COPELAND AE5-1181 Discharge Line Mufflers Instruction Manual

COPELAND AE5-1181 Discharge Line Mufflers

Product Specifications

• Manufacturer: Refrigeration Research
• Location: Brighton, Michigan
• Product Types: Discharge Line Mufflers, Compressor Muffler Plates

Discharge Line Mufflers
Discharge Line Mufflers are designed to smooth out pulsations and reduce noise in refrigeration systems. They are available in various sizes and capacities as listed in Table 1.

Table 1 – Refrigeration Research Mufflers

Compressor Muffler Plates
Compressor Muffler Plates are standard equipment on two-stage compressors. Refer to Table 2 for available muffler plates and their specifications.

Table 2 – Discharge Muffler Plates

Product Usage Instructions

Safety Information
It is vital to follow safety guidelines during the design, manufacture, installation, and maintenance of the system. Terminal venting and pressurized system hazards should be handled with caution to prevent injuries or damage.

Frequently Asked Questions (FAQ)

• Q: How do I determine the correct muffler size for my system?
  A: The recommended capacity range for each muffler size is provided in the tables. Actual performance may vary, so testing under normal operating conditions is necessary for precise determination.

• Q: Are gaskets included with the muffler plates?
  A: Yes, gaskets are required for installation. Refer to the part numbers and sizes listed in Table 2 for the appropriate gaskets.

AE4-1181 R7
January 2020
Reformatted November 2023

Discharge Line Mufflers

• The noise characteristics of a large refrigeration or air conditioning system, particularly when installed with long refrigerant lines and remote condensers, are not predictable. Variations in piping configuration, the pattern of gas flow, line sizes, operating pressures, the compressor and unit mounting, all can affect the noise generated by the system. Occasionally a particular combination of gas flow and piping will result in a resonant frequency which may amplify the sound and vibration to an undesirable level. Gas pulsation from the compressor may also be amplified in a similar manner.
• If gas pulsation or resonant frequencies are encountered on a particular application, a discharge line muffler may be helpful in correcting the problem. The purpose of a muffler is to dampen the pulses of gas in the discharge line and to change the frequency to a level which is not objectionable. A muffler normally depends on multiple internal baffles and/or pressure drop to obtain an even flow of gas. In general, the application range of a muffler depends on the volume and density of the refrigerant gas discharged from the compressor. Both are factors in muffler performance.
• A given muffler may work satisfactorily on a fairly wide range of compressor sizes, but it is also quite possible that a given system may require a muffler with a particular pressure drop to effectively dampen pulsations. On truly problem applications, trial and error may be the only final guide. While larger mufflers are often more efficient in reducing the overall level of compressor discharge noise order to satisfactorily dampen pulsations, smaller mufflers with a greater pressure drop are usually more effective. Adjustable mufflers are often helpful since they allow tuning of the muffler pressure characteristics to the exact system requirement.
• Table 1 lists mufflers manufactured by Refrigeration Research, Brighton, Michigan, which have been applied satisfactorily within the recommended capacity range. The size suggested will normally smooth out pulsations and reduce noise on most systems, but the exact performance on a given system can only be determined by actual tests under normal operating conditions.

Compressor Muffler Plates
Occasionally, a combination of operating conditions, mounting and piping arrangement may result in a resonant condition, which tends to magnify compressor pulsation and cause a sharp vibration, although noise may not be a problem. For larger Copelametic® compressors, discharge muffler plates have been developed for use when necessary to dampen excessive pulsation. The muffler plate fits between the discharge valve and the compressor body and has a number of muffling holes to provide the proper characteristics for the particular compressor displacement. The muffling holes break up the pattern of gas flow and create sufficient restriction to reduce the gas pulsation to a minimum.
Muffler plates are provided as standard equipment on two stage compressors. Table 2 lists muffler plates available should they be required.

Table 1
(Tentative Selection Only – Exact Performance Must Be Determined by Test) Refrigeration Research Mufflers

DISCHARGE MUFFLERS

M20 SHOW

Catalog Number| Part Number| Tons| O.D.| Overall Length| Fitting Size| Weight Pounds| Fusible Plug
---|---|---|---|---|---|---|---
M-2| 1760| 2| 2| 7 – 7/16| 3/8| 1.0| Not Required
M-3| 1761| 3| 2| 7 – 7/16| ½| 1.0| Not Required
M-5| 1762| 5| 2| 7 – 7/16| 5/8| 1.0| Not Required
M-10| 1758| 7 – 1/2 to 10| 3| 9| 7/8| 2.6| Not Required
M-15| 1792| 10 to 15| 3| 9 – 1/4| 1 – 1/8| 3.0| Not Required
M-20| 1771| 15 to 25| 3| 13 – 3/4| 1 – 3/8| 3.7| Not Required
M-30| 1772| 25 to 50| 4| 16| 1 – 5/8| 6.0| 362°F
M-60| 1790| 50 to 75| 6| 26 – 1/2| 2 – 1/8| 15.7| 362°F
M-80| 1791| 75 to 100| 6| 28| 2 – 5/8| 17.5| 362°F
M-110| 1793| 100 to 125| 6| 36| 3 – 1/8| 32.5| 362°F

ADJUSTABLE MUFFLER

Catalog Number| Tons| O.D.| Overall Length| Fitting Size| Weight Pounds
---|---|---|---|---|---
AM-5| 2 to 5| 4| 10| 5/8| 3.5
AM-10| 5 to 10| 4| 11| 7/8| 3.8
AM-25| 10 to 25| 4| 14 – 1/4| 1 – 1/8| 5.1

Table 2
Discharge Muffler Plates

Capacity Control Muffler Plate
003-0107-00| 9RP| 2| 2 – 3/4″| 6| 3/16″| 020-0489-00| 1.50
003-0107-00| 9RT| 2| 2 – 3/4″| 6| 3/16″| 020-0489-00| 1.50

The contents of this publication are presented for informational purposes only and are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. Copeland LP and/or its affiliates (collectively “Copeland”), as applicable, reserve the right to modify the design or specifications of such products at any time without notice. Copeland does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any Copeland product remains solely with the purchaser or end user.

IMPORTANT SAFETY INFORMATION

Those involved in the design, manufacture, and installation of a system, system purchasers, and service personnel may need to be aware of hazards and precautions discussed in this section and throughout this document. OEMs integrating the compressor into a system should ensure that their own employees follow this bulletin and provide any necessary safety information to those involved in manufacturing, installing, purchasing, and servicing the system.

Responsibilities, Qualifications and Training

• OEMs are responsible for system design, selection of appropriate components, integration of this component into the system, and testing the system. OEMs must ensure that staff involved in these activities are competent and qualified.
• OEMs are also responsible for ensuring that all product, service, and cautionary labels remain visible or are appropriately added in a conspicuous location on the system to ensure they are clear to any personnel involved in the installation, commissioning, troubleshooting or maintenance of this equipment.
• Only qualified and authorized HVAC or refrigeration personnel are permitted to install, commission, troubleshoot and maintain this equipment. Electrical connections must be made by qualified electrical personnel.
• Observe all applicable standards and codes for installing, servicing, and maintaining electrical and refrigeration equipment.

Terminal Venting and Other Pressurized System Hazards
If a compressor’s electrical terminal pin loses its seal, pressurized oil, refrigerant, and debris may spray out. This is called “terminal venting”.

The ejected debris, oil, and refrigerant can injure people or damage property. The oil and refrigerant spray can be ignited by electrical arcing at the terminal or any nearby ignition source, producing flames that may project a significant distance from the compressor. The distance depends on the pressure and the amount of refrigerant and oil mixture in the system. The flames can cause serious or fatal burns and ignite nearby materials.
Each compressor has a terminal cover or molded plug that covers electrical connections. The cover or plug helps to protect against electric shock and the risks of terminal venting. If terminal venting occurs, the cover or plug helps contain the spray of refrigerant and oil and reduces the risk of ignition. If ignition occurs, the plug or cover helps contain the flames. However, neither the terminal cover nor the molded plug can completely eliminate the risk of venting, ignition, or electric shock.
See copeland.com/terminal-venting for more details about terminal venting.
Additionally, a compressor’s refrigerant lines keep refrigerant and oil under pressure. When removing or recharging refrigerant from this component during service, this can pose a pressurized fluid hazard.

Flammable Refrigerant Hazard
If flammable refrigerant is released from a system, an explosive concentration can be present in the air near the system. If there is an ignition source nearby, a release of flammable refrigerant can result in a fire or explosion. While systems using flammable refrigerant are designed to mitigate the risk of ignition if the refrigerant is released, fire and explosion can still occur.

See copeland.com/flammable-refrigerants for more information on flammable refrigerant safety.

Electrical Hazards
Until a system is de-energized, and capacitors have been discharged, the system presents a risk of electric shock.

Hot Surface and Fire Hazards
While the system is energized, and for some time after it is deenergized, the compressor may be hot. Touching the compressor before it has cooled can result in severe burns. When brazing system components during service, the flames can cause severe burns and ignite nearby combustible materials.

Lifting Hazards
Certain system components may be very heavy. Improperly lifting system components or the compressor can result in serious personal injury. Use proper lifting techniques when moving.

POE Oil Hazards
This equipment contains polyol ester (POE) oils. Certain polymers (e.g., PVC/CPVC and polycarbonate) can be harmed if they come into contact with POE oils. If POE oil contacts bare skin, it may cause an allergic skin reaction.

Precautions

• Always wear personal protective equipment (gloves, eye protection, etc.).
• Keep a fire extinguisher at the jobsite at all times.
• Keep clear of the compressor when power is applied.
  • IMMEDIATELY GET AWAY if you hear unusual sounds in the compressor. They can indicate that terminal pin ejection may be imminent. This may sound like electrical arcing (sizzling, sputtering or popping). However, terminal venting may still occur even if you do not hear any unusual sounds.
• Never reset a breaker or replace a blown fuse without performing appropriate electrical testing
  • A tripped breaker or blown fuse may indicate an electrical fault in the compressor. Energizing a compressor with an electrical fault can cause terminal venting. Perform checks to rule out an electrical fault.
• Disconnect power and use lock-out/tag-out procedures before servicing.
  • Before removing the terminal cover or molded plug, check that ALL electrical power is disconnected from the unit. Make sure that all power legs are open. (Note: The system may have more than one power supply.)
  • Discharge capacitors for a minimum of two minutes
  • Always use control of hazardous energy (lock-out/tag-out) procedures to ensure that power is not reconnected while the unit is being serviced.
• Allow time for the compressor to cool before servicing.
  • Ensure that materials and wiring do not touch high temperature areas of the compressor.
• Keep all non-essential personnel away from the compressor during service.
• Remove refrigerant from both the high and low side of the compressor. Use a recovery machine and cylinder designed for flammable refrigerants. Do not use standard recovery machines because they contain sources of ignition such as switches, high- and low-pressure controls, and relays. Only vent the refrigerant into the atmosphere if the system is in a well-ventilated area.
• Never us a torch to remove the compressor. Only tubing cutters should be used.
• Use an appropriate lifting device to install or remove the compressor.
• Never install a system and leave it unattended when it has no charge, a holding charge, or with the service valves closed without electrically locking out the system.
• Always wear appropriate safety glasses and gloves when brazing or unbrazing system components.
• Charge the system with only approved refrigerants and refrigeration oils.
• Keep POE oils away from certain polymers (e.g., PVC/CPVC and polycarbonate) and any other surface or material that might be harmed by POE oils. Proper protective equipment (gloves, eye protection, etc.) must be used when handling POE lubricant. Handle POE oil with care. Refer to the Safety Data Sheet (SDS) for further details.
• Before energizing the system:
  1. Securely fasten the protective terminal cover or molded plug to the compressor, and
  2. Check that the compressor is properly grounded per the applicable system and compressor requirements.

Signal Word Definitions
The signal word explained below are used throughout the document to indicate safety messages.

| DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.
---|---
| WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
| CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury

References

• Flammable Refrigerants | Copeland US
• Terminal Venting | Copeland US

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