indicated on
the compressor Technical datasheet in the Embraco Product catalogue on
www.embraco.com
Avoid usage of different components.

Table 4.3 Electrical motor types
TYPE

DESCRIPTIONRSIR(Resistance Start Inductive Run)
This motor type, used in the compressor of small power, has a low starting torque (LST)and must be applied on systems with balanced pressures at the compressor start up(capillary tube or other expansion devices that allow balanced pressure during off cycle)..
The motor is characterized by a start winding with high ohm resistance that must be
disconnected when the rotor reaches the stabilized rotational speed. An electromagnetic
relay, calibrated for the specific motor current or a PTC - (Positive Temperature Coefficient)- solid state starting device, disconnects the start winding at the end of the startup.

CSIR(Capacitive Start Inductive Run)
This motor type has a start capacitor connected in series with the start winding when thecompressor starts up. An electromagnetic relay, calibrated for the specific motor current,
disconnects the start winding and start capacitor at the end of the startup. This motor
has a high starting torque and can be used on systems where the compressor has to startat unbalanced pressure conditions.
The similarity with the RSIR type is only apparent. It is not possible totransform a RSIR motor in CSIR ones just by adding a starting capacitor(except for the models with the electrical motor specifically designed forthis option, for more information see Embraco Product catalogue on
CAUTIONwww.embraco.com

RSCR(Resistance Start Capacitive Run)
Similar to RSIR motor version but uses a PTC solid state starting device and a permanentconnected run capacitor to improve its efficiency. This type of motor has a low starting
torque and must be used, as the RSIR, with system adopting a capillary tube (or pressure
equalizer device) where the pressure equalize before compressor start up. This motor
has high efficiency and high cosφ.

PSC(Permanent Split Capacitor)
This motor is characterized by the run capacitor permanently connected in series withthe start winding; both running and start winding remain connected even after the
motor starts. This type of motor doesn’t need a starting device; it has a low starting
torque and must be used with systems adopting a capillary tube (or a pressure equalizer
device) where the pressure equalize before compressor start up. These motors have highefficiency and high cosφ.

CSR(CSCR)(Capacitive Start & Run - Capacitor Start Capacitor Run)
This motor has a start capacitor and a run capacitor. The start capacitor isconnected in parallel with the run capacitor during the compressor start-up and
it is disconnected by a starting relay (voltage type) at the end of the starting;the run capacitor is permanently connected in series with the start winding. Bothrunning and start windings remain connected even after the motor starts. This
motor has a high starting torque and can be used on systems where the compressor
has to start at unbalanced pressure conditions; it has high efficiency and high cosφ.

3Ø

(Three-phase)Three-phase winding with star connections, this motor doesn’t need a starting device
and has a high starting torque.

4.4 ELECTRICAL MOTOR VOLTAGES AND FREQUENCIESWARNING

Operation of motor-compressor at different voltage range than assigned (marked
on the label) may result in improper function of motor-compressor, missing
actuation of overload protection or even to damage of motor-compressor and/or
its accessories.

Note: Not all voltages and frequencies listed in Table 4.4, are available on all compressor models. For theavailability of different voltages and frequencies for each model consult the Embraco Product catalogue
on www.embraco.com

Table 4.4 Compressor voltages & frequencies, operating voltage range
and minimum starting voltage
Voltage
Code

A
B
C
D
E
F
G
I
J
K
M
N
P
Q
R
S***
T
U
V
W
X
Z

Rated Voltage & Frequency (1)Voltage Working Range (*)

50Hz

220 - 240V 50Hz 1~

198V ÷ 254V

200 - 230V 50Hz / 208 - 230V 60Hz 1~

180V ÷ 244V

220V 50Hz 1~

200V ÷ 242V

60Hz

Minimum Start Voltage (*) (**)

50Hz

60Hz

187V
187V ÷ 244V

170V

177V

187V

208 - 230V 60Hz 1~

187V ÷ 244V

177V

115 - 127V 60Hz 1~

103V ÷ 134V

98V

100V 50HZ / 100 - 127V 60HZ 1~

90V ÷ 110V

90V ÷ 134V

198V ÷ 254V

198V ÷ 254V

115V 60Hz 1~
220 - 240V 50/60Hz 1~

85V

85V

187V

187V

103V ÷ 127V

230V 60Hz 1~

98V

207V ÷ 253V

195V

200 - 220V 50Hz / (230V 60Hz) 1~

180V ÷ 234V

207V ÷ 253V

170V

195V

380 - 420V 50Hz / 440 - 480V 60Hz 3~

332V ÷ 445V

396V ÷ 509V

323V

374V

200 - 240V 50Hz / 230V 60Hz 1~

180V ÷ 254V

207V ÷ 253V

170V

195V

380V 60HZ 3~

342V ÷ 418V

323V

100V 50/60HZ 1~

90V ÷ 110V

90V ÷ 110V

85V

85V

200V 50/60Hz 3~

180V ÷ 220V

180V ÷ 220V

170V

170V

400V 50Hz / 440V 60Hz 3~

360V ÷ 440V

396V ÷ 484V

340V

374V

220 - 230V 50Hz 1~

198V ÷ 244V

200V ÷ 242V

220V 60HZ 1~
230V 50Hz 1~

207V ÷ 253V

220V 50/60Hz 1~

200V ÷ 242V

220 - 240V 50/60HZ 1~
200 - 230V 60Hz 3~

187V

187V
195V

200V ÷ 242V

150V (160V) ÷ 240V (2)

187V

187V

150V (160V) (2)180V ÷ 244V

170V

(1) Voltage/Frequency range indicated in brackets may not be valid for all models and may
not be included in Agency approvals, contact Embraco Technical support team for availability.
(2) Depending on compressor family, for details contact Embraco Technical Support team.
(*) With compressor working or starting within the Table 11.6.1 and Table 11.6.2.
WARNING

16(**) Minimum starting voltage refers to the minimum voltage at the compressor pins during
the compressor start. It does not represent the voltage at the power supply outlet.
(***) For specific model refer to datasheet or consult with Embraco Technical support team.

4.5 ELECTRICAL COMPONENTS TYPESThe electrical components specified for each Embraco compressor model are indicated in the Technical datasheet,available in the Embraco Product catalogue on www.embraco.com

CAUTION

The compressor must be equipped with the electrical components indicated in theTechnical datasheet in the Embraco Product catalogue on www.embraco.com

The type of electrical components for each type of electric motor is indicated in Table 4.5, and is usually
supplied as compressor equipment.
Only under some circumstances agreed with the customer, the electrical components can be excluded from thecompressor supplied equipment; however the user must adopt the electrical components specified by Embraco.

WARNINGUse of other electrical components than the ones approved by Embraco (listed in
the Technical Datasheets and in Embraco Product Catalogue for each specificmodel) or their exclusion may damage the compressors and other parts and cause
serious injiury to persons.

Table 4.5 Electrical components types
STARTING DEVICE

TYPE OF MOTOR

Overload
Protector (1)

RSIR

√

RSCR

√

CSIR

√

CSR (CSCR)

√

PSC

√

3Ø

√

Current Relay

Voltage Relay√ (2)

CAPACITORSPTC (or TSD)

Start

√ (2)
√

√ (3)

Run

√

√ (3)

√

√

√

√
√

(1) Some models approved with Internal OLP, see details in the Embraco Product catalogue on
www.embraco.com(2) Certain RSIR compressor model adopts the starting current relay, other models adopt the PTC. To identify
the adopted starting device refer to the Embraco Product catalogue on www.embraco.com(3) Certain CSIR compressor model adopts the starting current relay, other models adopt voltage relays. To
identify the adopted starting device refer to the Embraco Product catalogue on www.embraco.com

17

4.6 COMPRESSOR COOLING TYPES
According to their design and power the various compressor models
require different cooling systems. The cooling system intended for eachcompressor model is indicated in the Embraco Product catalogue on
www.embraco.com
For information on the proper installation and cooling of the compressor, see
Chapter 10.1.3.7.
Usage of insufficient cooling of motor-compressor in case of fan cooled version
may result in:• Increase of average temperature of motor, thus reducing life time of motor
insulation.
WARNING• Overload protector recurrent actuations, with life time reduction of it and of otherparts.
• Other negative impacts to the performance of motor-compressor and its parts.

Table 4.6 Cooling types
TYPE

S

Static cooling: the compressor does not require forced ventilation cooling, but
it must be installed so that the natural air circulation can adequately cool thecompressors to avoid overheating.

F

Fan cooling: the compressor requires forced ventilation cooling through the useof a fan sized and installed as indicated in Table 10.1.3.7 and Figure 10.1.3.7.

IMPORTANT18

DESCRIPTION

The specific cooling type and Air flow rate for each compressor is indicated in
Embraco Catalog (see also Table 10.1.3.7. – Fan cooler characteristic). It can
influence the activation of Overload protector thus it must be observed to allow
the correct running condition of the compressor.

5. COMPRESSOR NAMEPLATES, MODEL AND
BILL OF MATERIAL CODE
5.1 COMPRESSOR LABEL
Figure 5.1 Compressor label
1
5

9

3

7

8

10

2

4

6

1
5

9

7

10

2

8
3

6

4

1

Compressor model2

Supply Voltage

3

Bill of Materials code

4

Serial Number

5

Agency Approval Marks

6

Date code or Production date7

Oil type and quantity

8

Refrigerant type9

Current Consumption(Rated Load Amperage, when applicable)

10

Locked Rotor Amperage(when applicable)

195.2 COMPRESSOR MODEL CODE
The information for identification of the compressor model, voltage, refrigerant to be used are printed on the
nameplate.

Figure 5.2.1 EM / NE / NT / NJ model code

NE K

6 214

Z

COMPRESSOR FAMILIESREFRIGERANT CODE

EM - NE - NT - NJ

EFFICIENCY LEVELAPPLICATION CODE
1 = LBP - LST
2 = LBP - HST

GE - GF - GG

R407C 1 ˜

GK - GJ

R404A/R507A/R452A 1 ˜

GS

R404A/R507A/R452A 3 ˜

GP

R407C 3 ˜Rgas recovery

U

R290 1 ˜Z

R134a 1 ˜

ZX

R134a 3 ˜

Y

R600a

3 = L/MBP - LST

COOLING CAPACITY

4 = L/MBP - HST

The first digit is the number ofzeros that must be added to thelast two digits to obtain the cooling
capacity (approx) in kcal/h at 50 Hz.
E.g.:214 -->1400 kcal/h at 50Hz.

5 = MBP* or HBP* - LST
6 = MBP* or HBP* - HST
7 = A/C
9 = M/HBP - HST

The V letter at the end of the compressor name stands for IPR valve.
*According to the refrigerant used

Figure 5.2.2 EM model code

EM T 70

H

L

P
ELECTRICAL COMPONENTCOMPRESSOR FAMILY

R = relay
P = PTC + optional run capacitor
C = PTC/TSD + mandatory run capacitor
X = relay + mandatory start capacitor
T = TSDEMEFFICIENCY LEVEL
T - first generation
U - second generation
Y - third generationZ - fourth generation
X - fifth generation
C - sixth generation

APPLICATION CODE
L = LBPH = M/HBP
D = HBPCOOLING CAPACITY
Rated cooling capacity divided by
10 expresse in btu/h (subcooled
liquid conditions) and referredto the frequency listed on thecompressor name plate.

20

REFRIGERANT CODE
H - R134a
C - R600a
U - R2905.3 COMPRESSOR BILL OF MATERIAL CODE
Figure 5.3269

M B 51 90 AF

COMPRESSOR
TYPE
PACKAGINGEXECUTION
MODEL CODEACCESORIESEXECUTION
VOLTAGE &FREQUENCY
SUPPLYELECTRICAL
VERSIONEXECUTION
EXTERNAL
VERSIONEXECUTION

5.4 MANUFACTURING DATE CODE
Embraco production date is stated on compressor label in one of below 2 ways:
1. Full date description (example 13/Jul/16)
2. Coded date, see detail in below Table 5.4

Figure 5.4 Date code
Month

A B

Year
From September to August of following year

A = September

M = 2000/2001

A = 2012/2013

B = OctoberN = 2001/2002

B = 2013/2014

C = November

P = 2002/2003

C= 2014/2015

D = December

R = 2003/2004

D = 2015/2016

E = January

S = 2004/2005

E = 2016/2017

F = February

T = 2005/2006

F = 2017/2018

G = March

U = 2006/2007

G = 2018/2019

H = AprilV = 2007/2008

H = 2019/2020

J = May

W = 2008/2009

J = 2020/2021

K = June

X = 2009/2010

K = 2021/2022

L = JulyY = 2010/2011

L = 2022/2023

M = AugustZ = 2011/2012

21

5.5 COMPRESSOR TEST CONDITION
Table 5.5 Test condition
TEST
CONDITIONS(RATING POINT)

EVAPORATINGCONDENSING

RETURN GASTEMPERATURETEMPERATURETEMPERATURE

°C

°C

°C

LBP

-35

40

MBP

-10

45

HBP

5

50

LBP

-23.3

48.9

4.4

MBP

-6.7

48.9

4.4

HBP

7.2

54.4

18.3

LBP

-31.7

40.6

4.4

MBP

-6.7

43.3

18.3

HBP

7.2

54.4

18.3

LBP

-23.3

54.4

MBP and HBP

7.2

LBP

-25

APPLICATION

EN 12900

ARI 540(2004)ARI 540(2015)

ASHRAESUBCOOLEDCECOMAFLIQUIDAMBIENTTEMPERATURETEMPERATURE

°C

°C

-

35

-

35

NO
SUB-COOLING

-

35

32.2

-

32.2

32.2

54.4

35

8.3K

-

35

55

32

NO
SUB-COOLING

-

32

20(*)

SUB-COOLINGNOSUB-COOLINGNOSUB-COOLING

8.3K

6. WIRING DIAGRAMS
6.1 ELECTRICAL CONNECTIONSThe electrical connections to the compressor must be carried out according to thewiring diagrams indicated for each compressor model in the Embraco Productcatalogue on www.embraco.com
WARNING22

A summary view of the connections is indicated in Figure 6.1.b.

Figure 6.1.a Wiring diagrams key

OVERLOAD PROTECTORPTC START DEVICE`OVERLOAD PROTECTORINTEGRATED PTC DEVICECURRENT START RELAY

CURRENT START RELAY
WITH CAPACITOR CONNECTIONS

3CR CURRENT START RELAY

3ARR3 START RELAY (VOLTAGE).

RUN CAPACITORRUN CAPACITOR(MANDATORY - NOT SUPPLIED)OPTIONAL RUN CAPACITOR

START CAPACITOR

FAN

M

PUSH BUTTONLAMPSINGLE PHASE MOTOR

3-PHASE MOTOR
LOW-HIGH PRESSURE SWITCHt

THERMOSTATEARTH CONNECTION
3-PHASE SUPPLYPILOT CIRCUIT 24 OR 220 V
SINGLE PHASE SUPPLY[CCOMMONC’COMMON(INTERNAL OVERLOAD PROTECTOR)

R

RUN

S

START

Br

BROWN CABLE

Bk

BLACK CABLE

Rd

RED CABLE[[[TERMINAL BLOCKWh

WHITE CABLEBlBLUE CABLEYG

YELLOW-GREEN CABLE
CONNECTIONS SUPPLIEDCONNECTIONS TO BE MADE
BY THE CUSTOMER (NOT SUPPLIES

23

Figure 6.1b Wiring diagrams
SM00 - EMT/NE SERIES RSIR PTC European Version

SM01 - EMT/NE SERIES RSCR PTC European Version

SM02 - EMT/NE SERIES RSCR TSD European Version

24

SM03 - EMT/NE SERIES RSIR Terminal Board & Start Device

SM04 - EMT/NE SERIES CSIR American Version

SM05 - EMT/NE SERIES CSIR Terminal Board & Start Device

25

SM06 - NE SERIES CSR Box

SM10 - NE SERIES CSR Box internal overload protector

SM12 - NJ SERIES CSIR box External overload protector

26

SM13 - NJ SERIES CSIR box External overload protector

SM15 - NJ PSC

SM16 - NJ SERIES CSR Box (Internal Overload Protector)

27

SM17 - NJ CSR Box (External Overload Protector)

SM18 - NJ SERIES 3-Phase (Internal Overload Protector)

SM19 - NT SERIES CSIR Terminal Board

28

SM20 - NT SERIES CSIR – American Version

SM21 - NT SERIES CSR Box

SM23 - NT SERIES CSR Box

29

SM24 - NJ SERIES CSIR box External overload protector

SM26 - NT SERIES CSR Box (Internal Overload Protector)

SM27 - NT SERIES 3-Phase (Internal + External Overload Protector)30

Notes on electrical component connections:•

RSIR/RSCR come with faston connection 4.8 mm•

CSIR come with terminal board with 6.3 mm external connections•

CSIR without terminal board come with relay and OLP with 6.3 mm faston•

CSR boxes come with screw connections placed on voltage starting relays(except for High IP degree full plastic cover CSR boxes which come with 6.3 mm
faston terminal board).

6.1.1 NOTES ON ELECTRICAL COMPONENTS ASSEMBLYWARNINGWARNINGWARNING

Avoid excessive shocks on the pins of the compressor. The force to insert theterminals of the electrical components or supply line must be along the axis ofpins: transversal forces not aligned with the pins or moments exerted on the pins
can bend them or cause cracks in the glass insulation. These cracks can lead toglass breaks, refrigerant/oil leakages and short circuits. This situation is particularly
dangerous in case of use of HCs refrigerants, as there is a risk of flammable
refrigerant leak, leading to an electrical arc that could trigger a flame.
Avoid to use the electrical components to get multiple connections on theirterminals: the excessive force necessary to fix all them together may damage thecomponents. If multiple connections are needed, use the terminal board provided
by Embraco for its compressors or other external terminal boards (complying withthe electrical safety standards) to be fix on the cabinet. For other solutions, contact
Embraco Technical Support team.
Position of electrical box in the application - is mandatory to be in vertical direction,
to assure correct functionality of relay, as indicated by arrows and sign SIDE UP
situated in the upper part of electrical box (see Figure 6.1.1).
Position of electrical box in the application - it is mandatory to assure min 15 mm
distance from the application wall, to provide S2 safety protection openingof capacitors. Electric box cannot be used in an open niche application.
(It is not a direct access assembly.)

Figure 6.1.1 Electrical box mounting position316.2 COMPRESSOR PIN POSITION
Figure 6.2.1
EM / NE / NT / NJ models
pin position

6.3 SCREW CLAMPING TORQUE OF SUPPLIED COMPONENTS
In order to facilitate their unscrewing, the connection screws on overload protectors, current relays, terminalboxes and ground plates are supplied with a clamping torque of 0.1 ÷ 0.3 Nm (1 ÷ 3 kgcm). Voltage relays
are supplied with clamping torque of 0.1 ÷ 0.4 Nm (1 ÷ 4 kgcm).

6.4 SCREW FINAL TIGHTENING
For the final tightening of the connections on the compressor electrical components and terminals madeat the installation of the compressor on the refrigeration system, a torque of 0.8 ÷ 1.4 Nm (8 ÷ 14 kgcm)
should be applied to the screws. The final clamping torque of electrical connections screw terminals shallbe compliant with the EN 60999-1 and part 2 for household and similar appliances.

6.5 QUICK CONNECTION (FASTON)
In order to assure firm connection between electrical accessories and the refrigeration system, it is necessary
to use suitable type of terminals. In case of quick connect terminals recommended material is phosphorus
bronze.

32

7. COMPRESSOR SUPPLY CONDITIONS

7.1 COMPRESSOR PERFORMANCE
The various models are supplied with performance and tolerances indicated in the Embraco Productcatalogue on www.embraco.com

7.2 COMPRESSOR EXTERNAL VIEWS
The compressor external view (size, tubes diameters, mounting base) of the various models are indicated in
the Embraco Product catalogue on www.embraco.com

7.3 ELECTRICAL INSULATION
All compressors are tested for dielectric strength and electrical insulation to ground according to requirementsof the following standards (latest edition):• EN 60335-2-34 (to be used with EN 60335-1)• UL 60335-2-34 (to be used with UL 60335-1)
Note: dielectric strength and compressor insulation to ground are different when the compressor is tested in
the air or in a system charged with refrigerant, due to the dielectric characteristics of the refrigerant.

WARNING

When motor-compressor is under vacuum, do not carry out any evaluation or testof the insulation (dielectric strength or hi-pot test) using voltage AC or DC. It may
result in damages of the insulation system and, consequently, in shortening theinsulation life.

7.4 COMPRESSOR APPROVALS BY SAFETY INSTITUTESThe safety approvals granted for the various compressor models are indicated in the Embraco Productcatalogue on www.embraco.com

33

7.5 “IP” DEGREE OF PROTECTION
The degree of protection provided by the terminal cover and the assembly of the electrical components
supplied with the compressor are listed in Table 7.5, in accordance with the EN 60529 standard.

Table 7.5 IP Degree
SERIESEM - NE - NT (*) (**)

NJ (**)"IP" DEGREE

IP 32

IP 33

(*) NT with vertical terminal fence (Figure 7.5.a) has IP 33.
(**) Specific NE/NT/NJ are available on demand with IP 34 CSR box (Figure 7.5.c).

Figure 7.5.a NT with vertical terminal fence (IP33)

Figure 7.5.b NT with horizontal terminal fence (IP32)

34

Figure 7.5.c CSR box with IP34

7.6 COMPRESSOR SHELL HYDROSTATIC STRENGTH
The compressor shell resists pressures above those prescribed in the standards:• EN 60335-2-34• UL 60335-2-34

7.7 DEHYDRATIONThe Embraco compressors have a drying process on their production line, before receiving the oil charge.
The residual humidity after drying is according to the Table 7.7.

Table 7.7 Maximum level of residual humidity (H2O mg)
SERIESRESIDUAL HUMIDITY MAXIMUM AMOUNT (H2O mg)

EM – NE

60

NT

80

NJ

90

7.8 PAINTING
The compressor paint resists corrosion for the exposure of salt spray of 96 hours according to ASTM B117.
The compressors are supplied with the tube ends and the hermetic terminals (compressor pins) unpainted.

35

7.9 COMPRESSOR PRESSURIZATION
Compressors are delivered pressurized to a pressure of about 1 bar with dry air (dew point lower than -40°C),
or with light vacuum, depending on models and refrigerants. For further details contact Embraco Technicalsupport team.
The compressor tubes are sealed with caps to avoid contamination by external air and humidity entering
inside the compressor.

7.10 OIL CHARGE
The quantity and type of oil charged into the compressors are indicated in the compressor Technicaldatasheet in the Embraco Product catalogue on www.embraco.com
A colored “O” stamped on the compressor cover indicates the presence and type of oil, for more information
see Table 7.10.
Oil type and oil quantity is indicated on compressor label.
The maximum humidity content in the oil, before being charged in the compressor, is 40 ppm.

Table 7.10 Lubricant oils approved for compressors
REFRIGERANTSOIL TYPECOMPOSITIONVISCOSITYGRADECOMMERCIAL
NAME

STAMP

Polyolester

POE

ISO 10EMKARATE RL 10H

Red

x

Alkylbenzene

AB

ISO 5

Q-SOL LAB-SY

Yellowx

Alkylbenzene

AB

ISO 2

ZEROL 2TRed

x only
HBP

Polyolester

POE

ISO 22EMKARATE RL 22H

White

x onlyHH

Alkylbenzene

AB

ISO 5

Q-SOL LAB-SY

White

Polyolester

POE

ISO 22EMKARATE RL 22HB

Yellow

Alkylbenzene

AB

ISO 46RENISO SP 46 V2

Blue

Polyolester

POE

ISO 22EMKARATE RL 22HB

Yellow

Polyolester

POE

ISO 22EMKARATE RL 22HB

Yellow

Alkylbenzene

AB

ISO 46RENISO SP 46 V2Blue

FAMILY
R134A

R404A

x

R290

x

x

R407C

R422D

x

EM
SK

EM
IT

R600a

x

x

x

x

x

NE
x
NT

x

x

x

x

x
x

NJ
x

Only for exceptional cases, in accordance with the Embraco Technical support team or Sales team, thecompressors can be shipped without oil.

36

7.11 MINIMUM QUANTITY OF LUBRICANT INSIDE THE
COMPRESSOR
The oil charge of each compressor model is indicated in the Embraco Product catalogue on
www.embraco.com
During the compressor running, oil is pumped out from the compressor. The system must be designed inorder to carry the oil back to the compressor, (see Chapter 10.3.2), however a certain amount of oil may
remain inside the system.
The minimum quantity of oil inside the compressor that guarantees the correct lubrication is indicated in Table 7.11.

Table 7.11 Minimum quantity of lubricant
SERIES

EM

NE

NT

NJ

OIL CM³ MIN.

90

200

300

500

Data mentioned in above Table 7.11 is valid for all the models (HFCs and HCs) of the same compressor series.
Oil quantities below the minimum prescribed level will not allow the oil pumping and will cause wear, leading
to the eventual seizure of the mechanical parts.
System prototypes have to be checked for the oil remaining into the line tubes, condenser, evaporator
and other parts after running in all the expected conditions that may happen in the field, assuring that thecompressor contains in all conditions at least the quantity of oil indicated in the Table 7.11.

7.12 SPECIAL VERSIONS
Table 7.12 Special external version examples
SERIESDESCRIPTION

EM/NE

Compressors with a bracket on the cover for the mounting of a water tray
Compressors without suction tubes but with a fixture for Rotolock valve (valve
not supplied)

NJ/NT

Compressors without suction tubes but with a fixture for Rotolock (suppliedwith unassembled valve and gasket)
Compressors with oil equalization tube for Gemini version (see Chapter 10.3.8)

ALL SERIES

Compressors supplied without grommets and sleeves37

8. COMPRESSOR PACKAGING
8.1 MULTIPLE PACKAGING
This type of package consists of a shipping skid of 835 mm x 1150 mm on which are positioned the elementscomposing the packaging of various compressor layers, as listed below, secured with straps to the shipping
skid (see Figures 8.1.1.a – f).

Table 8.1.1 Pallet packages compositionA

SHIPPING SKID

on which the base is positioned

B

BASE

on which the first layer of compressors is positioned

C

SEPARATOR SKID

are positioned between layers, in quantities according to
the compressor series

D

TOP SKID

upper element closing of the package

Figure 8.1.1.a “EM” (120 compressors)

Figure 8.1.1.b “EM” (100/88 compressors)

Figure 8.1.1.c “NE” (80/74 compressors)

Figure 8.1.1.d “NE” (40/37/28 compressors)

Figure 8.1.1.e “NT” (36/24 compressors)

Figure 8.1.1.f “NJ” (36/28 compressors)38

Table 8.1.2 Characteristics of multiple wooden packaging
QUANTITYSERIESPER

PACKAGING

CODE

TYPE

PALLET

REFERENCEELECTRICALCOMPONENTS

EM

120

S

6 layers of 20 compressors

Figure 8.1.1.a

NOT ASSEMBLED

EM

100

V/G

5 layers of 20 compressors

Figure 8.1.1.b

ASSEMBLED

EM

100

R

5 layers of 20 compressors

Figure 8.1.1.b

NOT ASSEMBLED

EM

88

W

2 layers of 14 compressors; 3 layers of 20 compressors

Figure 8.1.1.b

ASSEMBLED

NE

80

M

4 layers of 20 compressors

Figure 8.1.1.c

NOT ASSEMBLED

NE

74

O

1 layer of 14 compressors; 3 layers of 20 compressors

Figure 8.1.1.c

ASSEMBLED

NE

40

N

2 layers of 20 compressors

Figure 8.1.1.d

NOT ASSEMBLED

NE

37

Q

1 layer of 17 compressors; 1 layer of 20 compressors

Figure 8.1.1.d

ASSEMBLED

NE

28

H

2 layers of 14 compressors

Figure 8.1.1.d

ASSEMBLED

NT

36

C

2 layers of 18 compressors

Figure 8.1.1.e

NOT ASSEMBLED

NT

24

Z

2 layers of 12 compressors

Figure 8.1.1.e

ASSEMBLED

NJ

36

C

2 layers of 18 compressors

Figure 8.1.1.f

NOT ASSEMBLED

NJ

28

Y

2 layers of 14 compressors

Figure 8.1.1.f

ASSEMBLED

8.2 SINGLE PACKAGING
This type of package consists of a carton box and an internal separator to prevent any compressor movement.
The electrical components and accessories are included in the package (assembled or attached).
Complete palet package consists of a shipping skid of 830 mm x 1130 mm on which are placed carton
boxes with compressors secured with corner strip and straps (see Figure 8.2.2). Number of layers depends
on compressor families, as indicated in the Table 8.2.

Figure 8.2.1 Carton box for single
package

Figure 8.2.2 Single compressor palet
package39

Table 8.2 Characteristics of complete single package
SERIESQUANTITY PERPALLET

CODE

PACKAGING TYPE

ELECTRICAL COMPONENTS

EM

70

A

5 layers of 14 compressors

ASSEMBLED

EM

56

J

4 layers of 14 compressors

ASSEMBLED

NE

56

A

4 layers of 14 compressors

NOT ASSEMBLED / ASSEMBLED

NE

56

J

4 layers of 14 compressors

ASSEMBLED

NE

44

F

4 layers of 11 compressors

NOT ASSEMBLED / ASSEMBLED

NT

44

A

4 layers of 11 compressors

NOT ASSEMBLED / ASSEMBLED

NT

44

F

4 layers of 11 compressors

NOT ASSEMBLED / ASSEMBLED

NJ

33

A

3 layers of 11 compressors

NOT ASSEMBLED

NJ

33

F

3 layers of 11 compressors

ASSEMBLEDNOTE

CSR electrical box
included

CSR electrical box
included

CSR electrical box
included

Wooden packaging and pallets are created to comply with recycling regulations and are treated according tostandard ISPM No. 15 - Regulation of wood packaging material in international trade. IPPC mark is presented
on the wooden palets.

8.3 PACKAGE FOR ELECTRICAL COMPONENTS AND ACCESSORIESElectrical components and accessories if not assembled on compressors are packed separately in carton
boxes. A label is applied showing the following data:
Components packing label
1. Components bill of material code
(complete of electrical components and accessories)
2. Compressor model
3. Quantity
4. Customer mame (optional)
5. List of electrical components and accessories shipped(code/description/quantity)40

8.4 COMPRESSOR IDENTIFICATION MARKS
Labels are applied on two sides of each package and report the following data:
1. Compressor bill of material
2. Bar code of compressor bill of material (Type 39)
3. Compressor model
4. Voltage & frequency
5. Refrigerant
6. Package quantity (optional)
7. Packaging serial number
8. Bar code of packaging serial number (Type 128)

Figure 8.4.1 Compressor identification label for multiple packaging
1

2

3

5

4

6
8

7

Figure 8.4.2 Compressor identification label for single packaging

3

4

5

8
1

7

41

9. HANDLING, TRANSPORTATION AND STORAGE
9.1 HANDLINGIMPORTANTThe handling of the multiple packages must be done only by forklift with due care,to avoid damages of the packages and compressors. Access is available from all
four sides of the package. It is recommended the use of forks having a length
adequate to the size of manipulated goods.
The multiple packages must not be handled with cranes by means of cables andhooks. Use of improper handling can result in person injuries.

WARNING

Risk of pallets collapse and personal injuries, stacking higher than the recommended
maximum, indicated in Table 9.5.1 and Table 9.5.2, can cause accidents. Move
pallets or single compressors only with appropriate mechanical or handlingequipment according to the weight.
Keep the packages in the upright position. Keep the packaging dry at all times.
Do not stack single boxes on top of each other.

For packages storage and moving refer to the Chapters 8 and 9.

9.2 TRANSPORTATION
The transportation of all types of packaging must be made with the compressor in upright position.
Acceptable compressor positions during transportation are indicated in Table 9.3.

IMPORTANTIMPORTANT

Particular care is requested for the "Single packages", which are easier to damage.
Incorrect transport can cause deformation of brackets and internal mufflers and/or oil entering into the suction mufflers and stator shifts, which can result in a
reduction of stator/rotor air gap and reduction of bearings clearance.
The consequences during operation can appear with noise due to deformations of
the internal mounting springs, and with starting problems of the electric motor.
Before to use compressors which are suspected of improper transport or damaged
contact Embraco Technical support team.

9.2.1 SHIPMENT BY CONTAINER
The predominant method of transport is by container of which there are two different types for capacity andlength: 20ft (about 6.1 m) and 40ft (about 12.2 m). The standard container used by Embraco is the 20ft, whichallows in comparison to the 40ft, a higher ratio weight/volume and consequently a better utilization of theinternal volume (the number of the compressors in a 40ft container is limited by the admitted total weight).

42

Table 9.2.1 indicates the characteristics of the load. For each compressor series are indicated: number ofstocking pallet layer, number of compressors per each pallet layer and maximum total number of compressors.
Occasionally, some freight forwarders in the interest of expediency prefer to employ a 40ft container, evenwith the disadvantage of total volume utilization.

Table 9.2.1 Load characteristics for 20ft container
SERIESFIRST LAYERSECOND LAYER

THIRD LAYERTOTAL N° OF(N° OF PALLETS –(N° OF PALLETS –(N° OF PALLETS –N° OF COMPRESSORS)

N° OF COMPRESSORS)

N° OF COMPRESSORS)COMPRESSORS
MAX (1)14 - 120

14 - 802800

14 - 100

14 - 100

2800

14 - 88

14 - 882464

14 – 70 (2)14 – 70 (2)1960

14 – 56 (2)14 – 56 (2)1568

14 - 80

14 - 802240

14 - 74

14 - 742072

14 - 40

14 - 40

14 - 401680

14 - 37

14 - 37

14 – 371554

14 - 28

14 - 28

14 - 281176

14 – 56 (2)14 - 56 (2)1568

14 – 44 (2)14 – 44 (2)1232

14 - 36

14 - 36

14 - 361512

14 - 24

14 - 24

14 - 241008

14 – 44 (2)14 – 44 (2)14 – 36 (2)14 – 36 (2)14 - 28

14 - 28784

14 – 33 (2)14 – 33 (2)

924

EM

NE

NT

NJ

1232
(3)

1008

(1) Different load structure – maximum quantity of compressors - is determined by the ratio between the
maximum container weight and the compressor weight.
(2) Single packaging.
(3) Type of load which is rarely used. To be avoided due to an incomplete third layer.

Payload max 24 tons. Follow local limits.
IMPORTANT

Note: Above table is only indicative, taking to consideration one type of packaging and compressor family. For
specific cases contact Embraco Customer care.

439.2.2 SHIPMENTS BY TRUCK
The transportation of compressors by truck is the most common system for highway or short distanceswhere the stresses on the product are reduced. This type of transportation, if made without the necessary
precautions on load steadiness and travel on uneven roads can cause stresses to compressors with possible
damages to the suspension springs and to the internal discharge loop and muffler. For a 24,000 kg (11,000lb) truck, the load composition is indicated in Table 9.2.2.

Table 9.2.2 Characteristics of load by truck
COMPRESSORYFAMILY

EM

NE

N° OF

N° OF

N° OF

COMPRESSORS/PALLETPALLET/TRUCKCOMPRESSORS/TRUCK

120

21 ÷ 242520 ÷ 2880

100

24 ÷ 28

2400 ÷ 2800

88

28 ÷ 302464 ÷ 2640

80

24 ÷ 26

1920 ÷ 2080

74

24 ÷ 28

1776 ÷ 2072

40

42 ÷ 461680 ÷ 1840

37

48 ÷ 52

1776 ÷ 192428

54 ÷ 58

1512 ÷ 1624

36

28 ÷ 32

1008 ÷ 1152

24

42 ÷ 461008 ÷ 1104

36

24 ÷ 28864 ÷ 1008

28

28 ÷ 32784 ÷ 896

NT

NJ

Note: Above table is only indicative, taking to consideration one type of packaging and compressor family. For
specific cases contact Embraco Customer care.

9.3 ACCEPTABLE COMPRESSOR POSITIONS DURING
TRANSPORTATION OF FINISHED PRODUCTTable 9.3 represents the acceptable transportation positions. The positions marked with a cross are notallowed.
In particular cases the finished product may need to be transported in horizontal position (with thecompressor in lying position).

44

Table 9.3

SERIES

Acceptable compressor position during transportation offinished product

NORMAL(UPRIGHT)LABEL UPTERMINAL
BOARD UPLABEL DOWNTERMINAL
BOARD
DOWN

UPSIDEDOWN

EM

NE

NT

NJ

IMPORTANTCAUTION

In case the cabinet is transported with compressor in lying position, before to start
the cabinet after having up righted it, wait at least 15 minutes allowing the oil,eventually entered in the suction muffler, to drop out.

In case the compressors are lying during the assembly of the finished products,
oil will enter in the suction/service tubes causing problematic brazing of the line
tubes and hazardous fumes.

45

9.4 ACCELERATION DURING TRANSPORT AND HANDLING
Maximum allowable rate of deceleration/acceleration: 1g
IMPORTANT

Generally we advise against the rail transportation because during the shunting, stress to the compressors
from decelerations or acceleration can cause stator shifts, or deformation or breaking of internal discharge
tubes and brackets.
For conditional approval of specific cases please contact Embraco Logistics or Technical support team.

9.5 COMPRESSOR STORAGEWARNINGWARNING

Failure to follow these instructions can result in property damages and people
injuries. For the solution of potential positioning problems during assembling andtransport, consult the Embraco Technical support team.

The storage of palets can be done by placing one package upon another according
to the limits indicated in Table 9.5.1 and Table 9.5.2.

Table 9.5.1 Compressor multiple package storage - maximum height
NE – 28/37/40

EM-NE 74/80

EM 120EM 88/100

COMPRESSORSCOMPRESSORSCOMPRESSORSCOMPRESSORSMAX 3 UNITS

MAX 2 UNITS

MAX 2(*) UNITS

NT – 24/36
COMPRESSORSNJ – 28/36
COMPRESSORSMAX 5 UNITS(*) Note: in case of need to stack 3 units, contact Embraco Technical support team.
46

Table 9.5.2 Compressor single package storage - maximum heightEM - NE – 44 COMPRESSORS
NT – 44 COMPRESSORSNJ – 33 COMPRESSORSMAX 3 UNITS

EM - 70/56 COMPRESSORS
NE - 56 COMPRESSORSMAX 2 UNITS

All packages must be stored in places protected from humidity and bad weather as indicated in Chapter 9.6.
Embraco does not take any responsibility for occasional demages to the package and to the finished productresulting from not observing these instructions.
For the solution of potential positioning problems during assembling and transport, consult the Embraco
Technical support team.

9.6 STORAGE CONDITIONSIMPORTANT

Compressors and electrical components should be stored in closed ambient,protected against rain, water drops, dust and contaminants; air humidity should
not exceed 80 %. Salty sea ambient (transport by vessel, load, unload) are admitted
only for the periods of transportation and custom clearance; storage on the sea
board should be avoided.

Storage ambient temperature: min -25°C / max 55°C; for limited periods (like transportation in containers
in tropical areas) temperature up to 70°C are admitted.
In the case of storage at low temperatures, before the compressor is installed into the refrigeration system,
they must be stabilized at higher temperatures until the compressors are at +5 °C minimum. The same
must be applied to finished products stored at low temperatures before to start the compressor.
Even if properly stored, after prolonged storage period (over 5 years) the oil on the cinematic parts of thecompressor may dry, making the first start of the compressor difficult and the tube plugs may deteriorate
allowing air/humidity enter into the compressors.
In case of longer storage time, before using the compressors contact the Embraco Technical support team.

47

10. RECOMMENDATIONS ABOUT CORRECTCOMPRESSOR INSTALLATION
A functional and efficient refrigeration system is the combination of various components, properly selected
and assembled in order to reach the pursued safety level and performance of the finished product andrespecting the admitted limits of each component. The compressor is one of the system components: theinformation of this Installation Instructions relates only to the Embraco compressors with their standard
electrical components and accessories.

WARNING

IMPORTANTFor the compressor connection to the electrical supply line and for maintenance/
repairing operations, refer also to Appendix 1- Recommandations - safety instruction
for compressor instrallation.

Correct position of compressor when installed into the system is upright/verticalwith inclination tolerance of max 3°.

10.1 COMPRESSOR SELECTION
10.1.1 CHARACTERISTICS OF THE HERMETIC COMPRESSOR
The hermetic compressors are very specialized machines, designed:a) To work with a specific refrigerantb) For a specific type of application (LBP or MBP or L/MBP or HBP or ULBP)c) With LST or HST electrical motord) For electrical supply at 50 or 60 HZ with a certain supply voltagee) To deliver a certain cooling capacityf) To be properly cooledg) To operate in certain admitted working rangeh) To be properly installed

10.1.2 SELECTING THE PROPER COMPRESSORWARNING

Correct function of defined compressor and related electrical accessories ispossible only if requirements mentioned in points a) ...h) are assured. Working outof the defined limits may result in malfunction of the compressor caused damages
to properties and injiuries to persons.

The information corresponding to a), b), c), d), e) are indicated in the compressor label and compressor namecode (compressor model printed on the label contains in his code the rated cooling capacity see Chapter 5.2).
The compressor cooling capacities at various evaporating temperatures, with condensing temperatures asparameter are indicated in the Technical datasheets in the Embraco Product catalogue on www.embraco.com
The admitted voltage limits and admitted working ranges are indicated in Table 4.4 and Table 11.6.1.

48

10.1.3 RECOMMENDED GUIDELINE FOR THE COMPRESSOR
SELECTION
10.1.3.1 MINIMUM / MAXIMUM EVAPORATING TEMPERATURE
The minimum / maximum evaporating temperature of the system allows the identification of the compressor
application LBP or MBP or L/MBP or HBP or ULBP (see Table 4.1).

10.1.3.2 APPROPRIATE COOLING CAPACITY
The compressor model with adequate cooling capacity can be identified by referring to the Embraco
Product catalogue on www.embraco.com

10.1.3.3 REFRIGERANT TYPE
The refrigerant type admitted for each compressor model is indicated in Embraco Product catalogue on
www.embraco.com and on the compressor label.

WARNINGFor each compressor use only the refrigerant indicated in the Embraco Productcatalogue on www.embraco.com and on the compressor label. Usage of different
refrigerants can generate abnormal working conditions, excessive pressure in the
refrigeration system, damages of the compressor and explosions.

10.1.3.4 ELECTRIC MOTOR STARTING TORQUE
The selection of the electric motor starting torque type (LST - low starting torque; HST - high starting torque)must be made according to the suction and discharge pressures of the system at the compressor start.
The motor starting torque type (LST or HST) is indicated in the Embraco Product catalogue on
www.embraco.com and on the name code (see Chapter 5.2).
For systems with capillary tubes or expansion valves with pressure equalization at the compressor
start, a low starting torque (LST) is suitable (tests must be carried out on the cabinet at thenormal and abnormal expected conditions to verify the actual pressure equalization before eachcompressor start).
For systems with expansion valve or capillary tube where the suction and discharge pressures remain
unbalanced at the compressor start, it is necessary to use a high starting torque compressor (HST).
See the admitted starting limits in the Table 11.6.2.

49

10.1.3.5 SUPPLY VOLTAGES AND FREQUENCIESThe compressor must be selected according to the voltage and frequency conditions where the cabinet will
operate in the field.

CAUTIONWARNING

Verify that the voltage fluctuations are within the admitted limits of the selectedcompressor (see Table 4.4). Voltage must be measured at the compressor electricalpins at the start and running at the max load conditions, see the safety advice at
Chapter 10.10.1.

Deviations of the supply voltage from the approved limits may impact the overload
protector actuation and damage the compressor and other parts. See Chapter
10.1.6.

10.1.3.6 AMBIENT TEMPERATURE
The ambient temperature surrounding the system strongly influences the compressor working conditions.
The system must be designed and tested in order to ensure that the compressor works (at normal andabnormal expected conditions in the field) within its admitted limits (see Chapter 11.6) at the max ambient
temperature where the system will be installed.
Compressors are intended for indoor use. External use can be accepted only when
installed on cabinets specifically designed for this type of use.
CAUTION

IMPORTANTWARNING50

See the admitted starting limits in the Table 11.6.2.

An ambient temperature higher than 5°C is required for proper compressor
starting and working, in order to have a correct lubrication. If ambient temperatureis around the above value or lower and refrigerant charge is approaching or
overcoming the maximum allowed limit, the use of a crankcase heater is required(see Chapter 10.3.4).

Deviations from the admitted working limits of the compressor may damage it or
shorten its life time.

10.1.3.7 COMPRESSOR COOLING TYPE
The cooling type (static and/or fan cooling) of each compressor model is indicated in the Embraco Productcatalogue on www.embraco.com• Static cooling: compressor does not require forced ventilation cooling andnatural air circulation can adequately cool the compressors to avoid overheating• Fan cooling: compressor requires the use of a fan cooler (normally inlettype) positioned in such a way that the air flows to the compressor sideways,
see Figure 10.1.3.7• Static and Fan Cooling: compressor is approved to be used either with forced
air ventilation or natural air circulation

CAUTION

The compressor overload protector may not trip, and may not protect thecompressor properly in case the air flows directly on it (see Chapter 10.1.6).

The fan cooler shall provide an air flow indicated in Table 10.1.3.7 and be installed according to the Figure 10.1.3.7.

WARNING

Deviations from the recommended fan position may overheat the compressors;in certain cases may impact the overlad protector actuations and demage thecompressor and other parts. See Chapter 10.1.6.

Table 10.1.3.7 Fan cooler characteristics
COMPRESSOR SERIESEM* – NE - NT

NJFree Air Flow (m³/h)

520

800

*For some EM models the air flow is 270 m3/h. For detailed information, check Embraco Product catalogue
on www.embraco.com

51

Figure 10.1.3.7 Fan motor positioning
Fan motor should be placed at 30 cm ± 1 cm from the compressor with air flow oriented to the lateral sideof the compressor according to the picture below:

WARNING

OLP must not be in direct contact with the forced air.

10.1.4 NOISE AND VIBRATIONSThe Embraco compressors are characterized by low noise emission, low vibration and pulsation; furthermore
the internal mounting spring and discharge loop are designed in order to reduce the transmission of thestarting/stop torque reaction to the mounting base and to the line tubes.
Embraco supplies mounting grommets (see Chapter 10.8) that further reduce the transmission of vibration
and reaction torque to the fixing points and tube of the system. Base plate of the cabinet must havesufficient mass and stiffness to further reduce transmission of residual vibrations.
Line tubes must be designed to support stresses without be damaged and to reduce transmission ofvibrations to the cabinet structure and should be sufficiently flexible on the 3 axis.
Vibration/pulsation/resonances
Gas pulsation depends on gas flow rate and pressure conditions: each refrigeration system, due to thespecific cabinet structure, tube design and layout, has its own reaction to the:•Gas pulsations in the discharge line.

•

Torque/vibrations acting on the compressor mountings.

•

Torque/vibrations acting on the suction and discharge tubes connections andpipes.

•

Possible resonances (with suction and discharge lines, compressor base plateand other structural elements) generated by the compressor and fan motor(s)running.

All the above elements must be considered in the system design in order to avoid abnormal noise andcomponent breakages; the system should be checked at its normal and expected worse working conditions(starting, running, Hot Gas Defrost, high load, max ambient temperature, low voltage supply, etc): in caseabnormal pulsations are detected, measures must be taken to avoid them (contact Embraco Technicalsupport team).
52

Eventually a discharge muffler or a dumper on the system tubes can be adopted: contact Embraco Technicalsupport team for support.
Mechanical resonances can lead to breakages of tubes and structural parts due tofatigue or to other resonance problems: this issue is particular critic when using
HCs refrigerants. Regulations like EN 378 and similar require resonance tests on
the system components.

CAUTION

Check carefully the entire application for abnormal vibrations/resonances at all possible working conditions
and adopt measure to eliminate them, contact Embraco Technical support team for assistance and corrective
actions.

10.1.5 MAXIMUM CONTINUOUS CURRENT (MCC)
The compressor does not have a fixed max input current value (it can be defined making reference to therequirements of certain safety institutes, like UL).

10.1.6 OVERLOAD PROTECTOR (OLP)
The compressors are protected against overheating by the overload protector. It can be external (fixed on
the compressor shell), or internal (mounted on the motor head, or on the internal pins of hermetic terminal).
The OLP detects unusual motor temperature rise and/or abnormal high current input. The OLP trip is
influenced by several factors - working conditions, suction gas density/ temperature, supply voltage, etc.

CAUTION

In certain cases (described below), the overload protector (OLP) may not function
as intended:•

Loss of refrigerant charge.

•

System working outside the admitted working limits (Chapter 11.6.1), mainly withtoo low evaporating pressure and high condensing pressure.

•

Voltage over the admitted limit (see Table 4.4), mainly with low load.

•

Fails to start (e.g. Due to a supply voltage too low or abnormal pressure) with cold
compressor: in this case the thermal inertia of the olp cannot follow the motor
temperature gradient (normally of the start wiring) and the motor or starting
capacitor may burn-out.

•

Electrical motor stall (e.g. Due to abnormal pressure or low voltage) especiallyafter the starting: in this case the starting relay will switch on/off repeatedly,
overheating the electrical motor and/or the starting capacitor before the olp has
the possibility to detect the temperature rise.

•

Improper air flow on the overload protector by the cooling fan improper installed(see Table 10.1.3.7 and Figure 10.1.3.7).

•

Usage of motor fan on a compressor approved for static cooling operations.

53

10.1.7 ELECTRICAL SUPPLY LINE AND CABINET SUPPLY CABLEWARNINGWARNINGThe electrical supply line of the finished product must be protected against overcurrent, short-circuit, short-to ground. A Residual-Current Circuit Breaker (RCCB)
must be adopted. Design, components and installation must comply with theapplicable National and International Standards and regulations. The compressor
must be properly connected to ground.
The cables of the cabinet and of the compressor must be designed for temperature,
due to ampere load, and for voltage drop (see Table 4.4) taking into consideration
the max input current of the finished product and the compressor LRA (Locked
Rotor Amp), indicated for each model in the Embraco Product catalogue on
www.embraco.com

In any case, the supply cable, as well as all other cabinet cables, must be designed and protected in order
to comply with the applicable International standards and regulation, as well the National Standards andregulations of the country where the system will operate.

WARNINGFor the compressor connection to the electrical supply line and for maintenance/
repairing operation, refer also to Appendix 1 - Recommandations - safety
instruction for compressor installation.

10.2 COMPRESSOR UNPACKINGCAUTION

Remove the compressor from the package keeping it in upright position. Failure
to maintain the compressor in an upright position can result oil entering into thesuction and process tubes, with consequent brazing problems. Oil may also enter
inside the suction muffler and when the compressor start after the refrigerant
charge the compressor suction/discharge valve may be damaged.
For the same reasons, the compressor must remain upright while assembling thegrommets and sleeves (see Chapter 10.8) to the cabinet base plate.

10.3 SYSTEM COMPONENTS
The proper selection of components, the adherence to the applicable regulations and standards, the adoptionof correct design criteria and complete set of tests of the prototypes, accurate production processes andquality control allow the manufactures to produce reliable and safe refrigeration systems.
Because of the vast differences between refrigeration systems and the various working conditions typicalof each application, the reliability of the equipment should be validated by appropriate life and field tests
before to launch the mass production.
All the above tests shall confirm that the compressors are used - under the most severe conditions expected
to occur in the field - within their admitted working range (see Table 11.6.1).

54

10.3.1 HUMIDITY AND CONTAMINANTS
Embraco adopts consistent production and quality processes in order to keep the contaminants (solids
particles and not condensable residuals) and the internal humidity of the compressors within the strict
admitted limits. Furthermore, in all production processes of Embraco external suppliers, all substances
non-compatible with the refrigerant to be used and with the oils charged in the compressors have been
eliminated. These included all chlorine based compounds.
Cleanness and reduced humidity level in all the components of the refrigeration system are the primaryconcerns for the compressor good running and life

IMPORTANT

Embraco recommends the use of system components (tubes, condensers,
evaporators, oil separators, liquid receivers, valves, capillaries, etc.) having
humidity, soluble, insoluble, solid residuals as written below; and free of Chlorine
based compound (and free of no ester based oils for the compressor using
Polyolester oil - POE) and in accordance with the standards like EN 12735 (Copperand copper alloys).

Soluble and insoluble residuals which are ascertained by washing with solvents may not exceed 100 mg/
m2 of the entire inner volume. Of this, a maximum of 40 mg/m2 of soluble and 60 mg/m2 of insoluble ispermited. Parts which inner surface is lower than 0,2 m2, follow Table 10.3.1a.
The practical size of residuals to be below the following values:•

For flitters: thickness < 10µm, size ≤ 0,5mm•

For particles: size ≤ 0,1mm

Table 10.3.1a Soluble and insoluble residual limits
INNER SIZE M2SUME OF SOLUBLE AND INSOLUBLERESIDUALS (mg)

≤ 0,1

15

0,1 – 0,15

20

0,15 – 0,2

25

Humidity limits for components of circuite may not exceed 50 mg of water per m2 of inner surface. Parts
which inner surface is lower than 0,2 m2, follow Table 10.3.1b.

Table 10.3.1b Humidity limits
INNER SURFACE M2

PERMISSIBLE HUMIDITY (mg)

≤ 0,1

≤5

0,1 – 0,15

≤ 12

0,15 – 0,2≤ 14

Note: Above mentioned limits are extracted from standard DIN8964, which was withdrawn, though it is the only
one standard related to this topic. Embraco recommendation is to allow max 50% of this specification.

55

Presence of solid or soluble conductive elements may result in damage of insulation
system of motor-compressor. In the worst case failure of hermetic terminal
insulation may happen and consequent leak of refrigerant is possible.

WARNING

Special care shall be taken for removal of any cleaning residua after condenser or evaporator cleaning process.
Any solution which contains sodium, potassium or similar may result in serious damage of motor-compressor(creation of conductive path on hermetic terminal glass insulation).

10.3.2 PIPING BASIC PRINCIPLES
The entire refrigeration system must ensure that the compressor work within the admitted limits indicatedin the Chapter 11.6.1.
The design and layout of refrigerant piping system and components should:•

Avoid excessive pressure drops (that reduce the energy efficiency and may
overheat the compressor).

•

Ensure the lubricant oil returning to the compressor, preventing oil traps in any
part of the system at the minimum load conditions.

•

Avoid liquid refrigerant or oil slugs entering into the compressor during startingand operating.

•Minimize the refrigerant charge.

10.3.2a EVAPORATOR AND CONDENSER
Their design and layout depend on the system types and characteristics.

10.3.2b LIQUID LINES - VALID ALSO FOR CLOSE COUPLEDREMOTE SYSTEMS
Max length 10 m. For longer length contact Embraco Technical support team.
Pressure drop should be low in order to avoid gas formation in the liquid line and/or insufficient liquidpressure at the expansion device. As reference, the pressure drop due to friction in the liquid line should be
not greater than that corresponding to about a 0.5 to 1 K change in saturation temperature.
Liquid subcooling is necessary to get liquid at the expansion device (with HCs the subcooling should be
minimized in order to reduce the refrigerant charge). With insufficient subcooling the refrigerant will flash in
the liquid line reducing the feeding of the evaporator, with drop of performance and efficiency.
The friction pressure drops caused by accessories - such as solenoid valves, filter driers - and the losses
equivalent of line risers should be accounted for in order to define the proper liquid line subcooling.
In case the line tube passes in hot ambient (with transmission of heat to the tube) its insulation may benecessary.

56

10.3.2c SUCTION LINES - VALID ALSO FOR CLOSE COUPLEDREMOTE SYSTEMS
Max length 10 m, with suction line upright max 3 m. For longer length contact Embraco Technical support team.
Suction lines should be designed to generate a minimum pressure drop at full load as well as ensure the oilreturning to the compressor under minimum load conditions.
Pressure drop in the suction line forces the compressor to work at lower pressure than the ones required by
the evaporator, reducing cooling capacity and efficiency,
As reference the suction line is normally sized to have a pressure drop from friction, lower than the equivalentof 1 K change in saturation temperature.

IMPORTANT

Excessive pressure drops in the high pressure side and low pressure side reduce
the energy efficiency of the system and force the compressor to work at higher
compressor ratio with higher mechanical stresses

The horizontal suction line should have an inclination of at least 3 % toward the compressor.

IMPORTANT

Suction line design criteria must ensure oil returning to the compressors when
the system is working at minimum (normal or abnormal) load. This will generatehigher pressure drop at full/maximum load.

In certain systems, the suction lines should be insulated to ensure cool suction gas to the compressor. Coldgas is necessary in order to help cooling the motor windings of the static cooled compressors, as well as the
fan cooled ones (even if properly ventilated by the fan).
In any case the insulation should not cause liquid return to the compressor.

For compressor admitted working range see Chapter 11.6.1.
IMPORTANTAt any working conditions, avoid excessive suction gas overheating, as well as the return of liquid refrigerant
to the compressor.

WARNING

Suction lines insulation will help to prevent sweating. In any case the suction line
must be positioned away from the compressor terminal board (and other electricaldevices) to avoid electrical short circuits, grounds and rusting/corrosions causedby spills of condensed water droplets.
For the same reason, tubes discharging the water from defrost must not lie above
the compressor terminal board, in order to avoid drops of condensation water on it.

57

10.3.3 EXPANSION DEVICES
10.3.3a CAPILLARY
For preparing a prototype of a new refrigeration system, refer to the capillary tube selection tables(Chapter 10.7) as a first reference. For each system, the optimal dimensioning of the capillary tube should
be determined by appropriate tests in the application labs, in order to optimize the working conditions,performance and energy consumption.
It is not recommended to use a capillary tube with an internal diameter lessthan 0.6 mm
IMPORTANT

10.3.3b THERMOSTATIC EXPANSION VALVE (TXV)
Proper TXV size is determined by the refrigeration load requirement, the pressure drop across the TXV, andthe evaporator temperature.
TXV must be sized and set in order to get the appropriate superheat, avoiding“hunting” (*) in the evaporator and liquid back to the compressor.
IMPORTANTFor accurate sizing and installation the instructions the TXV manufacturer should
be consulted.

(*) Hunting of TXVs is the alternate excessive-reduced flow of the refrigerant injected in the evaporator, withpossible liquid return to the compressor.

10.3.4 USE OF LIQUID SEPARATOR AND CRANKCASE HEATERIMPORTANTIn case the refrigerant charge exceed the max admitted by Embraco compressor(see Table 10.6.1.5) a liquid receiver with proper size should be installed on thesystem suction line. A compressor cranckase heater should also be installed, toavoid mixing of liquid/oil entering into the cylinder at the compressor start after
prolunged stops.

At the lowest ambient temperature foreseen for the application, the crankcase heater should maintain theoil temperature at least 15 K higher than the saturation temperature of the low pressure side.
In case of cabinets working in low ambient temperature, the compressor should be equipped with a crankcase
heater to keep the compressor temperature over + 5°C.
The krankase heater need an indipendent electrical supply line: it should be energized sufficiently in advance(4-6 hours may be required) in case the compressor has to start after long stop.
During normal on-off compressor cycle, the crankcase heater should be switched off. If the compressor has
long off cycles, the crankcase heater should be switched on after 20-30 minutes after compressor stops.
During prolonged off cycles the refrigerant migrates to the component having the lowest temperature
and an accumulation of liquid refrigerant may occur inside the compressor crankcase, with refrigerant/oil
mixture.

58

If the compressor starts in this condition and the system has a refrigerant charge higher that the maximum
value allowed (see Table 10.6.1.5), the diluted oil cannot properly lubricate the cinematic parts causing
accelerated wear or seizure.
Furthermore the sudden pressure drop inside the compressor after the starting will generate a “flashing” of
the refrigerant with oil foam and consequent abnormal oil pumping out of the compressor, valve damages
and cylinder head gasket blow can occur.

10.3.5 LEAK CONTROL
It is recommended special attention to the correct brazing of the systemcomponents to avoid the possibility of refrigerant leaks.
IMPORTANTTo check for leakages, use leak detector suitable for the specific refrigerant, witha sensitivity of less than 3 g/year.

10.3.6 HIGH PRESSURE CONTROLTo protect the system from discharge overpressure and damages to the compressor as well as safety
risks, it may be necessary to install a high pressure limit switch (pressostat), according to the refrigeration
system design and the applicable International and national regulations, to control the maximum dischargepressure. The settings on this switch should be in accordance with the limits established in Table 11.4 andthe reset after switch-off should be manual

CAUTION

Do not use the compressor to pressurize the system for controlling the pressostat
set-point.

10.3.7 COMPRESSORS WITH INTERNAL PRESSURE RELIEF
VALVE (IPR)
In order to prevent abnormal pressure at the cylinder head, (that may be generated by condenser fan block,or dirtiness on the condenser), the NT compressor series has models equipped with an IPR. These models
are indicated with the suffix “V” in their denomination code. For the available models see the Embraco
Product catalogue on www.embraco.com
Note: The IPR also prevents damages to the valves/gaskets in case of overpressure due to flooded start
consequent to a migration of refrigerant inside the compressor during the compressor stops (in any case thissituation must be avoided and if the refrigerant charge exceed the max admitted limit, the preventive actions
said at Chapter 10.3.4 must be adopted).
On certain applications the IPR may contribute to comply with the requirements of the fan block test as
requested by some safety standards.

59

If the overpressure (difference between discharge and suction pressure), is beyond the preset limit, the IPR
discharge the refrigerant from the high pressure side to the low pressure side, in the inside of the compressor
shell (it does not relief pressure (refrigerant) outside the system).
The IPR, once opened may remain active until the compressor will stop by OLP trip, and the pressures areequalized.
In case the IPR appears to have a leakage, stop the compressor and wait for thepressure to equalize. Repeat 3 times this operation and if the leakage persists
replace the compressor.

IMPORTANT

10.3.8 EMBRACO COMPRESSORS WITH OIL EQUALIZATIONTUBE FOR GEMINI (TWIN)
The NT and NJ compressors have versions with a tube connection for parallel applications (contact Embraco
Sales for details on the available models).
The use of parallel compressors may present some advantages vs. two compressors working on independentcircuits (i.e. cost reduction by using a single larger TXV) or vs. a single larger compressor with equivalentcooling capacity (energy saving by operating the on-off in sequence and reaching a part load efficiency
similar to the full load one; low starting current when the compressor start successively).
However it requires an accurate system design, which validity should be confirmed by a complete set oftests (*), in order to verify that the parallel system ensures the essential requisites for a reliable application:•

The oil return to both the compressors•

The operation of the compressors within their admitted limits(*) Suggested tests should include (but not limited to): cabinet rated conditions, starting, defrost (if applicable),high load, low load and running at the more severe conditions (normal and abnormal) expected in the field.

In addition to the Chapters 10.1 up to 10.3.7, the following points shall be considered:
Number of parallel compressors: Embraco suggests to use parallel systemwith 2 Gemini compressors. For systems with more parallel compressors contact
Embraco Technical support team for instructions.
Supply conditions: the Gemini compressors are only supplied as single
compressor provided with the connection port for parallel application, see
Figure 10.3.8.1.

60

Figure 10.3.8.1 Gemini compressor with connection port

Detailed view

Compressor mounting: the compressors must be mounted on the same baseplate in horizontal position and at the same height in order to assure the proper
oil level in both the compressors, see Figure 10.3.8.2.
Oil equalizer tube: its OD shall be the equivalent to the ID of the compressor
oil equalizer tube and lean horizontally. It must have sufficient 3 axis flexibility;
in this case the compressors can be assembled independently on their rubber
grommet. If the oil equalizer tube is rigid, it’s necessary that also the compressors
are connected rigidly, by screwing them directly on the base plate or rails. Thebase plate must lean on rubber grommets, the same used for the NJ or NT
compressors, see specification in Figure 10.8. 2. When is necessary to use a longoil equalizer tube (> 0.4 m) add to the system a quantity of oil equivalent to theinternal volume of the tube (for the oil type see the Embraco Product catalogue
on www.embraco.com
Suction lines: the entering of the compressor must be interconnected in orderto ensure a balanced pressure drop and an equal distribution of the oil to thetwo compressors. Small differences may generate critical oil level differences, see
Figure 10.3.8.2.
System piping connections: should be designed with sufficient three-dimension
flexibility.
Condenser fans: use a multifan condenser, with a fan motor for each compressor.
Each fan motor and compressor should start together.
Check valve: use check valve on discharge lines to avoid condensation of therefrigerant inside the compressor head during off-cycle.

CAUTION

The high pressure safety switch: shall stop both compressors. Eventual pumpdown switch should be set slightly higher than the low side safety pressure switch;also this last one shall stop both the compressors.

TXV: iin case of using a single evaporator systems the selection of the TXV needs to consider both the max
and min load (if the cooling capacity is controlled by step-running of the compressors). It should be selectedslightly lower than the max load in order to ensure a min of 5 K superheat at min load. Care for avoiding“hunting” when the system is working at min load. (see Chapter 10.3.3b).

61

The refrigerant charge: should be sufficient to avoid flashing before the TXV at max load. If refrigerant
charge exceeds the double of the max refrigerant charge allowed for each compressor (see Chapter
10.6.1.5), adopt the preventive measures indicated in Chapter 10.3.4.
Compressor start with delayed starting of one compressor:a) initial start after prolonged off period; the first compressor shall start at balanced
pressure within the limit of Table 11.6.2; the second ones at unbalanced pressures
taking care that the suction pressure (its corresponding temperature) is below thevalue of the Table 11.6.2 for the unbalanced starting.
b) normal on/off cycling or after defrost; the compressors shall start with unbalanced
pressure according to the Table 11.6.2.
Gemini compressors have admitted working range as the standard ones, indicated in Figure 11.6.1.

Figure 10.3.8.2 Compressor mounting and oil level indication

62

10.4 LIQUID LINE FILTER DRYER
The filter-drier type to be adopted depends on the refrigerant used in the system. The adsorbing capacity ofthe dryer should be selected according to the system internal volume, refrigerant charge and system initial
humidity content.

Table 10.4a Suggested filter dryer molecular sieves: 3 or 4 Angstrom
REFRIGERANT

MOLECULAR SIEVE

R134a

XH - 7 - 9 - 11

R600a - R290

XH - 5 - 6 - 7

R404A - R507A - R407C

XH - 9 - 11

Filter-dryer manufacturers offer a list of drier types and models, depending on theapplication: always consult the manufacturer for the proper selection of a filter dryer.

IMPORTANT

Note: Polyolesters have high miscibility with HFCs and HCs refrigerants and high lubrication/temperature
characteristics; however they differ from mineral oils or AB oils in some basic aspects:•

They are highly hygroscopic, adsorbing humidity much more rapidly thanmineral oils.

•

They have “polar” structure, meaning that dirtiness and wear materials willremain in suspension and circulate throughout the refrigeration system.

•

They may hydrolyze in the presence of water generating acids.

A filter-drier for refrigeration systems with polyolesters has to positively face these characteristics.
Considering the effect of residual humidity (see Table 10.4b) in the refrigeration system, the drier used oncompressors with POE should have excellent humidity adsorption and should be sized with capacity 15-20 %bigger than the filter-dryers used in mineral oil systems.
The filter dryer must be properly protected from adsorption of ambient humidity
during assembly of the system according to the following practices:
IMPORTANTIMPORTANT•The dryers should be assembled on the system and brazed immediately after
opening of the dryer’s plugs•

The filters supplied without protection caps, in “blister” or in “hermetic boxes” must
be duly protected to avoid humidity adsorption before brazing.
The level of humidity present in the refrigeration circuit with the refrigerant charge
should be below 40 ppm. After the system has been operating, the filter dryer
should remove humidity in order to ensure a level below 20 ppm.

A reduced adsorption capacity of the dryer can cause an incomplete water adsorption by the molecular sieve.
Therefore, the humidity could circulate freely in the system with the effects indicated in Table10.4b.
63

Table 10.4b Problems caused by humidity in the system
ICE BUILD-UP

Reduces the cross-sectional area of the capillary tube, or expansion valve, up
to their complete obstruction.

HUMIDITYCIRCULATION

Causes serious problems in the compressor and to the molecular sieve of thedryer. Typical marks and consequences are:• Copper plating of valve plate, valve reeds, crankshaft bearings, etc.
• Etching of electric motor insulation by acids, with burning of motor windings• Disintegration of molecular sieve and build-up of “dusts”• Wears and blocks alternative and rotating mechanical parts

OIL HYDROLYSIS

Causes acidification (evidences by change of oil color - brown). It will cause
build-up of sludge, with subsequent poor lubrication of compressor.

IMPORTANTTo prevent desiccant grains from abrasion, ensure liquid refrigerant at the inlet ofthe expansion device and a rapid pressure balance in case capillaries are used. The
dryer should be installed in vertical position, with refrigerant inlet from the top.

10.5 BRAZING PROCESS
Welders must be trained and qualified technicians and all applicable safety regulations and procedures must
be adopted
Do not allow the flame from the torch to reach the housing during the brazing of
the compressor tube in order to avoid overheating, damages to brazing of housingtubes, and oil carbonization on the compressor's internal shell wall.
Do not allow the flame from the torch to approach the "hermetic terminal (fusite)”
CAUTIONin order to avoid the cracking of the glass insulating material of the pins andsubsequent gas leaks (see possible consequences on Chapter 6.1.1).

IMPORTANT

To minimize any entry of contaminants and humidity, the compressor should
remain open no more than 15 minutes between the extraction of the tube rubber
plugs and the system tubes brazing.

Also the system components should remain sealed as long as possible before their assembly. The brazingof the components to the system should be carried out no later than 15 minutes after their assembling.
We suggest removing the rubber plugs from the tubes of the compressor (keep it in upright position) in thefollowing sequence: discharge tube, suction tube and service tube.
A different sequence can cause oil being carried out of the compressor by the internal pressurization withsubsequent brazing difficulties on the tubes and internal contamination due to oil residues.
The internal oiling of the tubes can generate dangerous smoke when brazing, make the brazing difficult, andintroduce contaminants into the system due to "oil cracking".

IMPORTANT

64

To avoid compressor breakdown, capillary or expansion valve orifice plug, blow
oxygen-free-dry-nitrogen (OFDN) at very low pressure through the system during
brazing. OFDN removes the air and prevents the formation of copper oxides in thebrazed parts. that later can be dragged throught the system and block the above
components.

10.6 REFRIGERANT USE GUIDE
Embraco compressor range includes models for HFCs R134a, R404A/R507A, R407C and HCs R600a, R290,
see details in the Embraco Product catalogue on www.embraco.com

10.6.1 GUIDE LINE FOR USE OF HFCS R134A, R404A AND R407C
All operations related to the use of refrigerants shall be performed only by trainedand qualified technicians and in accordance with applicable International andNational standards, laws and regulations related to this subject.

WARNING

Users must have available and understand the applicable HFCs Material Safety
Data Sheets (MSDSs).

WARNING

10.6.1.1 HFCS R134A, R404A, R407C GENERAL INFORMATION
Table 10.6.1.1 R134a, R404A and R407C characteristics
ACCORDING TO EN378

R134a

R404A

R407C

Chemical Name

1,1,1,2-tetrafluoroethane

Mixture R-125/143a/134a

Mixture R-32/125/134a

Molecular Formula

CH2FCF3

weight % (44/52/4)

Weight % (23/25/52)

Safety Class

A1

A1

A1

PED fluid group

2

2

2

Practical Limit [kg/m ]

0.25

0.52

0.31

ATEL/ODL [kg/m3]

0.21

0.52

0.29

LFL [kg/m ]NF (*)

NF (*)

NF (*)

Vapour density 25°C, 101.3 kPa [kg/m3]

4.17

3.99

3.53

Molecular Mass [g/mol]

102

97.6

86.2

Normal Boiling Point [°C]-26

– 46.5 to – 45.7

– 43.8 to – 36.7

ODP

0

0

0

GWP [100 yr ITH]

1430

3922

1774

Autoignition temperature [°C]

743

728

704

Critical Temperature [°C]

101.06

72.12

86.139Critical Pressure [kPa abs]

4059.33734,94639.4Temperature glide at 1 bar abs pressure [K]

-

0.75

7 (zeotropic blend)

3

3(*) NF signifies non-flammable
Note: HFC refrigerants are classified in Safety Class A1 - lower toxicity, no flame propagation, (according to ISO817).

65

10.6.1.2 SYSTEM COMPONENTS COMPATIBILITY
All refrigeration system components shall be compatible with the R134a, R404A, R407C respectively used
and the lubricant charged in the compressor. Substances containing chlorine, mineral oils, paraffin andsilicone are not allowed.
All equipment used in the refrigerator manufacturing process that require
lubrication and may come into contact with the refrigeration system components,
must use exclusively polyolester oil as a lubricant (suggested viscosity 18 - 20 cSt@ 40°C).
Particular attention must be given to the internal cleanliness of the system (seeIMPORTANT
Chapter 10.3.1), avoid entering into the system of any solid residues (dust, brazing
flux, metal particles, etc.), humidity and free of debris or any particles including
copper residues.

10.6.1.3 SYSTEM EVACUATION
Before charging, the system shall be tested for leaks (refer to applicable standards like EN378 or similar).

WARNINGCAUTION

If the leak test is made by pressurizing the system keep the pressure inside thecompressor below 16 bars (see Chapter 7.6).

Do not mix HFCs and air to control leaks in the system.
Contact the refrigerant supplier for detailed information.

Good refrigeration practice suggests system evacuation from both low side and high side, achieving a
residual absolute pressure level lower than of 0.14 mbar (14 Pa or 100 µHg), measured at its stabilization
on both the low and high pressure sides.
The residual non-condensable in the system should be less than 0.3% by volume of the refrigerant charged
into the system.
Adopt vacuum pumps suitable for use of the HFCs. They should be dedicatedto the specific refrigerant normally used (R134a, or R404A or R407C). Consult
the manufactures to learn procedures for using the same pump with different
refrigerants.
IMPORTANTWARNING66

To avoid damages to the compressor, never start or perform high voltage test undervacuum (without refrigerant charge). Always “break the vacuum” with refrigerant(at least with pressure equivalent to the saturation at -10°C) before applying
power to the compressor. If power is applied with the system under vacuum, withthe conductivity of the air at low pressure, an electrical discharge arc may trigger
between pins and shell of the compressor damaging the pins insulation glass. The
damage may be immediately evident at the first starting of the compressor orremain latent and appear after the system has operated for a certain time in thefield, with risk of fire, expecially with HCs refrigerants.

10.6.1.4 REFRIGERANT CHARGECAUTION

Avoid that liquid or gasous refrigerants from vessel under pressure come in contacts
with human body. Skin, eyes may be permanently damaged: use protective devices(gloves, glasses).

Refrigerant charge amount depends from the internal volume of the system, its design and working
conditions, from the type of refrigerants and safety limits.
For each system, the optimal refrigerant charge should be determined by appropriate labs tests in order to
optimize the working conditions and energy consumption.
Effort should be done to minimize the refrigerant charge.

IMPORTANT

Refrigerant should preferably be charged into the liquid line after the condenser.
In case the refrigerant is charged into the compressor(*), and the quantity isapproaching or exceeding the max admitted refrigerant charge (see Table 10.6.1.5)
connect the charging line to the compressor process tube and allow the refrigerant
entering at vapor state: when the refrigerant vapor reach a pressure equivalent tothe saturation pressure of 5 to 10°C, start the compressor and continue to charge
the refrigerant at vapor state until the final charge is reached.

(*) After charging refrigerant into the compressor, wait at least 5 minutes before starting the compressor, inorder to allow the evaporation of the refrigerant.

In case of different charging procedures, contact Embraco Technical support team for assistance.

Use a filter drier in the refrigerant charging line.

IMPORTANTIMPORTANTDo not exchange the use of the suction and service tube. Charging the refrigerant
through the suction tube may damage the intake muffler and cause abnormal
overpressure at the first system startup, with possible damage of the valves andhead gaskets.

Refrigerant blends (R404A, R507A, R407C) must be drowning off by the vessel inliquid state and the flow must be adjusted in order to obtain it in the vapor state at
the compressor process tube.

In case the refrigerant charging procedures of the OEMs cause liquid flood back (also evidenced by typicalnoise) or starting problems, contact Embraco Technical support team for assistance.
Adopt charging equipment suitable for use of the HFCs. It should be dedicated to the specific refrigerant
normally used (R134a, or R404A/R507A, or R407C). Consult the charging equipment manufactures to learn
if it must be reconverted in case more than one of these refrigerants are used with the same equipment.

67

10.6.1.5

EMBRACO COMPRESSOR MAX REFRIGERANT CHARGE

Embraco prescribe a technical limit of refrigerant charge of the systems according to below Table 10.6.1.5, for HFC
and HC refrigerants, which do not require special precautions at the compressor startup after a prolonged stop.

Table 10.6.1.5 Max refrigerant charge admitted in the Embraco compressors
SERIESEM

NE/VNE

NT

NJ

Max. refrigerant charge for HFC (g)

250

350

800

800

Max. refrigerant charge for HC (g)

150

250

400

500

From safety and reliability reasons, it is always recommended to minimize
the refrigerant charge as low as possible.

IMPORTANT

10.6.1.6 ALTERNATIVE REFRIGERANTS
Embraco performed extended testing program on different alternative refrigerants, and conclusions aredescribed below in Chapters 10.6.1.6.a and 10.6.1.6.b

Table 10.6.1.6 R452A, R449A, R448A, R513A and R450A characteristics
ACCORDING TO
EN378

R452A

R449A

R448A

R513A

R450A

Chemical Name

MixtureR32/R125/R1234yf

MixtureR32/R125/R1234yf/
R134a

MixtureR32/R125/R1234yf/
R134a/
R1234ze(E)MixtureR134a/R1234yf

MixtureR134a/R1234ze(E)Molecular Formulaweight % (11/59/30)

weight %(24.3/24.7/25.3/25.7)

weight %(26/26/20/21/7)

weight % (44/56)

weight % (42/58)

Safety Class

A1

A1

A1

A1

A1

PED fluid group

2

2

2

2

2

Practical Limit [kg/m3]

0.423

0.357

0.388

0.319

0.319

ATEL/ODL [kg/m3]

0.423

0.357

0.388

0.319

0.345

LFL [kg/m3]

NF (*)

NF (*)

NF (*)

NF (*)

NF (*)

Vapour density 25°C,
101.3 kPa [kg/m3]

4.30

3.62

3.58

4.256

4.54

Molecular Mass [g/mol]

103.51

87.21

86.28

108.4

108.67

Normal Boiling Point-47 to -43.2-46 to -39.9-45.9 to -39.8-29.05-23.4 to -22.8

ODP

0

0

0

0

0

GWP [100 yr ITH]

2140

1397

1387

631.4

604.7

Autoignition
temperature [°C]

ND

ND

ND

ND

ND

Critical Temperature [°C]

74.9

81.5

83.7

96.5

104.4

Critical Pressure

4001.7

4447

4660

3766

3820

Temperature glide at
1 bar abs pressure [K]

3.8

6.1

6.3

0.1

0.8

[°C]

[kPa abs](*) NF signifes non-flammable.

Note: HFC refrigerants (R452A, R449A, R448A, R513A and R450A) are classified in Safety Class A1 - lower
toxicity, no flame propagation, (according to ISO817).
6810.6.1.6a R404A
R452A is presenting the same or lower thermal profile when compared with R404A. Therefore, Embraco
approves R452A as an alternative refrigerant for all Embraco R404A compressor series and autorize its use, bothin LBP and MBP applications, maintaining the same operating envelope of R404A refrigerant and other Embraco
application guidelines as for example the system charge limitations defined for each Embraco compressor family.
R448A and R449A testing indicate relatively higher temperature level then R404A. Usage of thoserefrigerants may require system changes such as, system condensing temperature reduction (larger
condenser, improved ventilation) or return gas temperature reduction in order to achieve a similar thermal
profile as with refrigerant R404A. To maintain Embraco warranty, final application needs to be validated by
Embraco Technical Support Team case by case. Usage in systems operating under high compression ratio
conditions in particular should be avoided.

10.6.1.6b R134a
Embraco approves R513A as well as R450A as an alternative refrigerants for Embraco R134a compressors
and authorize its use, both in LBP and HBP applications, maintaining the same operating envelope of R134a
refrigerant and other Embraco application guidelines as for example the system charge limitations definedfor each Embraco compressor family.
Refrigerant R513A, according to the calorimetric evaluation is showing no impact on cooling capacity while
refrigerant R450A is showing drop of cooling capacity about 12% in average, when tested at calorimeter.
Actual impact on performances has to be verified on specific application. Embraco R134a compressors,
using R450A and R513A, are maintaining the same electrical components and are showing the same
reliability as with R134a refrigerant.

10.6.2 GUIDE FOR THE USE OF HCs REFRIGERANTS
R600a AND R290 - SAFETY WARNINGSWARNINGThe R600a and R290 are hydrocarbon (HCs) refrigerants. Their flammability
and other different characteristics versus other refrigerants (HFCs, HCFCs) must
be considered for the entire cycle of the applications (from design to disposal),including production and repairing work places, installation, servicing.

Embraco recommends to the HCs equipment producers, installers, repairs to carry out a complete risk assessment
considering all the elements and components related to the use of HCs refrigerants, including the production/
repairing/testing workplaces, storage of finished systems, installation in the field, use, repairing and disposal andto adopt all the actions to minimize the risks. The potential explosive ambient where the system are produced
or repaired must be properly ventilated, free from ignition sources and equipped with leak detectors. All theequipments must comply with the safety requirements of flammable refrigerants.
Therefore:
A complete risk assessment of the use of HCs refrigerants must be carried out considering all the above
points when Embraco compressor is applied on the refrigerating equipment.
The use of HCs refrigerants in refrigeration is actually regulated by international/regional/national safety
standards as product family standards, especially IEC/EN/UL 60335-2-24, -2-40, -2-89 or by horizontal
generic standard, especially EN378, ISO5149, ASHRAE 15. Above mentioned standards fixes charge limits
according to the application design, location where it is installed and public accessibility.

69

Please note, that product family standards dealing with the safety of refrigerating systems takes precedence
over horizontal and generic standards covering the same subject. International, regional and national
standards can be overruled by local rules (like building codes, ministerial decree, fire marshal or otherlocal authorities’ decisions, etc) that apply to potential explosive atmospheres, must be followed. Whileusing equipment with Embraco hydrocarbon compressors (R290 and R600a) you should comply with all thestandards and codes from your jurisdiction.
Embraco requires that only competent technicians trained on the safe use of
HCs are allowed to intervene on systems where is required the opening of therefrigeration circuit.
WARNING

Technicians using HCs must have available and know the meaning of the applicable
Material Safety Data Sheets (MSDSs) and act accordingly.

10.6.2.1 HCs R600a AND R290 GENERAL INFORMATION
Table 10.6.2.1 R600a and R290 characteristics
ACCORDING TO EN378

R600a

R290

Chemical Name

Isobutane (2-methylpropane)

PropaneMolecular Formula

C4H10

C3H8

Safety Class (1)A3A3

PED fluid group1

1

Practical Limit [kg/m3] (2)

0.011

0.008

ATEL/ODL [kg/m3]

0.059

0.09

LFL [kg/m3]

0.043

0.038

Vapour density 25°C, 101.3 kPa [kg/m3]

2.38

1.8

Molecular Mass [g/mol]

58.1

44.0

Normal Boiling Point [°C]

-12

-42

ODP

0

0

GWP [100 yr ITH]

3

3

Autoignition temperature [°C]

460

470

Critical Temperature [°C]134.66

96.74

Critical Pressure [kPa abs]

3629

4251.2(1) Highly flammable substances are defined by a lower flammability limit of less than or equal to 0.10 kg/
m3 at 21°C and 101 kPa or a heat of combustion greater than or equal to 19 kJ/kg; (according to ISO817,
classified in Safety Class A3 – lower toxicity, higher flammability).
(2) Practical limit according to EN 378-1: it is used if the HC refrigerant of the system can leak into an
occupied ambient.
70

10.6.2.2 R600a AND R290 PURITY
Use refrigerant with technical grade 99.5 % per weight purity (test method SYNTH-GC). For the remaining
0.5 % refer to ISO817 or equivalent standards. However sulfur should be < 1ppm wt (SYNTH-TS), water <10 ppm wt (SYNTH-TU) and unsaturated hydrocarbons < 250 ppm V (SYNTH-GC).

10.6.2.3 EMBRACO R600a AND R290 IDENTIFICATION ANDWARNING SYMBOLSThe Embraco compressors for R600a and R290 have on the nameplate label - or as separate label - a
warning symbol for flammable substances, even if they do not contain any refrigerants when delivered from
Embraco factories.

Figure 10.6.2.3 Warning symbol

The refrigerant to be used is printed on the compressor label, also the compressor model includes a code
identifying the refrigerant to be used (see Chapter 5.2).
The R600a and R290 Embraco compressors are certificated by recognized testing agencies (with IEC/EN 603352-34) and adopt overload protectors and starting relay complying with the relevant requirements of EN 60079-15.
However Embraco cannot guarantee that the compliance with the applicable standards eliminates all thepossible risk of fire.

10.6.2.4 SAFETY WARNINGSWARNINGThe Embraco R600a and R290 compressors are only allowed to be installed on
cabinets fulfilling the requirements for the safe use of flammable refrigerants (like theEN60335-2-24 / 89 for cabinets with less than 150 g for each separated refrigeration
circuit) and intended to obtain the approvals from certification bodies.

For systems with the limit of 150g for each separated refrigeration circuit there are no restrictions in room
size and occupancy category, however they must be located in ambient having minimal volume to ensure
the practical limit (see Table 10.6.2.1) is not exceeded.
Refrigerant charge higher than 150g may be used provided all the applicable regulations and standards(like EN 378 or similar) are respected as well as safety regulations locally applied. These regulations include
restriction in room size and occupancy category.
In case of use of refrigerant charge higher than 150g, consult with Embraco Technical support team.
Embraco recommend to the HCs equipment producers, installers, repairs to carry out a complete risk
assessment considering all the elements and components related to the use of HCs refrigerants, including
the production/repairing/testing workplaces, storage of finished systems, installation in the field, use,
repairing and disposal and to adopt all the actions to minimize the risks.
71

The potential explosive ambient where the system are produced or repaired must
be properly ventilated, free from ignition sources and equipped with leak detectors.
WARNINGAll the equipments must comply with the safety requirements of flammable
refrigerants.

10.6.2.5 SYSTEM COMPONENTS COMPATIBILITY
All refrigeration system components shall be compatible with the refrigerant R600a or R290 respectively
used and the lubricant charged in the compressor as indicated in the Embraco Product catalogue on
www.embraco.com. Compatibility data can be obtained from the refrigerant suppliers. Substances
containing chlorine and silicone are not allowed

10.6.2.6 EXPANSION DEVICES
Capillary tubes:
Generally, when changing a system from R134a to R600a ones, for preliminary capillary selection the same
capillary sizing can be adopted. The same criterion is valid also when changing from R404A to R290 (practicalexperience have demonstrated when changing from R404A to R290, is preferable a length increase ofaproximately 10 %). See Chapter 10.7.
For preparing a prototype of a new refrigeration system, the capillary tube selection tables (Chapter 10.7)
based on practical experience, can be considered as a first reference.
For each system, the optimal dimensioning of the capillary tube should be determined by appropriate tests
in the application labs, in order to optimize the working conditions, performance and energy consumption
and to minimize the refrigerant charge and ensuring that the compressor works within its admitted limits.
It is not recommended to use a capillary tube with an internal diameter lower than 0.6 mm.
Thermostatic expansion valve:
Thermostatic valve manufactures have available products for R290 (normally R600a is adopted in small
systems that don’t use TXV). Contact them for guide for the valve selection and instructions for theapplications.

10.6.2.7 LIQUID AND SUCTION LINE TUBES
When designing refrigerant lines, specific hydrocarbon refrigerant pipe sizing literature should be examined.
The criteria indicated on Chapter 10.3.2 may only represent a first reference. Normally the line tubes of HCs
system have smaller inner diameter to minimize the refrigerant charge; the specific volume and ability ofcarrying the oil back to the compressor are different than HFCs and need to be considered.

72

10.6.2.8 EVAPORATORS AND CONDENSERS
The evaporator and condenser used for R134a and R404A may represent only an initial reference respectively
for R600a and R290, as thermodynamic and oil transport property are different and design valid for otherrefrigerants are not directly applicable.

The evaporator internal design may need revision due to the different thermodynamic characteristics,
volume flow and oil transport of R600a and R290 vs R134a and R404A respectively. It is necessary to verify
that the refrigerant flow velocity assures the oil return to the compressor.

There may have regions in multiple channels or even single channel circuitsthat may tend to trap oil.
IMPORTANTWARNING

Eventual liquid accumulator requires a careful design. R600a and R290 are lighter
than the oil used in the compressors (R134a and R404A are heavier) and the oil
can be trapped in the liquid accumulator if it is not properly designed. This applies
also to the “cells” accumulators at the end of the roll-bond evaporators.

With R290, the design of the Al roll-bond evaporator shall take into consideration
the high burst pressure required by the safety standards.

10.6.2.9 WATER TRAY

IMPORTANTDue to the low isentropic coefficients of R600a and R290 and to the high efficiency
solution of the Embraco compressors, the compressor shell and discharge
temperature with these refrigerants are lower than the ones using HFCs (seeTable 11.4). Therefore it will be necessary to check the consequent evaporative
effect of the water tray eventually installed on the compressor shell or in thecabinet base plate, adopting the necessary modifications.

10.6.2.10 FILTER DRYER
Refrigerants R600a and R290 require the use of a normal filter dryer, see Chapter 10.4.
Always consult the manufacturer for the proper selection of the filter dryer.

73

10.6.2.11 SYSTEM COMPONENTS BRAZINGSpecial attention must be dedicated when performing the brazing, or otherforms of union of the system components, to avoid the possibility of flammable
refrigerant leaks.
For brazing procedure refer to Chapter 10.5.
WARNINGUse of brazing torches is allowed only on new cabinets before the refrigerant ischarged into the system. After charging, the service tube should be sealed withlock-ring or ultrasonic brazing apparatus

10.6.2.12 SYSTEM EVACUATION
Generally the vacuum level for an R600a and R290 systems is the same used for a system with R134a andR404A (see Chapter 10.6.1.3).

IMPORTANTGood refrigeration practice suggests evacuation from both low side and high side
and achieving a minimum level of 0.14 mbar (14 Pa or 100 µHg), with a noncondensable residual value of less than 0.3% by volume. Due to the small pressure
difference between inlet-outlet of the expansion devices of R600a systems,
performance/noise are more adversely influenced by high non condensable
residual than systems using other higher pressure refrigerants.

Vacuum pump (that may be used on systems that has been repaired after the refrigerant charge) shall besuitable for safety use on systems using HCs, consult the producers for detailed information.
Never start compressor under vacuum, see Chapter 10.6.1.3.
WARNING

10.6.2.13 REFRIGERANT CHARGE
Test carefully the system for leakages before charging the refrigerant.
IMPORTANT

Leak detection with Helium is recommended.

If the leak test is made by pressurizing the system keep the pressure insidethe
compressor below 16 bar (see Chapter 7.6).

WARNING

74

Higher pressure may deform the compressor shell and terminal pin holders andlead to eventual cracks on the insulation glass with refrigerant leaks and possible
grounding of the pins. This will generate flame/explosion especially in case of HCs
refrigerant are used.

Generally the quantity of the refrigerant R600a or R290 charged into the systems can be reduced from 40– 50 % compared to the required charge of R134a or R404A respectively.
For each system, the optimal refrigerant charge should be determined by appropriate lab tests in order toobtain the best working conditions and minimum energy consumption.
Efforts should be done to minimize the refrigerant charge in order to reduce the risk of flammability and its
consequences, see Safety warnings in Chapter 10.6.2.4.

IMPORTANTIMPORTANTCAUTION

Do not exchange the use of the suction and service tube. Charging the refrigerant
through the suction tube may damage the intake muffler and cause abnormal
overpressure at the system startup, with possible damages of the valves andgaskets, see Chapter 10.6.1.4.

R600a and R290 are single component fluids and can be charged into the systems
either in the liquid or vapor state. After charging refrigerant into the compressor,
wait at least 5 minutes before starting the compressor, in order to allow theevaporation of the refrigerant.
Use charging equipment suitable for use in potential explosive ambient (ATEX
approved or similar) for the refrigerant R600a and R290. Contact the producers fordetails information and instructions.

10.6.2.14 MAXIMUM REFRIGERANT CHARGEWARNING

IMPORTANT

Provided that all the applicable regulations and standards are respected, in casethe refrigerant charge of the system exceeds 150 g, see Table 10.6.1.5 and theprecaution of Chapter 10.3.4.

Due to the relative small amount of the HCs refrigerant charge and the influenceof its variation on the application performance and energy consumption, it isrecommended to measure the refrigerant charge with the needed accuracy(normally 1%).

10.6.2.15 LEAK CONTROLFor checks after refrigerant charging, use a leak detector designed for refrigerants R600a and R290.
Contact the apparatus producers for detailed information and instructions

CAUTIONDue to the risk related to leaks of flammable refrigerants and the impact on
performance for the small amount of the refrigerant charge, the leak detectors
should have a sensitivity of less than 3 g/year.

75

10.7 CAPILLARY TUBES SIZE
During the initial steps of the design of a new cabinet, tables of Chapter 10.7.1 (a-g) can provide guidance
for starting with the selection of the appropriate capillary tube dimensions.
They represent capillaries adopted in practical on systems performing properly and requiring a cooling
capacity indicated on the below tables, corresponding to the Embraco compressor rated cooling capacity,
for the various refrigerants and applications.

IMPORTANTThe exact size of the capillary must however be determinated according to theresults of laboratory tests performed on prototype cabinets. For this reason thecapillary here indicated are classified as “suggested capillary for preliminary
selection”.

The capillary sizing indicated on Tables 10.7.1 (a-g) refers to cabinets adopting a suction line heat exchangerof minimum length 0.9 m and with 0°C sub-cooling, working within the indicated range of evaporating
temperature.

10.7.1 SUGGESTED CAPILLARY FOR PRELIMINARY SELECTION
Table 10.7.1a R600a LBP applications
Compressor
Rated cooling capacity(W)

Dimension I.D. (mm) x length (m)CECOMAFASHRAE (*)

ARI 540(2004) (*)

Evaporating
temperature-30°C to -20°C

Evaporating
temperature-20°C to -5°C

40 - 60

60 - 80

50 - 70

0.66 x 4.00

0.66 x 3.45

60 - 75

80 - 105

70 - 900.78 x 3.50

0.78 x 3.10

75 - 100

105 - 140

90 - 120

0.78 x 3.20

0.91 x 3.20

100 - 125

140 - 175

120 - 150

0.78 x 3.00

0.91 x 3.00

125 - 150

175 - 210

150 - 180

0.78 x 2.70

0.91 x 2.60

150 - 180

210 - 250

180 - 215

0.91 x 3.60

1.06 x 3.60(*): Approximate equivalent cooling capacity to the Cecomaf.

76

Table 10.7.1b R600a HBP applications
Compressor
Rated cooling capacity(W)

Dimension I.D. (mm) x length (m)EN12900 (*)

ASHRAEARI 540(2004) (*)

250 - 300

275 – 350

250 - 320

Evaporating
temperature-15°C to -5°C

Evaporating
temperature-5°C to +10°C

0.78 x 2.50

0.91 x 2.40

0.78 x 2.10

0.91 x 2.00

300 - 400

350 – 450

320 - 400

0.78 x 2.40

0.91 x 2.30

400 - 500

450 – 570

400 - 520

0.78 x 2.30

0.91 x 2.20

500 - 650

570 – 750

520 - 675

0.91 x 2.90

1.06 x 2.70

650 - 750

750 – 850

675 - 775

0.91 x 2.40

1.06 x 2.50

750 - 900

850 – 1000

775 - 900

1.06 x 3.20

1.27 x 3.30(*): Approximate equivalent cooling capacity to the Ashrae HBPTable 10.7.1c R134a LBP applications
Compressor
Rated cooling capacity(W)

Dimension I.D. (mm) x length (m)EN12900 (*)

ASHRAEARI 540(2004) (*)

Evaporating
temperature-35°C to -20°C

Evaporating
temperature-20°C to -5°C

35 - 45

70 – 90

60 - 75

0.61 x 4.00

0.61 x 3.50

45 - 55

90 – 120

75 - 95

0.78 x 4.00

0.91 x 4.00

55 - 65

110 – 130

95 - 1100.78 x 3.70

0.91 x 3.70

65 - 80

130 – 160

110 - 135

0.78 x 3.50

0.91 x 3.50

80 - 95

160 – 190

135 - 160

0.78 x 3.30

0.91 x 3.30

95 - 110

190 – 220

160 - 190

0.91 x 4.00

1.06 x 4.00

110 - 150

220 – 300

190 - 255

0.91 x 3.30

1.06 x 3.30

150 - 200

300 – 400

255 - 350

0.91 x 2.90

1.06 x 3.00

200 - 250

400 – 500

350 - 425

1.06 x 3.25

1.06 x 2.50

250 - 345

500 – 680

425 - 610

1.06 x 3.00

1.20 x 3.50(*): Approximate equivalent cooling capacity to the EN12900

77

Table 10.7.1d R134a HBP Applications
Compressor
Rated cooling capacity(W)

Dimension I.D. (mm) x length (m)EN12900 (*)

ASHRAEARI 540(2004) (*)

250 - 300

275 – 350

250 - 320

Evaporating
temperature-15°C to -5°C

Evaporating
temperature-5°C to +10°C

0.78 x 2.50

0.91 x 2.40

0.78 x 2.10

0.91 x 2.00

300 - 400

350 – 450

320 - 400

0.78 x 2.40

0.91 x 2.30

400 - 500

450 – 570

400 - 520

0.78 x 2.30

0.91 x 2.20

500 - 650

570 – 750

520 - 675

0.91 x 2.90

1.06 x 2.70

650 - 750

750 – 850

675 - 775

0.91 x 2.40

1.06 x 2.50

750 - 900

850 – 1000

775 - 900

1.06 x 3.20

1.27 x 3.30

900 - 1200

1000 - 1350

900 - 1250

1.24 x 4.00

1.37 x 3.30

1200 - 1500

1350 - 1700

1250 - 1550

1.37 x 3.50

1.50 x 3.30

1500 - 2000

1700 - 2300

1550 - 2100

1.37 x 3.10

1.50 x 2.90

2000 - 2500

2300 - 2850

2100 - 2600

1.63 x 3.60

1.78 x 3.30

2500 - 3000

2850 - 3500

2600 - 3200

2x1.50 x 4.00

2x1.63 x 3.00(*): Approximate equivalent cooling capacity to the Ashrae HBPTable 10.7.1e R290 (**) - R404A - R507A LBP applications
Compressor
Rated cooling capacity(W)

Dimension I.D. (mm) x length (m)EN12900 (*)

AshraeARI 540(2004) (*)

Evaporating
temperature-40°C to -20°C

Evaporating
temperature-20°C to -10°C

120 - 145

230 - 280

170 - 210

0.78 x 3.80

0.78 x 2.70

150 - 185

280 - 355

210 - 2650.91 x 4.00

0.91 x 2.80

185 - 260

335 - 500

250 - 375

0.91 x 3.10

0.91 x 2.20

260 - 340

500 - 650

375 - 480

0.91 x 2.70

1.20 x 2.80

340 - 390

650 - 750

480 - 560

1.20 x 3.40

1.20 x 2.50

390 - 470

750 - 900

560 - 675

1.20 x 3.10

1.20 x 2.20

470 - 550

900 - 1050

675 - 800

1.20 x 2.90

1.40 x 3.00

550 - 640

1050 - 1400

800 - 1050

1.40 x 3.50

1.40 x 2.60

730 - 900

1400 - 1750

1050 - 1300

1.60 x 3.50

1.60 x 2.70(*): practical experience have demonstrated when changing from R404A to R290, is preferable a length increaseof aprox 10 %(**): Approximate equivalent cooling capacity to the Ashrae LBP

78

Table 10.7.1f R290 (**) – R404A – R507A – R407C M/HBP application
Compressor
Rated cooling capacity(W)

Dimension I.D. (mm) x length (m)Ashrae

EN12900MBP(**)

ARI 540 MBP(**)

Evaporating
temperature-20°C to -5°C

Evaporating
temperature-5°C to +10°C

650 - 750

350 - 400

350 - 400

1.06 x 3.30

1.06 x 2.80

750 - 850

400 - 450

400 - 450

1.06 x 3.10

1.06 x 2.55

850 - 1000

450 - 550

450 - 550

1.06 x 2.80

1.20 x 3.30

1000 - 1200

550 - 650

550 - 650

1.20 x 3.00

1.20 x 2.35

1200 - 1600

650 - 850

650 - 850

1.20 x 2.75

1.27 x 2.45

1600 - 2000

850 - 1050

850 - 1050

1.27 x 2.55

1.27 x 1.80

2000 - 2400

1050 - 1250

1050 - 1250

1.27 x 2.15

1.27 x 1.50

2400 - 2800

1250 - 1500

1250 - 1500

1.37 x 1.90

1.37 x 1.50

2800 - 3300

1500 - 1750

1500 - 1750

1.63 x 2.75

1.63 x 1.60

3300 - 3800

1750 - 2000

1750 - 2000

1.90 x 2.65

2.16 x 2.05

3800 - 4500

2000 - 2400

2000 - 2400

2.16 x 2.45

2x1.63 x 1.70

4500 - 5700

2400 - 4200

2400 - 4200

2.16 x 1.90

2x2.16 x 2.35(*): practical experience have demonstrated when changing from R404A to R290, is preferable a length increaseof aprox 10 %(**): Approximate equivalent cooling capacity to the Ashrae M/HBP
Note: Compressor test conditions see in Table 5.5

7910.8 RUBBER GROMMETS AND SLEEVES
Alternating forces of first order, such as rotating masses and masses having rectilinear alternating motion,
are duly balanced inside the compressor. Inertial alternating forces of greater order are not balanced;
however, they are partially absorbed by internal suspension springs and by the rubber grommets, whencorrectly applied to the external mounting base. The rubber grommets and the sleeves have been selected
in order to guarantee the following characteristics:•

Reduction of vibrations transmission of more than 50%.

•

Partial adsorption of inertial, tangential forces and relative moments, particularly
noticeable at compressor start and stop.

The components of this external suspension system are supplied partly by Embraco (rubber grommets andsleeves) while the remaining components for their blocking - screws, washers and nuts (or suitable alternate
systems), must be sourced by the customer.

As an alternative solution to grommets and sleeves Embraco compressrs may be supplied with
“Snap-on” fixation (rubber grommet, pin and clamp), see Figure 10.8.1 – Pin and clamp. The components ofthis external fixation are fully supplied by Embraco.

IMPORTANT

It is very important that these components are assembled correctly in orderto guarantee, as indicated in Figure 10.8.1 – A Correct mounting, the proper
clearance between the rubber grommet and flat washer, fixed between nut andsleeve – version with screw and nut.

This clearance, avoiding an abnormal compression of the rubber grommet (Figure 10.8.1 – B Incorrect
mounting), allows the proper damping of the vibrations transmitted by the compressor.

For each compressor serie, a rubber grommet has been defined to be coupled to the relative sleeve or pin
with clamp as indicated in Figure 10.8.2.
The use of grommets and sleeves different from the ones designated may increase the transmission ofvibrations, resulting in noise increase.

IMPORTANT80

The compressor must be maintained in vertical position during the production
process of the finished cabinet, including the mounting of the grommets andsleeves (see Chapter 10.2).

10.8.1 RUBBER GROMMETS ASSEMBLY
Figure 10.8.1 Rubber grommets assembling scheme
A - CORRECT MOUNTING
Screw and Nut

Pin and Clamp (Snap-on fixing)

B – INCORRECT MOUNTING

LEGENDA

WasherF

Cabinet base plate

B

Free Gap (app. 1mm)

G

Clamp

C

SleeveH

Screw M6 (M8)D

GrommetI

PinE

Compressor mounting base

J

Nut

10.8.2 RUBBER GROMMETS/SLEEVES DIMENSION
Table 10.8.2 Rubber grommets/sleeves dimensions
CODE

A

B

C

D

E

F

AM01

17.2

9

6.6

16.5

4.9

3

AM02

16.6

11.1

8.7

16.5

AM03

18.3

11.1

8.7

17.5

AM05

23

11.1

8.7

23

9.4

3.2

AM06

23.5

7.5

16.5

4.9

3

G

H

L

M

N

P

Q

10.3

3

20.5

16

10.5

8.5

10.3

3

23.8

17.5

11.1

4.7

9.5

4

23.3

19

11.1

3.2

15

4

23.8

19

14.3

10.6

10.3

3

20.5

16

10.5

8.5

R

S

T

17

25
28.6

17.5
19

31.8
23.5

31.7

17

25

81

Figure 10.8.2 Rubber grommets and sleeves
SERIE
AM01

22210112222018AM022221001

2222014AM032221003

2222015AM05

2221004

2222016AM06

22210112037140

EM, NE(with
Europeanbase plate)NE(nonstandard)

NE(withUniversal
base plate)NT, NJ

Snap-on
EM, NE(with
Europeanbase plate)82

10.9 ROTOLOCK VALVESFor NJ and NT series compressors, upon customer's request, can be supplied a special version having, inplace of the suction tube, a threaded union brazed on the cover of the housing, suitable for fixing a Rotolock
suction valve.
A cap screwed on the union guarantees its protection and the internal pressurization of the compressor. This
special version can be supplied in two ways:•

Compressor with union for valve, without supplying the Rotolock valve•

Compressor with union for valve, supplying also unassembled Rotolock valve,equipped with the appropriate sealing gasket

The threading of the union of 1" - 14 NS-2 accepts Rotolock valves with different dimensions according to
the compressor type, as indicated in the Embraco Product catalogue on www.embraco.com
The assembly of the valve on the compressor union must be done by inserting the gasket on its seat on the union,
after dampening both with light oil film (of the same type charged into the compressor). The valve nut should betightened to the torque indicated in the Table 10.9.1. The valve can be oriented, as necessary, within 360°.

Use a new gasket seal in case of replacement of the Rotolock valve.
IMPORTANT

10.9.1 ROTOLOCK TIGHTENING TORQUES
Table 10.9.1 Recommended tightening torques for In/Out valves
Component
legendComponent name1

Spindle2

Process or Manometer port

1/4”

7 – 11.5

3

Pressostat port

1/4”

7 – 11.5

4

Rotolock connection1” – 14UNS

67 – 82

5

Inlet/Outlet connection for customer

6

Nut

1/4”

14.5 – 17.5

6

Nut

3/8”

21.5 – 26.5

6

Nut

1/2”

33.2 – 38.7

6

Nut

5/8”

43.1 – 47.0

IMPORTANT

Dimension

Torque specification (Nm)
10 – 12The opening and closing of valve spindle can be effected with electric or pneumatic
drivers having a speed lower than 360 rpm. Higher speed damages the spindle andvalve body tightness seats.

83

Figure 10.9.1 Rotolock valve types
2-way valve 1/2”
with mechanical connection

2-way valve 5/8”
mechanical connection

3-way valve 5/8”
with soldered connection

The Rotolock valve can be supplied for mechanical connection (flared and nut) or for soldered connections to
the line tubes, as indicated in Figure 10.9.1.
For the soldered version, in order to avoid overheating during brazing, which candamage the gasket, we recommend to effect the brazing before applying thegasket, and than connect the valve to the compressor. It is a good practice to keep
the brazing time to a minimum in order to not overheat the spindle tightness, even
if it is produced with material resistant to high temperatures. For other brazing
information see Chapter 10.5.

IMPORTANT

10.9.2 VALVE SYSTEM POSITION

Figure 10.9.2 Valves position

6

5

4

3

2

SPINDLE MIDDLE POSITION:
All open

1

SPINDLE BACK POSITION:
Process port closed

SPINDLE FRONT POSITION:
Customer inlet/outlet connection closed

TORQUE SPECIFICATIONS:
1SPINDLE

10 - 12 Nm

2

PROCESS OR MANOMETER PORT 1/4" SAE

7 - 11.5 Nm

3PRESSOSTAT PORT 1/4" SAE

7 - 11.5 Nm

4

ROTOLOCK CONNECTION 1" - 14UNS

67 - 82 Nm

5

INLET/OUTLET CONNECTION FOR CUSTOMER

6

NUT 1/4"

14.5 - 17.5 Nm

6

NUT 3/8"

21.5 - 26.5 Nm

6

NUT 1/2"

33.2 - 38.7 Nm

6

NUT 5/8"

43.1 - 47.0 Nm

Note: the port for the connection with the pressostat may never be closed.

CAUTION84

Do not install a system and leave it unattended with the service valves closed.
This will prevent from people accidentally operating the system and potentiallydamaging the compressor and/or generating dangerous high pressure.

10.10 ELECTRIC SUPPLY
10.10.1 SUPPLY VOLTAGE ADMITTED LIMITSThe compressor assembled on the refrigeration system must be connected to a voltage supply line withcharacteristcs within the limits indicated in Table 4.4. Due to voltage drops on the supply circuit, the voltage
must be measured at the compressor terminal pins. (*)

CAUTION(*) As it’s not allowed to run the compressor without the terminal cover properly
fixed on the terminal fence, this measure must be taken outside the cover, as close
as possible to the compressor pins.

WARNINGFor the compressor connection to the electrical supply line and for maintenance/
repairing operation, refer also to Appendix 1- Recommandations - safety
instruction for compressor installation.

In the Table 4.4, are indicated minimum starting voltages at which the compressor can start.
In Chapter 11.6.2 are indicated, for compressor start, the values of balanced and unbalanced pressure
conditions.

The correct sizing of the electric supply cables is important to guarantee low voltage drops at compressor
start and during running under high load (see Chapter 10.1.7).

WARNING

In case of operation of motor-compressor out of working voltage range may result
damage of motor-compressor and/or its accessories. In some specific conditions
in when working out of operation voltage range, overload protector function may
not be assured (see Chapter 10.1.6).
Voltage drop below the Embraco approved limits may cause a prolonging tart-upof the compressor, with possible damages of it and of other electrical components.

10.10.2 PRELIMINARY SELECTION OF FUSESWARNINGThe electrical wiring and safety protections must be performed according to thelaws and regulations applicable in the country in which the refrigeration system
will operate.

85

11. RUNNING DATA AND COMPRESSOR CHECKINGPROCEDURES
The performance and longevity of a refrigeration system is strongly influenced by how the system wasdesigned (and the components selected and matched), processed, installed, used and maintained.

WARNING

During operation in the field, the system can encounter some factors worsening theworking conditions, such the reduction of the effectiveness on the condenser due
to clogging, partial leakage of the refrigerant, fan motor failures, etc. Because of
these factors, it is recommend to size the system with a good margin and test it
under the more severe conditions (normal and abnormal) expected in the field, toensure that the system will operate within the prescribed limits of Chapter 11 andin safety conditions.

11.1 MINIMUM COMPRESSOR TEMPERATURE

IMPORTANTIn case of storage at low temperature, before to install the compressor on the
refrigeration system, charge and start it, is required to stabilize the compressor inambient at higher temperature in order to allow it reaching +5°C min. The same
criteria are valid also before to electrically supply finished products stored at low
ambient temperature.

The compressors are intended for internal usage, however, in case of cabinets working in low ambient
temperature, the compressor should be equipped with a crankcase heater to keep the compressor
temperature over +5°C. For use of the crankcase heater see Chapter 10.3.4.

11.2 MAXIMUM TEMPERATURE OF ELECTRIC MOTOR
WINDINGS
The temperature of the motor windings should not exceed 130°C max, under normal running conditions.
The wiring temperature can be measured while the compressor is running through suitable equipment (forinst. SILYTESTER of BIDDLE USA), or through the method of ohmic resistance measurement, by disconnecting
the compressor supply.

CAUTION86

The compressor shall be connected to the supply line only when the hermetic
terminal cover is properly fixed. When the compressor is energized, all the electricalmeasures must be done outside the cover (see Chapter 10.10.1).

The ohmic resistance measurement method requires the compressor to be stabilized at the ambient
temperature and the availability of instruments for measuring the ohmic resistance (digital Ohmmeter,
Wheatstone’s bridge) and the temperature.
a) Measure the ohmic resistance Rf of the main winding (run) between the pinsof the hermetic terminal C “common” and R “run”. Measure the corresponding
stabilized reference temperature Tf.
b) Measure the ohmic resistance Rc of the main winding (run) between the pins C
and R with hot motor, at the working conditions to which you intend to measure
the motor temperature.
c) Calculate the above hot motor temperature Tc with the following formula:
Calculation formula for Cu winding:Tc =(Rc - Rf)
Rf

(234.5 + Tf) + Tf

Calculation formula for Al winding:Tc =(Rc - Rf)
Rf

(225 + Tf) + Tf

Where:
Tc = Unknown temperature with hot motor
Tf = Motor temperature measured at the stabilized reference temperature
Rc = Measured ohmic resistance, corresponding to the Tc temperature
Rf = Measured ohmic resistance, corresponding to the Tf temperature

11.3 MAXIMUM DISCHARGE GAS TEMPERATURE
Discharge gas temperature must be kept below the maximum temperature indicated in Table 11.4,
measured by thermocouples fixed on discharge tube at a distance of 100 mm from the compressor housing
and thermally insulated from the surrounding ambient, under stabilized running conditions.

CAUTIONCAUTIONWARNING

Do not touch the compressor shell or discharge line when the system is running or
shortly before its stop, to avoid skin burns.

The compressor shell may reach temperatures close to 150 °C (and the discharge
tube even higher) in case of certain system failures (condenser/evaportator fan,refrigerant leaks). Keep away from compressor shell and discharge tube the wiring
insulation and other materials which can be damaged by this temperatures.

The plastics used on the cabinets base where is installed the compressor must be
self-extinguishing and placed away from the compressor discharge tube.

8711. 4 MAXIMUM DISCHARGE GAS PRESSURES ANDTEMPERATURES
Systems shall be designed for Maximum operating pressures according to applicable standards (EN 378 orsimilar applicable standards) that must not be exceeded.
In any case, for Embraco compressors the maximum pressure peak, during“Pull-Down”, the maximum pressures under continuous running and the maximum
discharge gas temperature under continuous running, shall be kept below thevalues indicated in Table 11.4.

CAUTION

Table 11.4 Discharge gas maximum pressures/temperature
PULL-DOWN
Maximumpeak

Refrigerant

Maximum
dischargegas
temperaturestatedconditions

Maximum
statedcondition

kgf/cm²(rel.)

Mpa
(rel)

bar
(rel.)

kgf/cm²(rel.)

Mpa
(rel)

bar
(rel.)

°C

R290

20.6

2.0

20.2

18.4

1.8

18.1

130

R134a

15.9

1.6

15.6

14.2

1.4

13.9

130

R600a

7.8

0.8

7.7

6.9

0.7

6.7

120

R407C

24.8

2.4

24.3

21.9

2.1

21.5

130

R404A

28.3

2.8

27.7

25.2

2.5

24.7

130

R507A

29.0

2.8

28.5

25.9

2.5

25.4

130

R422D

24.6

2.4

24.1

21.8

2.1

21.4

130

R170

20.5

2.0

20.1

17.9

1.8

17.6

130

R508B

24.2

2.4

23.8

21.0

2.1

20.6

130

Note:

● Stated condition at condensing temperature 55°C. Maximum peak at condensing temperature 60°C
● Stated condition at condensing temperature -10°C. Maximum peak at condensing temperature -5°C for ULT
Do not use the compressor for pressurizing the system to check the pressostat
limits.
IMPORTANTThe high-pressure and low pressure cut-out eventually used should have a manual reset feature for thehighest level of system protection.

Ensure that the discharge gas temperature is always higher than the saturation
temperature (including during compressor start after long stop and defrost).
IMPORTANT

88

11.5 SUCTION GAS OVERHEATINGIMPORTANT

Ensure a proper suction gas overheating, to avoid return of liquid to the compressor
at any working conditions (min. 5 K with HFCs). This limit is valid also for HCs on
systems with refrigerant charge up to 150 g, For systems with higher refrigerant
charge, contact Embraco Technical support team.

In case a capillary tube is used, for the definition of the heat exchanger length for a proper suction gas
overheating (and proper liquid subcooling) a length of 0.9 to 1.3 m can be adopted as a preliminary reference.
Definitive heat exchanger length can be defined only after system testing.

11.6 COMPRESSOR OPERATING FIELDS
The system should be designed in order to assure that the compressor operate within the limits ofevaporating and condensing temperatures defined in the Figure 11.6.1, by the green area (k), at indicatedconditions of ambient and return gas temperature.

The red area (m) is acceptable only during transient periods.
IMPORTANT

Avoid to operate the compressor outside its approved limits. The consequentabnormal working conditions (high pressure, high temperatures, overload) can
early damage the compressor.
CAUTION

Outside these approved limits, the system causes the compressor to operate atabnormal conditions (high pressures, high temperatures and overload) and canlead to early damages to the compressor.

The compressor damaged by applications operating outside the prescribed limits will not be considered
under warranty.

11.6.1 COMPRESSORS ADMITTED OPERATING FIELDS
The working fields represented in this section are valid for all models and series of compressors for thecorrespondent application and refrigerant used.
LEGEND
Tc

Condensing Temperaturek

Ambient 32°C and return gas 20°C

Te

Evaporating Temperaturem

Ambient 32°C and return gas 20°C
(for transitory period)

89

Figure 11.6.1 Compressor approved operating fields
LBP
R404A/R507A/R452A - R290

LBP
R134a - R600a
Tc

Tc

70

70

65

65

60

60

m

55

m

55

50

50

45

45

40

40

k

35

30

25

25

20

20

15

15

10

10

5

Te
-45

-40

-35

-30

-25

-20

-15

k

35

30

-10

-5

5

Te

0

-50

L/MBP
R290, R600a, R134a

-45

-40

-35

-30

-25

-20

-15

-10

-70

-65

-60

-5

ULBP
R508B/R170 - second stage of cascade

Tc

-105

70
65
60

m

55

-100

-95

-90

-85

-80

-75

Te
-5
-10

50

-15

45
40

-20

k

35

-25
-30

k

30
25

-35

20

-40

15

-45

10

-50
-55

5

Te

-60
-65

-35

-30

-25

-20

-15

-10

-5

0

5

10

Tc
Note ULBP: Ambient temperature 32°C, return gas 0°C

MBP
R404A/R507A/R452A - R290

HBP
R134a - R600a

Tc

Tc

70

70

65

65

60

60

55
50

50

45

45

40

40

k

35

k

35

30

30

25

25

20

20

15

15

10

10

5

Te
-25

90

m

55

m

-20

-15

-10

-5

0

5

10

15

20

5

Te
-25

-20

-15

-10

-5

0

5

10

15

20

AC - R407C

Tc
65

Many compressor models are released forcondensing temperature down to 20 °C, or 10 °C.
For details please contact Embraco TechnicalSupport.

60

m
55
50

k

Note: Operating envelopes were modified comparing
to latest Installation Instructions or Catalog edition​.
For details contact Technical support team.

45
40
35

Te
-15

-10

-5

0

5

10

15

20

25

Operation Condition
Transient Condition

30

Tc Condensing Temperature °CkAmbient 32oC and return gas 20oC
Te Evaporating Temperature °C
m Ambient 32oC and return gas 20oC
(for transitory period)

11.6.2 START CONDITIONSThe Table 11.6.2 indicates temperature conditions corresponding to balanced and unbalanced pressures
limits at which the compressor can start for voltages greater than or equal to 85% of rated voltage (seealso Table 4.4).

IMPORTANTFor applications where the temperature and voltage are outside the indicatedlimits, compressor start is not guaranteed.

Table 11.6.2 Temperature conditions corresponding to balanced andunbalanced pressures

Application

Balancedpressure conditions LST+HST(ºC)

Unbalanced
pressure conditions HST(ºC)

Discharge

SuctionDischarge

Suction

ULBP

22

22

55

-6.67

LBP

22

22

55

-6.67

MBP

27

27

55

8

L/MBP

27

27

55

8

M/HBP

27

27

55

8

HBP

30

30

55

8

AC

30

30

N/A

N/A

91

11.6.2.1 NOTES ON STARTING PRESSURES
HST models:
the suction starting pressures corresponding to the temperatures of the Table 11.6.2 represent the upper
admitted suction limits for starting at unbalanced conditions at the discharge pressure temperature there
indicated.
In case the system has higher suction pressure at the starting:a) the compressor may not startb) in case of start, due to the high suction pressure, the OLP may trip, the compressor
may stall and the starting relay cycles repetitively on/off with motor and/or
starting capacitor burn out (see case of OLP not operating in Chapter 10.1.6)
HST and LST models:
after starting at balanced pressure for the LST (and unbalanced or balanced for the HST), while the dischargepressure is increasing up, must be ensured that the suction pressure decreases quickly enough to avoid excessive
load to the electric motor. If the suction pressure remains high the consequences are the same of case b).
The electrical supplier companies shall provide voltage to the users within the limits admitted by the local
regulations. Check that these limits comply with the compressor characteristics.
Voltage drop of the supply line from the electrical plug to the compressor, both at starting and running
conditions should be low enough to ensure that the voltage at the compressor pins is within the admitted
limits of Table 4.4.
Startability limits vary with winding temperature. Higher winding temperature will reduce the pressures
under which compressor is able to start.

11.6.3 USE OF TRANSFORMER TO RAISE THE VOLTAGE
The sizing of the this transformer needs careful consideration of the compressor LRA and of the max runningcurrent of the application, otherwise it may damage the compressor instead of improving its operation.
The transformer shall ensure that:CAUTION•

With the LRA at the starting, the compressors pins receive at least the minimum
starting voltage listed in Table 4.4 for various compressor motors.

•

At the compressor max running condition, does not overheat and generate voltage
drop out of the limits of the above table.

•

Does not raise the voltage over the limits admitted by the compressor (see Table4.4), when the supply line voltage reaches the max value.

As reference, the transformer capacity should be at least 2.5 times the compressor rated VA and should bedesigned for startability of hermetic compressor (motors having LRA even more than 10 times the FLA).
When ordering a transformer, inform the producer/dealer on the above characteristics.
Contact the Embraco Technical support team in case of need of technical support.

92

11.6.4 COMPRESSOR CYCLING (ON-OFF)

IMPORTANT

System normal cycling are 4-6 cycles per hour, with sufficient run time to ensure
the proper return of the oil to the compressor(*) and sufficient stop time forbalancing the pressure before restart (in case a LST compressor is used).
(*) Effect of short on-cycle:

Compressor pumps oil in the system (small weight percentage of the pumped refrigerant) during running.
At compressor starting oil may be pumped in higher amount: after each start the compressor has to run
for a time (depending on system design) long enough to assure the oil returns to the compressor. Contact
Embraco Technical support team if more info are needed.

WARNING

Significant increase of cycling may result in early damage of starting device(especially electromechanical relays) or starting capacitors if incorporated and ofcompressor internal mounting springs and discharge loop.

Compressors with PTC starting devices must be re-started after a minimum time of 5 minutes from their off
cycle in order to allow a temperature reduction sufficient to reset its conductivity.

IMPORTANTIMPORTANTThe thermostat or other on-off controllers shall allow an adequate running time of
the compressor. Normally in a well design system, on-cycles of 5-7 minutes after
starting are sufficient for the oil returning to the compressor.

The trip of OLP (thermal/current protector of the compressor) requires that thecompressor re-start occurs after the necessary time for the protector to reset (thismay require even more than 1 h for internal OLP).

11.6.5 RUNNING TIME
Systems should be sized for max 80% of normal running time.
Running time of 100%, may be accepted under heavy load and high ambient temperature conditions. The
systems should be tested in order to assure that even if working at 100% while simulating the worse
conditions expected in the field, the compressor works within its approved operating limits of Table 11.4,
Figure 11.6.1 and Table 11.6.2.

93

11.6.6 HOT GAS DEFROST
Hot gas defrost (HGD) systems perform a faster and effective defrost compared to electric defrost systems,with a remarkable energy saving. However it presents stressing conditions to the compressor.
(*) Effect of short on-cycle:

IMPORTANT

Systems must be designed in order to avoid liquid back to the compressor
and abnormal working conditions, ensuring operation during HGD with amax suction pressure equivalent to a saturation temperature of 7°C and a
max discharge pressure equivalent to the saturated temperature of 35°C
These limits apply to all the types of refrigerants prescribed for the various
Embraco models.

The cabinet must be checked under the more severe expected working conditions, at the minimum admitted
supply voltage, to verify the respect of the above suction and discharge pressure. In case these limits are
overpassed, inconvenient like the Note 11.6.2.1 may happen.
In case of need, contact the Embraco Technical support team.

12. COMPRESSOR CONTROL PROCEDURES
The technicians who maintain or open the circuit of a refrigeration system should be properly trained,
experienced and certified by a recognized certification body according to the applicable legislations.
Those technicians should operate only in adherence with the instructions of the manufacture of the finishedequipment and with all the applicable regulations and standards.
Before beginning to check the compressor:

WARNINGWARNINGWARNINGWARNING94

For the compressor connection to the electrical supply line and for maintenance/
repairing operation, refer also to Appendix 1- Recommandations - safety instruction
for compressor instrallation

Disconnect the electrical power (check that the contactors are open) before
removing the compressor terminal cover.

Do not replace a burnt fuse (or switch-on an open cut-off relay) without firstchecking for a short circuit. The intervention of these devices shows that shortcircuit is present or occurred.

NEVER try to switch on a GFCI (Ground Failure Circuit Interrupter) or RCD (Residual
Current Device), according to country technical requirements, after it tripped; it isan evidence that a short circuit to ground is present or occurred. It is mandatory firstto evaluate and eliminate the causes of the short circuit to ground.

NEVER switch-on compressors having an electrical short circuit or current
leakage to ground (short circuit to ground); it may damage the compressor pin
terminal insulation and cause refrigerant leakage, ignition sparks and fire. In casecompressors presents the short circuit or leakage to ground, replace it, avoiding toconnect it to the electrical supply line. To check for a short circuit to ground use amegohmmeter or a Hi-Potential Ground Tester (follow the producer´s instructions
for their safety use); with a normal ohmmeter it is not possible in certain conditions
to detect a short circuit to ground.

WARNING

Before supply power to the compressor, ensure that the compressor is properly
connected to ground and the compressor terminal cover is firmly fastened. Eventual
electrical measurement during the compressor running must be carried out in otherpoints of the electrical circuit (see Note 10.10.1).

WARNING

Do not supply power to a compressor that has motor failure (short circuit on wiring,
short circuit to ground). This can generate a significant enough shock which can
result in death. The high electrical current due to the short circuit may suddenly
overheat the compressor pins and crack the glass insulation, with possible fire
ignition (see Chapter 6.1.1).

WARNING12.1 TROUBLESHOOTING AND SERVICE CHART
The operational failures effecting the compressors that may happen to the refrigeration system, can be, inmost cases, identified and eliminated by consulting Table 12.1.
This Troubleshooting Chart is not comprehensive and does not intend to replace the instruction provided by
the producer of the refrigeration system.
The listed failures in Table 12.1 are among the most common to be found in established applications. For
other possible defects which do not appear in the list or for running problems in the design phase of theapplications, contact Embraco Technical support team.
It is recommended (before verifying the cabinet working conditions, analyze the deviation from normal
conditions and define the problem route causes), to start from a check list like:•

Visual check of the electric boards, wiring, fuses etc.

•

Check that the compressor electrical components are the ones specified by _Embraco.

•Check their assembly compared with the electrical corresponding diagram asindicated in Chapter 6.1 or the compressor.

•

Check setting and proper operation of all safety and protection devices.

•

Check pressure and other switches, if installed.

•

Check that all valves (eventually installed) are in the correct position for therunning conditions.

•

Check the system for leaks, starting from the most critical points.

95

Table 12.1 Troubleshooting and service chart
PROBLEM

1

2

3

4

Compressor
does not start- No humCompressor
does notstart (hums)
but trip on
the overload
protector

Compressor
starts, butdoes notswitch off
start winding

Compressor
starts andruns, but
short cycles
on overload
protector.

POSSIBLE CAUSEREPAIR

1.1

Line disconnected. Starting relay does not pick-up.

Check the line and starting relay.

1.2

Fuse removed or blown.

Check the root case and solve the problem - replace
the fuse.

1.3

Overload protector tripping.

Check the electrical connections.

1.4

Pressure-switch stuck in open position.

Replace the pressure-switch.

1.5

Thermostat not correctly adjusted.

Reset or replace the thermostat.

1.6

Electrical connections improper or loose.

Check wiring against diagram, or tighten theconnections.

2.1

Improperly connected.

Check wiring against diagram. Arrange the electricalconnections according to the electrical diagram.

2.2

Low voltage at the compressor.

Determine reason and correct.

2.3

Start capacitor defective.

Determine reason and replace the capacitor if
necessary.

2.4

Starting relay failing to close.

Determine reason and correct, replace the relay ifnecessary.

2.5

Compressor motor has a winding open or shorted.

Replace the compressor.

2.6Internal mechanical problem in compressor.

Replace the compressor.

3.1

Improperly connected.

Check wiring against diagram.

3.2

Low voltage at the compressor.

Determine reason and correct.

3.3

Run capacitor defective.

Determine reason and replace.

3.4

Starting relay failing to open.

Determine reason and correct, replace if necessary.

3.5

Excessively high discharge pressure/suction pressure.

Check discharge shut-off valve, possible overcharge,
excessive heat load, insufficient cooling at condenser.

3.6

Compressor motor has a winding open or shorted.

Replace the compressor.

3.7Internal mechanical problem in compressor (tight).

Replace the compressor.

4.1

Additional current passing through overload protector.

Check wiring diagram. Check for added fan motors,
pump, etc, connected to the wrong side of protector.

4.2

Low voltage at compressor (or unbalanced if threephase).

Determine reason and correct.

4.3

Overload protector defective.

Check current, replace protector.

4.4

Run capacitor defective.

Determine reason and replace.

4.5

Excessively high discharge pressure.

Check ventilation, restrictions in cooling medium,medium, restriction in refrigeration system.

4.6

Excessively high suction pressure.

Check for possibility of incorrect application. Use
stronger unit.

4.7

Compressor too hot. Return gas hot.

Check refrigerant charge, check and repair eventual
leaks; add gas if necessary.

4.8

Compressor motor has a windings shorted.

Replace the compressor.
CONTINUE...

96

...FOLLOWPROBLEM

5

6

7

8

POSSIBLE CAUSEREPAIR

5.1

Overload protector.

See section 4.

5.2

Thermostat.

Differential set too close. Widen.

5.3High pressure cut-out due to insufficient air or watersupply.

Check and correct air or water supply to condenser.

5.4High pressure cut-out due to gas overcharge.

Reduce the refrigerant charge.

5.5High pressure cut-out due to air in the system.

Repeat vacuum and refrigerant charge.

5.6

Low pressure cut-out due to liquid line solenoid leaking.

Replace solenoid valve.

5.7

Low pressure cut-out due to insufficient refrigerant
charge.

Repair leak and add refrigerant.

5.8

Low pressure cut-out due to restriction in expansion
valve.

Replace the expansion valve.

6.1

Low refrigerant charge.

Repair leak and add charge.

6.2

Refrigerated space has excessive load or poor insulation. Determine fault and correct.

6.3

System inadequate to handle load.

Replace with larger system.

6.4

Evaporator coil iced.

Check defrost operation; eventually repair it.

6.5

Restriction in refrigeration system.

Determine location and remove.

6.6

Dirty condenser.

Clean condenser.

7.1

Prolonged operation of the start relay due to low voltage
Determine reason and correct.
to unit.

7.2

Prolonged operation of the start relay due to improperly
relay.

Replace the starting relay.

Start capacitor
open, shorted 7.3
or blown

Prolonged operation on start cycle due to starting load
too high.

Determine reasons and correct them; use pumpdown arrangement if necessary.

7.4

Excessive repeated short cycling.

Determine reason for short cycling (see section 5)
and correct.

7.5

Improper start capacitor.

Determine correct size and replace.

8.1

Improper run capacitor.

Determine correct model and replace.

8.2

Excessively high line voltage (out of the allowable limit)

Determine reason and correct.

Unit runs
OK but shortcycles on

Unit operates
long orcontinuously

Run capacitor
open, shorted,
blown

CONTINUE...

97

...FOLLOWPROBLEM

9

10

11

12

13

98

Relay
defective or
burned out

Refrigerated
space
temperatures
too high

Suction line
frosted or
sweating

Liquid line
frosted or
sweating

POSSIBLE CAUSEREPAIR

9.1

Incorrect starting relay.

Check and replace.

9.2

Incorrect mounting angle.

Remount relay in correct position.

9.3

Line voltage too high or too low.

Determine reason and correct.

9.4

Excessive short cycle.

Determine reason (see section 5) and correct.

9.5

Relay being influenced by loose mounting, vibration

Remount the relay tightly; check for excessive
vibrations and eliminate them.

9.6

Incorrect run capacitor.

Replace with proper capacitor.

10.1

Control setting too high.

Reset control.

10.2

Expansion valve too small.

Use a larger valve.

10.3

Cooling coils too small.

Add surface or replace.

10.4

Inadequate air circulation.

Improve air movement.

11.1

Expansion valve passing excess refrigerant or oversized.

Readjust valve or replace with smaller valve.

11.2

Expansion valve stuck open.

Clean valve of foreign particles, replace if necessary.

11.3

Evaporator fan-motor not running.

Determine reason and correct.

11.4

Overcharge of refrigerant.

Correct charge.

12.1

Restriction in drier or strainer.

Replace part.

12.2

Liquid shut-off (main valve) partially closed.

Open valve fully.

13.1

Loose parts or mountings.

Locate and tighten.

13.2

Rubber grommets mounted without sleeves orincorrectly assembled.

Add the sleeves or mount correctly.

13.3

Tubing rattle

Reposition/change loops to be free of contact.

13.4

Bent fan blade causing vibration.

Replace fan.

13.5

Fan motor bearing worn.

Replace fan-motor.

13.6

Tubes joint incorrect (gas noise)

Reconnect joint correctly.

Unit noisy

13. ELECTRIC CIRCUITS CONTROLThe electric tests, described in this chapter, allow determining the causes of possible anomalies or defects ofelectric components, electric motor and wiring for each type of electric motor. In case the problems appear
during the final testing of the refrigerating application, before starting the check procedures, it is better to be
sure that the connections are correct according to the electric wiring diagrams stated in Chapter 6.
To carry out the check, it is necessary to use suitable instruments for checking the continuity and for measuring
the ohmic resistance, respecting the indicated sequence and referring to the electric diagrams (see Chapter 6).
Consider that the continuous lines represent the leads belonging to the electric component, or to the
supplied wiring, while the dashed lines represent the suggested connection leads pertaining to the customer.
During operation in the field, the system can encounter some factors worsening the working conditions, suchthe reduction of the effectiveness on the condenser due to clogging, partial leakage of the refrigerant, fanmotor failures, etc.
Because of these factors, it is recommend to size the system with a good margin and test it under the more
severe conditions (normal and abnormal) expected in the field, to ensure that the system will operate within
the prescribed limits of Chapter 11 and in safety conditions.

WARNING

Wiring carried out differently from the ones indicated in Chapter 6, may required adifferent check procedure and measurement as indicated one

13.1.1 VERSION RSIR - RSCR WITH PTC STARTING DEVICE
Valid for EM/NE series

SM00 RSIR PTC starting device

SM01 RSCR PTC starting device

Verify with voltmeter the presence of the correct voltage on the “L” and “N” terminals of PTC starting device. If
there is insufficient voltage, the thermostat is defective due to open contacts, connections, or an interruption
in the cables.

99

Disconnect the other electrical components if present (motor fan, motor, etc), disconnect the voltage to thecircuit at the supply line and carry out the following operations and checks:
1. Check the continutity on the terminal “3” of the overload protector. If continuity
lacks, the thermostat must be replaced due to open contacts.
2. Take off the PTC starting device from the hermetic terminal.
3. If there is a run capacitor (RSCR version) disconnects it.
4. Take off the protector from the PTC starting device and check between points 1 and3. If there is no continuity, be sure that the protector has no open contacts due to
its trip. In this case, repeat the check after 10 minutes. Otherwise, the protector isdefective due to open contacts.
5. Check the electric motor according to the procedure described in Chapter 13.2.1.
6. Check the ohmic resistance of the stator run and start windings according to theprocedure described in Chapter 13.2.2.
7. On the PTC starting device check between the two fastons N and 2 the ohmic
resistance of the PTC pill which must be 8÷16 ohm for the 230V models and 2÷4
ohm for the 115V model, at the ambient temperature of 25°C.

CAUTION

The ohmic resistance values measured with a normal tester can be out of theindicated by as much as 25% ÷ 30%.
8. If there is a run capacitor (RSCR version), check it according to the proceduredescribed in Chapter 13.2.3.

If problem was not observed based on above checks, there is no capillary clogging and the system does not
run correctly yet, replace the compressor

13.1.2 VERSION RSCR WITH TSD STARTING DEVICE
Valid for EM series

SM02 RSCR TSD starting device

Verify with voltmeter the presence of the correct voltage on the terminal “1” on OLP and “N” terminal on TSD
starting device. If there is insufficient voltage, the thermostat is defective due to open contacts, connections,or an interruption in the cables.

100Disconnect the other electrical components if present (motor fan, motor, etc), disconnect the voltage tothe circuit at the supply line and carry out the following operations and checks:
1. Check the continutity on the terminal “3” of the overload protector. If continuity
lacks, the thermostat must be replaced due to open contacts.
2. Check the electric motor according to the procedure described in Chapter 13.2.1.
3. Check the ohmic resistance of the stator run and start windings according to theprocedure described in Chapter 13.2.2.
4. Take off the protector from the TSD starting device and check between points “1”and “3”. If there is no continuity, be sure that the protector has no open contacts due
to its trip. In this case, repeat the check after 10 minutes. Otherwise, the protector
is defective due to open contacts.
5. Check run capacitor according to the procedure described in Chapter 13.2.3.
6. Connect V-meter to terminals “L” and “N”. Try to start compressor. Voltage across“2-N” terminals should drop close to 0V for period of 300-600ms. If there is notvoltage drop there is probably failure of TSD electronics. Voltage drop is possible
to observe with good resolution digital V-meter or eventually galvanic V-meter.
TSD is timing starting device which connects starting winding for 300-600ms andduring this time the voltage across “2-N” terminals drops close to 0V. This happens
immediately after closure of thermostat contacts.
If problem was not observed based on above checks, there is no capillary clogging and the system does not
run correctly yet, replace the compressor.

CAUTION

Check of # 6 requires skilled electrician with adequate education to avoid electric
shock hazard.

13.1.3 VERSION RSIR WITH TERMINAL BOARD AND CURRENTRELAY STARTING DEVICE
Valid for EM/NE series

SM03 RSIR Terminal board and current relay starting device

Verify with voltmeter the presence of the correct voltage on the “1” and “N” terminals of terminal board. If
there is insufficient voltage, the thermostat is defective due to open contacts, connections, or an interruption
in the cables.

101Disconnect the other electrical components if present (motor fan, motor, etc), disconnect the voltage to thecircuit at the supply line and carry out the following operations and checks:
1. Remove the terminal board, take off the starting relay and disconnect the protector
cable from the hermetic terminal.
2. Check the continuity between the points “1” on the protector and “1” on theterminal board. If there is no continuity, the protector can be:a) faulty due to open contactsb) tripped; then repeat the check after 10 minutesc) not connected to the terminal board.
3. Keep the start relay in the same vertical position as assembled on the hermetic
terminal (do not incline or overturn).
4. Check continuity between terminals “N” on the terminal board and “S” on the relay.
If there is continuity the relay is defective due to closed contacts.
5. Check continuity between terminals “N” on the terminal board and “R” of relay. If
there is no continuity, the defect can be due to:a) relay with open coilb) relay not connected to the terminal board.
6. Check the electric motor according to the procedure described in Chapter 13.2.1.
7. Check the ohmic resistance of the stator run and start winding according to theprocedure described in Chapter 13.2.2.
If from all above checks a problem was not found, there is no capillary clogging and the system does not yet
run correctly. Replace stating relay, excluding possible faults of contats opening and closing (pick-up anddrop-out currents) that can not be determined with above checks.
If compressor does not yet run correctly, it must be replaced due to internal defects.

13.1.4 VERSION CSIR AMERICAN VERSION AND CURRENTRELAY STARTING DEVICE
Valid for NE/NT series

SM04/SM20 CSIR American version and current relay starting device

WARNING

102

Starting relay contacts are normally open.

Verify with voltmeter the presence of the correct voltage on the terminals “2” of relay and “3” of protector.
If there is insufficient voltage, the thermostat is defective due to open contacts, connections, or there isan interruption in the cables. Disconnent the other electric components if present (motor fan, motor, etc),
disconnect the voltage to the circuit at the supply line and carry out the following operations and checks:
1. Check the continuity between the points “1” and “3” of the protector. If continuity
lacks, be sure that the protector has no open contacts due to its trip. In this caserepeat the check after 10 minutes.
2. Take off the start relay from the hermetic terminal and keep it in the same vertical
position (do not incline or overturn).
3. Check continuity between terminals “1” and “S” on the relay. If there is continuity
the relay is faulty due to closed contats.
4. Check continuity between terminals “2” and “R” of relay. If there is no continuity therelay coil is open.
5. Check the electric motor according to the procedure described in Chapter 13.2.1.
6. Check the ohmic resistance of stator run and start windings according to theprocedure described in Chapter 13.2.2.
7. Check the start capacitor according to the procedure indicated in Chapter 13.2.3.
If from all above checks a problem was not found, there is no clogging in the expansion device and the systemdoes not yet run correctly. Replace stating relay, excluding possible faults of contats opening and closing(pick-up and drop-out currents) that can not be determined with above checks.
If compressor does not yet run correctly, it must be replaced due to internal defects.

13.1.5 VERSION CSIR TERMINAL BOARD AND CURRENTRELAY STARTING DEVICE
Valid for EM/NE/NT series

SM05/SM19 CSIR Terminal board and current relay starting device

WARNING

Starting relay contacts are normally open.

103

Disconnect the other electrical components if present (motor fan, motor, etc), disconnect the voltage to thecircuit at the supply line and carry out the following operations and checks:
1. Remove the terminal board, take off the starting relay and disconnect the protector
cable from the hermetic terminal.
2. Check the continuity between the points “1” of protector and “1” of terminal board.
If there is no continuity, the protector can be:a) faulty due to open contactsb) tripped; then repeat the check after 10 minutesc) not connected to the terminal board.
3. Keep the start relay in the same vertical position as assembled on the hermetic
terminal (do not incline or overturn).
4. Check continuity between terminals “N” on the terminal board and “R” on the relay.
If there is no continuity the defect can be due to:a) relay with coil breakingb) relay not connected to the terminal board.
5. Check continuity between terminals “1” and “S” of relay. If there is continuity, therelay is faulty due to closed contacts.
6. Check the electric motor according to the procedure described in Chapter 13.2.1.
7. Check the ohmic resistance of the stator run and start winding according to theprocedure described in Chapter 13.2.2.
8. Check starting capacitor according to the procedure indicated in Chapter 13.2.3.
If from all above checks a problem was not found, there is no clogging in the expansion device and the systemdoes not yet run correctly. Replace stating relay, excluding possible faults of contats opening and closing(pick-up and drop-out currents) that can not be determined with above checks.
If compressor does not yet run correctly, it must be replaced due to internal defects.

13.1.6 VERSION CSR/CSIR BOX WITH EXTERNAL OVERLOAD
PROTECTOR
Valid for NE/NT/NJ series

SM06/SM17/SM21/SM23/SM24 CSR/CSIR box with external overload protector
CSR version

104

CSIR version

Verify with voltmeter the presence of the correct voltage on the terminals “4” and “5” of starting relay.
If there is insufficient voltage, the thermostat is faulty due to open contacts, connections, or there is aninterruption in the cables.
Disconnent the other electric components if present (motor fan, motor, etc), interrupt the voltage to thecircuit disconnecting it from supply line and carry out the following operations and checks:
1. Disconnect all the connections on terminals “2” and “5” of the starting relay.
2. Check the continuity between terminals “2” and “5” of the starting relay. If there isno continuity, there is a broken coil and the relay must be replaced.
3. Check the continuity between terminals “1” and “2” of starting relay. If there is no
continuity, the contact is open and the relay must be replaced.
4. If there is an external overload protector, check, according to the type, the continuity
between terminals “1” and “3” or “1” and “2”. If there is no continuity, the protector
can be faulty or there could have been a trip, so repeat the check after 10 minutes.
5. Check the electric motor according to the procedure described in Chapter 13.2.1.
6. Check the ohmic resistance of the stator run and start windings according to theprocedure described in Chapter 13.2.2.
7. Disconect one of the two cables of the starting capacitor.
8. Check the start and run (not in case of CSIR) capacitors according to the proceduredescribed in Chapter 13.2.3.
9. Check the continuity of the cables disconnected from the “2” and “5” terminals of
the starting relay.
If from all above checks a problem was not found, there is no clogging in the expansion device and the systemdoes not yet run correctly. Replace stating relay, excluding possible mistakes of opening and closing of thecontact (pick-up and drop-out currents) that can not be determined with above checks.
If compressor does not yet run correctly, it must be replaced due to internal defects.

13.1.7 VERSION CSR/CSIR BOX WITH INTERNAL OVERLOAD
PROTECTOR
Valid for NE/NT/NJ series

SM10/SM13/SM16/SM26 CSR/CSIR box with internal overload protector
CSR version

CSIR version

105

Verify with voltmeter the presence of the correct voltage on the terminals “4” and “5” of the starting relay.
If there is insufficient voltage, the thermostat is faulty due to open contacts, connections, or there is aninterruption in the cables.
Disconnent the other electric components if present (motor fan, motor, etc), interrupt the voltage to thecircuit disconnecting it from supply line and carry out the following operations and checks:
1. Disconnect all the connections on terminals “2” and “5” of the starting relay.
2. Check the continuity between terminals “2” and “5” of the starting relay. If there isno continuity, there is a broken coil and the relay must be replaced.
3. Check the continuity between terminals “1” and “2” of starting relay. If there is no
continuity, the contact is open and the relay must be replaced.
4. There is an internal overload protector, check the continuity of motor run and startwinding with ohmmeter directly on pins of hermetic terminal. Run winding resitance
between “C-R” pins, and start winding resistance between “C-S” pins. If there is an
infinite resistance on run or start winding the protector/winding can be faulty or
there could have been a trip, so repeat the check after 1 hour.
Internal overload protector typically takes longer time to re-set than the external one.
IMPORTANT

5. Check the electric motor according to the procedure described in Chapter 13.2.1.
6. Check the ohmic resistance of the stator run and start windings according to theprocedure described in Chapter 13.2.2.
7. Disconect one of the two cables of the starting capacitor.
8. Check the start and run (not in case of CSIR) capacitors according to the proceduredescribed in Chapter 13.2.3.
9. Check the continuity of the cables disconnected from the “2” and “5” terminals of
the starting relay.
If from all above checks a problem was not found, there is no clogging in the expansion device and the systemdoes not yet run correctly replace starting relay, excluding possible mistakes of opening and closing of thecontact (pick-up and drop-out voltages) that can not be determined with above checks.
If compressor does not yet run correctly, it must be replaced due to internal defects.

13.1.8 VERSION PSC WITH INTERNAL OR EXTERNALOVERLOAD PROTECTOR
Valid for NJ series

SM12/SM15 PSC with internal or external overload protector
External OLP version

106

Internal OLP version

Verify with voltmeter the presence of the correct voltage on the terminals “R” and “C” of hermetic terminal(version with internal protector) or between “R” on hermetic terminal and “1” on external overload protector.
If there is insufficient voltage, the thermostat is faulty due to open contacts or there is an interruption on thecables or on the connections.
Disconnent the other electric components if present (motor fan, motor, etc), interrupt the voltage to thecircuit at the supply line, and carry out the following operations and checks:
1. If there is an external overload protector, check the continuity between points “1”and “3”. If there is no continuity, the protector can be faulty, or can trip, so repeat
the check after 10 minutes.
2. Check the electric motor according to the procedure described in Chapter 13.2.1
3. Check the ohmic resistance of the stator run and start windings accordint to theprocedure described in Chapter 13.2.2
4. Check the run capacitor according to the procedure indicated in Chapter 13.2.3.
If from all above checks problem was not found, there is no clogging in the expansion device, and the systemdoes not yet run correctly, replace the compressor.

13.1.9 VERSION 3-PHASE INTERNAL OVERLOAD PROTECTOR
Valid for NJ series

SM18 3-phase internal overload protector

Verify with voltmeter the presence of the correct voltage of the three phases, on the three pins of thehermetic terminal. If there is insufficient voltage, check the presence of a break on the contacts of relay,
cables and connections.
Disconnent the other electric components if present (motor fan, motor, etc), interrupt the voltage to thecircuit at the supply line, and carry out the following operations and checks:
1. Check the continuity of the winding of the three phase electric motor, among thepins of the hermetic terminal (3 measures carried out between 2 pins at a time).
The lack of continuity indicates an interruption in the electric motor winding.
2. Check the continuity among the three pins of the hermetic terminal and the groundplate on the compressor. If there is continuity, the electric motor has the windings
shorted.
3. Check with a suitable instrument the ohmic resistance of the three phases of thestator windings, through the three pins of the hermetic terminal on the compressor.
The values of resistance indicated in Embraco Technical datasheet must result within the tolerance of ±10%
at the ambient temperature of 25°C.
107

Note: Each of the three phases can have different ohmic resistance value.
IMPORTANTIf from all above checks problem was not found, there is no clogging in the expansion device, and the systemdoes not yet run correctly, replace the compressor.

13.1.10 VERSION 3-PHASE INTERNAL + EXTERNALOVERLOAD PROTECTOR
Valid for NT series

SM27 3-phase internal + external overload protector

Verify with voltmeter the presence of the correct voltage of the three phases, on the 2 pins of the hermetic
terminal and terminal 1 of the overload protector. If there is insufficient voltage, check the presence of abreak on the contacts, cables and connections.
Disconnent the other electric components if present (motor fan, motor, etc), interrupt the voltage to thecircuit at the supply line, and carry out the following operations and checks:
1. If there is an external overload protector, check the continuity between points “1”and “3”. If there is no continuity, the protector can be faulty, or can trip, so repeat
the check after 10 minutes.
2. Check the continuity of the winding of the three phase electric motor, among thepins of the hermetic terminal (3 measures carried out between 2 pins at a time).
The lack of continuity indicates an interruption in the electric motor winding or
opened internal overload protector. Repeat the test approximately after 1 hour tobe sure overload protector had time enough to re-set.
3. Check the continuity among the three pins of the hermetic terminal and the groundplate on the compressor. If there is continuity there is short circuit to the ground.
4. Check with a suitable instrument the ohmic resistance of the three phases of thestator windings, through the three pins of the hermetic terminal on the compressor.

108

The values of resistance indicated in Embraco Technical datasheet must result within the tolerance of ±10%
at the ambient temperature of 25°C.

Note: Each of the three phases can have different ohmic resistance value.
IMPORTANTIf from all above checks problem was not found, there is no clogging in the expansion device, and the systemdoes not yet run correctly, replace the compressor.

13.2 CONTROL PROCEDURES

13.2.1 CONTROL OF ELECTRIC MOTOR (STATOR) WINDINGS
1. Check the continuity between the pins “C” and “S” of the hermetic terminal. If
there is no continuity, there is an interruption in the electric motor start winding.
2. Check the continuity between the pins “C” and “R” of the hermetic terminal. If
there is no continuity, there is an interruption in the electric motor run winding.
3. Check the continuity between the pin “C” of the hermetic terminal and the groundplate on the compressor. If there is continuity, the electric motor windings areshorted to ground.

13.2.2 CONTROL OF STATOR WINDINGS OHMIC RESISTANCE
1. Check with a suitable instrument the ohmic resistance of the start and run stator
windings through the three pins of hermetic terminal on compressor.

The values of start winding resistance (measured on pins “C-S”) and run winding resistance (measured on
pins “C-R”) indicated in the Embraco Technical Datasheet must be within the tolerance of ±10% at theambient temperature of 25°C.

13.2.3 CONTROL OF START AND RUN CAPACITORS
1. Check the run and start capacitor on the two terminals using a capacitance meter.

109

14. COMPRESSOR REMOVAL AND REPLACEMENT
Statistics after analysis of returned compressors to Embraco indicate that the higher percentage (aprox
35 %) are without failures and have been disassembled by misunderstanding of the real problems on the
refrigeration system.
The replacement of a compressor is an onerous task and requires an accurate diagnosis of the system before
deciding to proceed with it.
Improper procedures to remove the failed compressor and install a new one, maycause injury to person, release of refrigerants and oil to the environment, fire anddamages to propriety.

WARNINGWARNING•••

Avoid repairing and leaving unattended a system with:
No refrigerant charge.
Rotolock valve and other service valves closed.
Holding OFDN charge used for pressurization or leakage test.

14.1 COMPRESSOR REMOVAL AND REPLACEMENT - HFCSMODELSWARNING

When repairing a refrigeration system, replacing a compressor and installing a newones, follow all applicable international regulation and standards, (like EN 378-4 orsimilar), and the local ones, as well as the safety warnings and recommendations
indicated in this Installation Instructions.

The transport of pressure vessels (like the ones containing refrigerants) are covered by international
regulations, like the ADR (European Agreement concerning the International Carriage of Dangerous Goods
by Road) and by local regulations that must be applied.
Storage and handling of vessel refrigerants shall be made in accordance with applicable regulations.
For recovery, reuse, recycling and reclamation of the refrigerant follow EN 378-4 or equivalent standards, aswell as the applicable local regulations.

14.1.1 COMPRESSOR REMOVAL PROCEDUREWARNING110

The compressor replacement must be carried out in properly ventilated ambient.
Disconnect the system from the electrical power.

Ground the cabinet••••

Check the conditions of the electrical wirings and connections, with special care to
the ground wire; replace eventual damaged parts.
Check the system for leakages with leak detector suitable for the refrigerant usedon the system and having a sensitive of at less than 3 g/year.
Remove the protective shield to access the compressor.
Remove the compressor terminal covers and disconnect all the compressor
electrical components.
Recover the entire refrigerant charge before removing the compressor (if the line
tubes are cut when the system contains even fractions of the refrigerant charge,
it will cause a rapid release of refrigerant mixed with oil, with pollution to theenvironment and possible injury due to inhalation of gas or frostbite).

CAUTIONTo recover the refrigerant use a suitable recovery units and apparatus, follow the instruction of the producers
and the applicable regulations.

The only acceptable practices on refrigerant removed from systems are recovery,
reuse, recycling and reclamation. All the applicable standards and regulations forthese operations must be followed.

CAUTION

Avoid to vent refrigerants in the ambient. In several countries there are legal obbligation on technicians
to prevent this uncorrect operation and to act minimizing leaks and repair systems with leaks as soon as
possible..
To remove the refrigerant:• Connect a hose to the service valve, if available on the system. Otherwise use apiercing valve (with a schrader connection) on the service tube, connect the hose(with schrader connection) to the recovery unit in order to start the refrigerant
recovery procedure.
• Use a filter dryer at the entry of the recovery unit.
• Adhere the instructions of the recovery machine producer. Go down with recovery
up to a residual pressure of 0.3 abs bar (make reference to EC 842 or equivalentapplicable regulations).
Be careful not to exceed the maximum charge indicated on the recovery vessel forthe specific refrigerant. Overcharges can lead to vessel explosion.

WARNING••••

Unsolder the line tube from the compressor.
Remove the compressor from the cabinet base plate (see Chapter 15 for compressor
disposal).
In case the compressor has to be returned to Embraco, follow the instruction ofChapter 16.
Purge the system using OFDN only.

111

14.1.2 COMPRESSOR REPLACEMENT PROCEDURE
Do not perform unnecessary tests before install or start a new compressor. All
tests have been already carried out in the Embraco production lines and labs.
IMPORTANT•

Change the dryer, as the refrigeration system has been opened.

•

For the assembling of a new compressor and brazing, follow the procedure ofChapter 10.5.

•

Brazing requires specific trained personnel and brazing procedure approvals.

•

Assemble the electrical components according to the wiring diagram of Figure
6.1b.

•

When replacing a compressor do not use the electrical components installed on thereplaced compressor. Use new components supplied with the new compressor andcheck the correspondences with the ones prescribed for the specific compressor
model as listed in the Embraco Product catalogue on www.embraco.com
Connect the components with the care indicated in Chapter 6.

•

After assembly, the system shall be tested for leakages by pressurizing with
OFDN. Pressure must be according to the applicable regulation and to the designpressure of the system components in order to avoid injuries and damages.

•

When testing the low pressure side of the system, pressure to the compressor
shell must not exceed 16 bar (see Chapters 10.6.1.3 and 7.6).

•

Release the OFDN and carry out vacuum, refrigerant charge and leak test (refer tothe Chapters 10.6.1.3 – 10.6.1.5, and 10.3.5 of this Installation Instructions forthese operations).

CAUTION

IMPORTANTIn case the refrigerant has to be charged into the compressor, connect the charging
line to the compressor process tube and allow the refrigerant entering at vapor
state. When the refrigerant vapor reaches a pressure equivalent to the saturationpressure of 5 to 10°C, start the compressor and continue to charge the refrigerant
at vapor state until the final charge is reached.

It is allowed to charge the system only with the refrigerant type (that must correspond with the refrigerantmarked on the compressor label). and quantity indicated on the cabinet label.
When the charge procedure is finished, fix strongly the cap on the Schrader valve (or pierce strongly theservice tube, cut the Schrader valve and close the tube by brazing (eventually use a lokring cap).
Fix properly the compressor terminal cover and ensure the compressor and the system is grounded before
supply voltage.

WARNING112

After repairing, the system should be checked for leakages, use leak detector
specific for the adopted refrigerant, with a sensitivity of less than 3 g/year and run
for analyzing the performance and Watt/Amps input. For compressor, refer to theTechnical datasheet in the Embraco Product catalogue on www.embraco.com
For entire application refer to data that the cabinet manufactures should provide.

14.2 COMPRESSOR REMOVAL AND REPLACEMENT - R600a
AND R290 MODELS
Only competent technicians trained on the safety use of flammable refrigerants
are allowed to open refrigerant circuits or equipment housing of hydrocarbon
systems.
WARNING

International and National regulations and rules that apply to potential explosive
atmospheres must be followed.

For repairing the system, technicians should follow the instructions issued by the finished productmanufactures and all the applicable international and national regulations and standards, operating in orderto prevent as much as possible the risk of flammable refrigerant leaking into the surrounding.
In addition to the instructions of Chapters 10.6.2 in case of use of flammable refrigerant, the following
actions must be adopted.

14.2.1 PREVENTIVE ACTIONS TO BE ADOPTED
When possible, do not carry out repairs on site but only in workshops equipped to operate in security on
systems with HCs refrigerant.
Due to the flammability of R600a and R290, the processing area of the cabinets containing these refrigerants
should be intrinsically safe and with adequate forced ventilation.
•

Before to start any activities, carry out a risk assessment of the entire operation.

•

Avoid presence of flammable substances in the repairing area.

•

Avoid presence of ignition sources at a distance according to applicable regulations(at least 3 m).

•

Ensure the presence of fire extinguishers (powder or CO2 type, their characteristics
and location must be according to applicable local regulations).

•

The working area must be monitored with a hydrocarbon detector suitable forpotential explosive atmosphere (ATEX approved or similar approvals) with visible
and audible alarm, located at low level (HCs are heavier than air), with sensitivity
detecting lower than the 15% of the refrigerant LFL.

•

The working area must be marked by warning and prohibition signs applicable topotential explosive atmosphere and according to the local regulation.

•

There must be no tunnels, culverts, drains where the refrigerant may enter.

•

Use only tools/apparatus suitable for potential explosive environments (i.e.
vacuum pump, recovery machine, fan motors, etc, all granting ATEX or equivalentapprovals).

•

Keep a safety distance between the various repairing zones, in order to avoid
dangerous situation in case of HC leakages (good practices suggest 3 m).

•

Wear antistatic shoes and an antistatic-electricity tag.

113

14.2.2 FAILURE DIAGNOSIS•

Ground the cabinet to avoid electrostatic sparks.

•

Remove the protective shield to access the compressor.

•

Remove the compressor terminal cover.

•Check the electrical connection diagrams and the connections to the compressor,
check the conformity of the compressor electrical components - protectors, relays,
capacitors with what is prescribed by Embraco on the compressor Technicaldatasheets on the www.embraco.com•

Check the integrity of the cables and terminal retention (especially the groundwire). Eventually change and fix them properly.

•

Visually analyze each system component: condenser, capillary tube, evaporator,
fan motor, thermostat, etc.., and the integrity of pipes, solders, etc.

•

Check all the system for leakages, using a leak detector for the specific flammable
refrigerants and suitable for potential explosive atmosphere (ATEX or similar
approvals), sensitivity of less than 3 g/year, see Chapter 10.6.2.15.

•

Open the cabinet door(s) and blow air inside (in general blow air inside any confinedpart of the refrigeration machine) using blower suitable for potential explosive
atmospheres (having ATEX or similar approvals).

•

Before supplying energy to the system, blow air on the compressor and condenser
zone using blower suitable for explosive atmosphere. If the leak (previously
undetected) is on the high pressure side, it will be more pronounced while thecompressor is running.

•

Fix properly the compressor electrical cover and the protected shield of the cabinet.

•

Supply energy to the cabinet (after ensuring that the compressor and the cabinet
are properly grounded) checks again leakages on the high pressure side.

•

Diagnose the failure causes.

14.2.3 COMPRESSOR REMOVAL
In case is necessary to replace the compressor:

114•

Disconnect the cabinet from the electrical supply line•

Ground the cabinet to avoid electrostatic sparks•

Remove the protective shield to access the compressor•

Remove all the compressor electrical components•

Fit a needle valve on the service tube•

Remove the refrigerant charge using a recovery machine and apparatus that
fulfill the safety requirements of potential explosive atmosphere or vent therefrigerant charge in the atmosphere - in case the venting of HCs is admitted by
local regulations for the quantity of refrigerant charged into the system - in an
outside ambient that respects the safety conditions, away from heat and ignition
sources (see Figure 14.2.3a) and limited by warning signs of danger. The recovery
machine should be operated until a residual pressure of 0.3 bar (abs) is reached.

Figure 14.2.3a HCs refrigerant venting

WARNING
Refrigeration
systemoilseparator

3 m minimum
Venting hose

1m
minimum

In case of recovery, use specific vessel suitable for HCs carrying proper marking.
Be careful not to exceed the maximum charge indicated on the recovery vessel
for the specific refrigerant. Overcharges can lead to vessel explosion. Due to thedifferent density of HCs vs HCFCs/HFCs refrigerants, it’s possible to fill the same
cylinder (same volume) with only 40% of HCs weight vs HCFCs/HFCs.

WARNING

Remove the needle valve, cut - do not use flame - the tube and insert a Schrader
valve (to get a larger port) or other connection (flare and nut or quick connection).

CAUTION

14.2.4 SYSTEM WASHING BY OFDN(OXYGEN-FREE-DRY-NITROGEN) PROCEDURE

CAUTION•

Make a first vacuum for at least 5 minutes.

•

Fill the system using ofdn only, at max 6 bar pressure (this pressure will avoid
demages to roll-bond evaporators eventually used) - first washing.

•Release the ofdn and make a second vacuum for 5 minutes.

•

Fill the system with ofdn at max 6 bar - second washing.

•Release the OFDN.

•

Cut the suction and discharge line tubes by using a cutter (do not use flame)•

Remove compressor from the cabinet within 15 minutes after system purging•

See Chapter 15 for compressor disposal or Chapter 16 if the compressor has to be
returned to Embraco.
Do not reuse compressors disassembled from system containing flammable
refrigerants. HC refrigerants remain mixed with the oil and may generate flame
when attempt to braze the used compressor to the system.
115

14.2.5 INSTALLING A NEW COMPRESSOR•

Install new compressor on the cabinet base, see Chapter 10.8.

•

On the compressor´s service tube braze additional tube (approx. 15 cm long) witha Schrader valve at its end, or use quick connections. If the system was arranged
for a 2 sides vacuum, set up in the same way a second connection on the highpressure side.

•

Braze the discharge and suction line tubes to the corresponding compressor tubes(for the brazing operation see Chapter 10.6.2.11).

•

Charge the system with OFDN to a pressure corresponding with the system design(see Chapter 7.6 for the max pressure inside the compressor shell).

•Check the tightness of the system.

•

Release the OFDN.

14.2.6 SYSTEM VACUUM, CHARGING AND SEALING•

Carry out a vacuum. For the vacuum conditions and procedure see Chapter
10.6.2.12.

•

Pierce strongly the service tube of the high side (normally due to the small chargeof HCs, the systems are charged through the compressor service tube) and cut
with a cutter the Schrader valve (or remove the quick connection) of the service
tube on the system high side.

•

Drop a bead of sealant on the lokring cap and place by twisting it on the tube.

•

Apply the jaws of the clamp on the cap and close the clamp strongly. The cap is
properly secured if the two parts fit together perfectly.
Charge the refrigerant through the compressor service tube and measure carefully(*)
the amount of refrigerant filled in the system, in order to be sure to charge thesame quantity originally charged by the cabinet producer, as specified on thecabinet label.

•(*) Note: due to the small amount of the HCs refrigerant charge compared to equivalent HFCs, an accurate
weighting of the HC charged in the system is mandatory to ensure proper performance and energy consumptionof the repaired cabinet.

116•

Close the valve of the HC vessel immediately after finishing the charge procedure.
If the vessel is a movable one, store it in the proper storing area for flammable
refrigerants.

•

Close the service tube with a lokring, proceeding as done with the second way
vacuum tube.

•

Install and connect the new electrical components of the compressor (checkthe correspondence with the prescribed components in the Embraco Productcatalogue on www.embraco.com using only original spare parts with the careindicated on the Chapter 6.1.1.

•

Check all the electrical connections to be sure they are properly connected,
particularly check the continuity of the ground connection of the cabinet.

•

Check leaks by using a leak detector for the specific flammable refrigerant and use
only detector that have been manufactured and certified intrinsically safe (ATEX or
similar approvals) for HCs (sensitivity of less than 3 g/year).

14.2.7 REPAIRED CABINET VERIFICATIONWARNING•

Make sure that the compressor and the cabinet are properly grounded.

•

Fix the protective cover on the compressor terminal.

•

Fix the protective shield on the cabinet.

•

Connect the cabinet to the electrical supply line and run it.

•

Check again the high pressure side of the system for a leakage.

•

Check the cabinet working conditions.
For the compressor connection to the electrical supply line and for maintenance/
repairing operation, refer also to Appendix 1- Recommandations - safety
instruction for compressor instrallation.

14.2.8 RETROFITTING
Embraco does not approve retrofitting.

WARNING

Due to the specific safety aspects that must be consider when designing HCs
equipments and their components versus the HCFCs and HFCs ones, Embracodoes not approve the retrofitting with R600a and R290 of systems designed forother refrigerants.

15. COMPRESSOR DISPOSALS
Disposal of refrigerating systems, its parts and components shall be undertaken in accordance with thesystem producer’s instructions and with national regulations.
For recovery, reuse, recycling and reclamation of the refrigerant follow EN 378-4 or similar standards, as wellas the applicable local regulations.
Use the correct equipment and method for removal the compressor (see Chapter 14.1.1 for HFC model, or
the applicable parts of Chapters 14.2.3 and 14.2.4 for HC model).
Drain out the oil from the compressor and treat it according to the applicable regulations.
Dispose the compressor according to applicable regulations.

WARNINGThe oil of the compressors disassembled from HC systems contains a certain
amount of HC refrigerants. The oil must be drained out and the compressor tube
sealed.

The compressors shall be stored in ambient properly ventilated.
Oil drained from used HC compressors must not be mixed with other oils and must be treated as a hazardous
waste material according to the local applicable regulations.
When necessary, an expert in dealing with safe disposal of refrigerants and oils should be consulted.
11716. HOW TO RETURN SUPPLIED PRODUCTS TOEMBRACO EUROPE
For the warranty on products supplied by Embraco, refer to what is indicated in the sales conditions.
The validity of the warranty (if applicable) is subject to the results of the analysis carried out in Embraco on
the returned compressors. A technical report of the analysis will be send to the customer.
Customer may participate in the analysis.
The return (and delivery terms) of compressors to Embraco for technical analysis has to be agreed between
Embraco Sales Department and the Customer. The delivery conditions and documents shall be according to
the Embraco Sales Department instructions.
To ensure a timely analysis and the correct definition of the root causes of the problem, Embraco request to
observe the following rules:• Disassembly of the compressor from the system, following the instruction (seeChapter 14.1.1 for HFC model, or the applicable parts of Chapters 14.2.3 and14.2.4 for HC model).
• Disconnect the supply wirings from the compressor terminals without remove theelectrical components.
• Cut the line tubes at least 50 mm away from the compressor ports (do not unsolder)and close them with the specific rubber taps or by brazing if the compressor is a
HFC model.
• Use taps if the compressor is a HC model only (in this case the oil still contains
flammable refrigerants and can generate fire in case of brazing).
CAUTION• Do not carry out potential destructive tests (i.e. Dielectric strength test) and do notremove the oil from the compressor.
• Do not abrade or eliminate the nameplate.
• Indicate on the compressor top with a marker (or on a adhesive label) the reasonsof the replacement.
It is sufficient macro-indication like:- noisy- leakages on tube/shell (evidencing the leak point)- does not start (specify in which conditions)- does not cool the system- OPL trips- grounded- short circuit- motor winding interrupted.
• Handle with care, to avoid damages of the compressor and its electrical components• All materials must be properly packaged according to the type of shipment and inorder to avoid damages during transport; (in case of delivery by air the compressors
disassembled from a HC system, may not be allowed due to the presence of HC
refrigerant diluited in the oil, or may require special measures. Consult the shipping
agency before delivery).
• Do not return defective compressors as a consequence of mishandling.
• Do not return open compressors or tampered components; (to avoid erroneous
diagnosis, the compressor must be opened with suitable tools, available at Embraco
factories).
The material that does not correspond to the above requirements may be considered not valid for analysis
and may void the warranty.
All the materials that, after analysis, appear to be working and are free of quality problems, can neither be
returned nor replaced (the complete analysis involves the opening of the compressor and its disassembling).
The analyzed product, before its disposal, remains available for the customer for a maximum period of
30 days starting from the date of the Technical Report issued by the Sales and delivered to the customer.

118

17. TESTS ON THE CUSTOMER APPLICATIONS
Embraco “Application Test Laboratories” are available for the customers to perform tests to verify the working
conditions of their equipments. For qualifying the proper use of the compressor installed, for selecting thecompressor and the main components of the refrigeration system (condenser, evaporator, capillary, refrigerant
charge) and other special tests that may be agreed with the customer.
The feasibility of the requested tests (and the delivery terms of the equipments) shall be agreed between thecustomers and Embraco Sales Department according to the Embraco Application Tests schedule.
PLEASE NOTE: THE TRANSPORT EXPENSES ARE CHARGED TO THE CUSTOMER
The test results will be given to the customer, who can use them as information or to define or modify his
application.
PLEASE NOTE: THE TEST RESULTS CANNOT BE USED IN CASE OF CONTROVERSY AND ACTIONS BROUGHT
AGAINST A THIRD PARTY, UNLESS THERE IS A WRITTEN AUTHORIZATION FROM EMBRACO.

APPENDIX 1
SAFETY RECOMMENDATIONS FOR COMPRESSORINSTALLATIONGENERAL RECOMMENDATIONS
Only trained personnel can perform diagnostic and maintenance procedures onrefrigeration systems.
WARNING

Installation and repair requires special training, technical information, special tools andspecial equipment.
Make sure in advance if the environment for maintenance is adequate and airy.
Tools and process equipment should be available. The required Personal Protective
Equipment (PPE) must be used by the technician.
Before starting maintenance or diagnostics, first make sure that the cooling system is
disconnected from the mains.
After disconnecting the system from the mains, wait for the compressor to cool down.
Only perform maintenance or diagnostic procedures with the cold compressor (25 ° C± 5 ° C).
The compressors shall be powered only in electrical installations with a ground fault
circuit interrupter (GFCI) circuit breakers or residual current device (RCD), according to
the country technical requirement.
Correct grounding is required for the use of compressors.

119

Failure to shut down the mains compressor during maintenance procedures and to apply
a system without a ground fault circuit interrupter (GFCI) or residual current device (RCD),
according to the country technical requirements, may cause serious physical hazards byelectric shock and/or fire to the technician.
Failure to disconnect the compressor from the mains may, in the event of a short circuitin the region of the hermetic terminal of the compressor, cause expulsion of the hermetic
pins causing leakage of the cooling fluid. This situation becomes more critical when
applying inflammable refrigerants, because if it is associated with an ignition source,
there may be flame generation and serious risks to the technician's physical integrity.

1 • ELECTRICAL ACCESSORIES
Before removing the protective plastic cover from the electrical components, check if the compressor is
disconnected from the mains and that starting and / or running capacitors are used.
Never handle any electrical accessory with the compressor connected to the mains.
Failure to shut down the mains compressor during maintenance procedures and to apply
a system without a ground fault circuit interrupter (GFCI) or residual current device (RCD),
according to the country technical requirements, may cause serious physical hazards byelectric shock and/or fire to the technician.
Starting and / or running capacitors must be handled with care, as they may cause
electric shock even when disconnected.

When it is necessary to remove the capacitors, carefully disconnect these components with extra attention to the
exposed electrical terminals. The capacitor must be discharged before handling.
Check that the capacitance range (μF) printed on the starting and running capacitor label (if applicable) comply
with the compressor data sheet that is installed in the system. The ACV Voltage value printed on the capacitor
label must be equal to or greater than the value specified in the compressor data sheet. If one of the values(ACV Voltage and / or Capacitance) is not in accordance with the compressor specification, replace the capacitor.
Application of an unsuitable capacitor and / or application of unspecified starting devices(relay or PTC) may cause the capacitor to overheat. Overheated capacitors are subject torupture which can lead to leakage of overheated material, that can lead to burns.
When necessary to disconnect the electrical components of the hermetic compressor terminal, remove theexternal overload protector and the starting device (relay or PTC) by applying longitudinal effort to the pins. Never
apply transverse forces to the pins of the hermetic compressor terminal.
Improper removal of these accessories may cause poor electrical connection, damaging
the hermetic compressor terminal, and causing refrigerant and oil leakage. This situation
becomes more critical when applying flammable refrigerant, because if it is associatedwith an ignition source, there may be flame generation and serious risks to the technician's
physical integrity.
Compare the printed code on the external overload protector, relay or PTC with the compressor data sheet. If thecode is different, replace the component. There are no universal or similar electrical accessories, always use theone specified in the compressor's data sheet
120

Not specified starting devices (relay or PTC) may cause the capacitor to overheat.
Overheated capacitors are subject to rupture which can lead to leakage of overheatedmaterial that can lead to burns.
The use of external overload protector or starting device (relay or PTC) other than specified
can generate short circuit in the hermetic compressor terminal, causing the expulsion ofhermetic pins causing refrigerant and oil leakage. This situation becomes more criticalwhen applying flammable refrigerant, because if it is associated with an ignition source,
there may be flame generation and serious risks to the technician's physical integrity.

1.1 • ELECTRICAL INSTALLATION
GroundPhase

Neutral* related with products produced in Europe, illustrative picture.
In single-phase installations, the Phase wire must be protected by a circuit breaker and connected to the external
overload protector. In case of internal overload protector, the Phase wire must be protected by a circuit breakerand connected directly to common pin. The neutral wire must be connected to the starting device (relay or PTC).
The system must be grounded

GroundPhase 1
Phase 2In the case of two-phase installations, it is mandatory to use a 2-pole circuit breaker, because in case of a shortcircuit both phases of power supply are protected. The system must be grounded121

Failure to use a 2-pole circuit breaker leaves the compressor susceptible to short circuit in
the region of the hermetic compressor terminal, which may cause the hermetic pins to beejected causing the refrigerant and oil to leak. This situation becomes more critical when
applying flammable gas, because if it is associated with an ignition source, there may be
flame generation and serious risks to the technician's physical integrity.
Application of a system without grounding may expose the technician to risk of electric
shock.

2 • COMPRESSOR
If you need to replace the compressor, be aware of the following safety recommendations:.
I.

Make sure the compressor is disconnected from the mains.
Failure to shut down the compressor from the mains during maintenance procedures
may expose the technician to risk of electric shock and fire.

II.

Never remove the compressor before removing all refrigerant from the system. For this, the use of a
fluid collecting machine is recommended. In the case of flammable fluids, such as R290 and R600a,
ensure the removal of small accumulations of gas from the system.

The presence of flammable fluid residues may expose the technician to riskIII.

Use a pipe cutter to disconnect the compressor tubes. Under no circumstances use the flame of thetorch to disconnect the compressor tubes.
The use of a torch to disconnect compressors using flammable refrigerant may cause fireand release toxic vapors.

IV.

In case of compressor burning and / or internal contamination of the system, clean the piping with asuitable solvent applied according to the solvent manufacturer's technical guidelines.
Failure to comply with the solvent manufacturer's technical guidelines may expose thetechnician to fire hazards and intoxication.

V.

Before connecting a compressor, make sure that:.
-

The voltage at the compressor label is suitable for the mains and the electricalinstallation complies with item 1.1.
The application of a compressor in incorrect voltage may cause short circuit in
the hermetic compressor terminal, causing the expulsion of hermetic pins causing
refrigerant and oil leakage. This situation becomes more critical when applying
flammable gas, because if it is associated with an ignition source, there may be flame
generation and serious risks to the technician's physical integrity.

-

The plastic cover for electrical protection is properly seated.
The non-use or improper positioning of the plastic cover may expose the electrical
technician the risk of electric shock and fire.

122

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Subject to alteration without previous notice - Date: November 2022