Copeland YB12K1E, Manual

Page 1: ...Copeland Scroll Compressors for Refrigeration Applications YB12K1E to YB36K1E Application Guidelines ...

Page 2: ...3 2 Mounting parts 8 3 3 Brazing procedure 8 3 3 1 General brazing procedure 9 3 3 2 Brazing procedure for YB K1E compressors in parallel applications 9 3 4 Pressure safety controls 10 3 4 1 High pressure protection 10 3 4 2 Low pressure protection 10 3 5 Protection of A2L refrigerant systems operating below atmospheric pressure 10 3 6 Crankcase heater 11 3 7 Discharge gas temperatureprotection 12...

Page 3: ...procedure 23 5 6 Run in time 23 5 7 Initial start up 23 5 8 Rotationdirection 23 5 9 Starting sound 24 5 10Deep vacuum operation 24 5 11Shell temperature 24 5 12Pumpdowncycle 24 5 13Minimum run time 25 5 14Shut off sound 25 5 15Supply frequency and voltage 25 5 16Oil level 25 6 Maintenance repair 26 6 1 Qualificationof workers 27 6 2 Preparation and work procedure 27 6 3 Disassembling system compo...

Page 4: ...AGL_Ref_ST_YBK1E_EN_Rev01 Appendix 1 Tightening torques 32 DISCLAIMER 32 ...

Page 5: ......

Page 6: ...e allowed to be used with flammable refrigerants Emerson marks all compressors that are qualified for flammable refrigerants with a sticker indicating the usage of such refrigerants Systems using flammable refrigerants must be executed correctly while observing safety rules as specified in corresponding safety standards such as but not limited to EN 378 They must comply with any and all applicable...

Page 7: ...l necessary precautions to mitigate the risk as determined in the risk assessment Use personal safety equipment Safety goggles gloves protective clothing safety boots and hard hats should be worn where necessary 1 3 General instructions WARNING Pressurized system Serious personal injuries and or system breakdown Accidental systemstart beforecompleteset upmustbeavoided Never leave the system unatte...

Page 8: ... 21 TFMN YB36K1E 9 45 9 28 10 1 9 52 9 52 8 62 6 09 5 82 5 01 TFMN Table 1 YB K1E model overview for MT applications with A1 refrigerants Compressor Cooling capacity kW Motor R454C R455A R454A R1234yf YB12K1E 2 76 2 93 3 31 1 84 PFZN TFMN YB17K1E 3 89 4 15 4 64 2 6 PFZN TFMN YB21K1E 4 92 5 22 5 91 3 29 PFZN TFMN YB24K1E 5 55 5 88 6 6 3 71 PFZN TFMN YB31K1E 6 95 7 4 8 32 4 67 TFMN YB36K1E 8 23 8 78...

Page 9: ...filter dryers NOTE R454C R455A R454A and R1234yf are classified as A2L mildly flammable refrigerants Compressors YB12K1E to YB36K1E Qualified refrigerants R454C R455A R454A R1234yf R404A R407A R407F R448A R449A R407C R513A R134a R450A Qualified oil factory charged RL32 3MAF Servicing oil RL32 3MAF Single phase models are released for use with R454C R407C and R134a refrigerants only Table 4 Qualifi...

Page 10: ... pressures temperatures and internal free volumes The PED category is assigned according to the Pressure Equipment Directive PED 2014 68 EU Requirements apply to the relevant pressure levels in the compressor if a limit value for the product of pressure relative to the environment and relevant internal f ree volume is exceeded For the calculation of the PED category a differentiation must be made ...

Page 11: ...165 8 247 5 252 8 115 5 49 YB24K1E 418 391 9 215 4 294 1 75 3 165 8 247 5 252 8 115 5 49 YB31K1E 442 409 6 225 2 296 7 79 6 185 5 260 5 254 9 124 7 44 YB36K1E 442 409 6 225 2 296 7 79 6 185 5 260 5 254 9 124 7 44 Table 7 Dimensions of YB K1E compressors Compressor Suction inch Discharge inch YB12K1E YB17K1E YB21K1E YB24K1E YB31K1E YB36K1E Table 8 Connection sizes of YB K1E compressors NOTE The con...

Page 12: ...age Compressor malfunction Only use the lifting eyes whenever the compressor requires positioning Using discharge or suction connections for lifting may cause damage or leaks The compressor should be kept vertical during handling The discharge connection plug should be removed first before pulling the suction connection plug to allow the dry air pressure inside the compressor to escape Pulling the...

Page 13: ...rts 3 3 Brazing procedure WARNING Air flammable refrigerant mixture Creation of a potentially flammable atmosphere Fire hazard Remove all refrigerant before opening the system When working on a refrigerant filled system make sure to follow the safety and working instructions given in Chapter 6 Maintenance repair WARNING High temperature Burning Proceed with caution when brazing system components D...

Page 14: ...om flowing into it 3 3 2 Brazing procedure for YB K1E compressors in parallel applications WARNING Air flammable refrigerant mixture Creation of a potentially flammable atmosphere Fire hazard Remove all refrigerant before opening the system When working on a refrigerant filled system make sure to follow the safety and working instructions given in Chapter 6 Maintenance repair Only compressor model...

Page 15: ...ng below atmospheric pressure WARNING Operation below ambient pressure Fire hazard During operation below atmospheric pressure a flammable mixture can form inside the system Ensure system tightness to prevent any ingress of air Special requirements for safety and tightness apply to YB K1E compressor systems that are to be operated below atmospheric pressure The following precautions must be observ...

Page 16: ...ld is a very critical moment for any compressor because all load bearing surfaces are new and require a short break in period to carry highloads under adverse conditions The crankcase heater must be turned on a minimum of 12 hours prior to starting the compressor This will prevent oil dilution and bearing stress on initial start up The crankcase heater must remain energized during compressor off c...

Page 17: ...system performance and short cycling NOTE The maximum discharge gas temperatures indicated in this chapter are valid for safe operation within the approved application envelope The discharge line thermostat has the function of a compressor protection device it is not designed to control the operating envelope For compressor envelope control an additional control device or regulation must be used 3...

Page 18: ... contactwith sharp objects To avoid any impacton tripping temperature by the ambient the discharge line thermostat mustbe insulated Wrap thermal insulation around the pipe left and right of the thermostatand secure itwith plastic straps Wrap a second layer of insulation around the firstone and around the thermostatand secure it with plastic straps 3 8 Internal pressure relief valve There is an int...

Page 19: ...nd shell material is not an ignition source for A2L refrigerants R454C R455A R454A and R1234yf NOTE Please see Emerson spare parts software at www climate emerson com en gb tools resources to check the available sound shell kits according to compressor model 3 13 Insulation material Insulation material is commonly used in a system to insulate the suction line suction accumulator expansion valve bu...

Page 20: ...include defrostand varyingloads If thesystemis reversible thetestsshouldbeconductedinbothoperation modes System engineers should review the system design and operation to identify the critical conditions and to check oil return oil balancing liquid floodback and oil dilution For discussionof individual test results and system behaviour eg with regard to oil dilution please contact the Application ...

Page 21: ...and oil dilution tests If an accumulator is used the oil return orifice should be from 1 to 1 4 mm in diameter for all YB K1E modelsdependingoncompressorsizeand compressorfloodbackresults To protectthissmall orifice from plugging with system debris a large area protective screen no finer than30 x 30 mesh 0 6 mm openings is required Tests have shown that a small screen with a fine mesh can easily b...

Page 22: ...is not an ignition source during normal operation but could become one if not installed properly according to installation instructions Ensure correct mechanical and electrical installation System capacitors may remain charged for several minutes after shutdown Before starting to work on the electrical installation make sure sparking is not possible Continuously check if the ambient atmosphere is ...

Page 23: ...HP limiter S1 Auxiliary switch F4 LP limiter RCD Residual currentdevice A2L systems C S R Common C Start S Run R C2 Run capacitor Figure 14 Wiring diagrams for single phase YB K1E compressors Run capacitor for single phase compressor Compressor Run capacitor YB12K1E PFZN 45 µF 370 V YB17K1E PFZN 50 µF 370 V YB21K1E PFZN 60 µF 370 V YB24K1E PFZN 60 µF 370 V Table 11 Run capacitor selection table fo...

Page 24: ...tingwithflammablerefrigerantsshalluseonly thequalified terminal box supplied with the compressor CAUTION Mechanical stress or shock Overheating Terminal Fusite damage and leakage Mechanical stress and shocks to the Fusite must be avoided as they could damage the glass and or ceramic This might result in hermetic failure or loss of terminal performance Precautions are required to prevent striking o...

Page 25: ...shock hazard Shut off power supply before high potential testing CAUTION Internal arcing Motordestruction Donotperform high voltageorinsulation tests if the compressor housing is under vacuum Emerson subjects all scroll compressors to a high voltage test after final assembly Each motor phase winding is tested according to EN 60034 1 at a differential voltageof 1000 V plus twice the nominal voltage...

Page 26: ...zones The compressor high side and low side maximum allowable pressures PS have to be respected at all times 5 1 2 System strength pressure test A strength pressuretest of individual sections of theentiresystemis permitted Oncethecompressor is isolated the rest of the system can be tested with the required pressure values The strength pressure test can also be conducted with the compressor connect...

Page 27: ...the vacuum pump this serves to avoid incorrect measurements resulting from the pressure gradient along the connecting lines to the pump Evacuating the system only on the suctionside of a scroll compressor can occasionally result in a temporary no start condition for the compressor The reason for this is that the floating seal could axially seal with the scroll set with the higher pressure on the f...

Page 28: ...wer during the initial running period Published performance ratings are based on calorimeter testing which is carried out after run in Therefore users should be aware that before the performance specified by EN 12900 is achieved the compressor needs to be run in Recommended run in times for YB K1E compressors to attain the published performance are 16 hours at the standard conditions 5 7 Initial s...

Page 29: ...ystems Operating scroll compressors in deep vacuum could damage internal motor parts and lead to unacceptable high temperatures in the compressor housing 5 11 Shell temperature During normal operation the discharge gas as well as the compressor top shell and discharge line can reach temperatures up to the maximum discharge gas temperature of 130 C see section 3 7 Discharge gas temperature protecti...

Page 30: ...of considerations must be taken into account when applying scroll compressors with variable speed including system design inverter selection and operating envelopes at various conditions Onlyfrequenciesfrom50to 60Hzareacceptable Operationoutsidethisfrequency range is possible but should not be done without specific ApplicationEngineering review The voltage must vary proportionally to the frequency...

Page 31: ... inert gas before undertaking any work and before brazing WARNING Open flame in a potentially flammable atmosphere Fire hazard The area shall be checked with an appropriate refrigerant detector prior to and during work on an A2L refrigerant system to ensure the technician is aware of a potentially toxic or flammable atmosphere Ensure that the leak detection equipment being used is suitable for use...

Page 32: ...rigerant in a confined space 6 3 Disassembling system components When disassembling system components please follow the main steps described hereunder 1 For A1 refrigerant systems R404A R407A R407F R448A R449A R407C R513A R134a and R450A recover refrigerant and evacuate system using a recovery unit and vacuum pump All the refrigerant shall be recovered to avoid significant release 2 For A2L refrig...

Page 33: ...lacement In the case of A2L refrigerant compressor replacement the oil has to be drained out of the compressor and the compressor should be flushed with dry nitrogen DO NOT close the stubs with plugs In case of a motor burnout the majority of contaminated oil will be removed with the compressor The rest of the oil is cleaned through theuse of suction and liquid line filter driers A 100 activated a...

Page 34: ...gtool Drainand recovercompressoroilproperly Flush the compressor with dry nitrogen again for a few minutes The compressor should be returned free of oil and with connections open do not close connections with plugs Collect and secure the oil properly Provide information about the quantity of oil drained from the compressor and its colour Ideally send a good picture Dispose of the oil according to ...

Page 35: ...m an oil sample should betakenand tested for moisture Sight glass moisture indicators currently available can be used with the HFC refrigerants and lubricants however the moisture indicator will just show the moisture content of the refrigerant The actual moisture level of POE would be higher than the sight glass indicates This is due to the highhygroscopicity of thePOEoil To determinetheactual mo...

Page 36: ...l legislation and regulations 8 References Please visit www climate emerson com en gb for free download of Application Guidelines and Technical Information Performance and technical data The latest version of Copeland Select software with performance data and technical data is available from the webpage www climate emerson com en gb Spare parts and accessories Visit www climate emerson com en gb t...

Page 37: ...antees express or implied regarding the products or services described herein or their use or applicability 2 Emerson Climate Technologies GmbH and or its affiliates collectively Emerson as applicable reserve the right to modify the design or specifications of such products at any time without notice 3 Emerson does not assumeresponsibility for the selection use or maintenance of any product Respon...

Page 38: ...i Free Zone South Dubai UAE Tel 971 4 811 81 00 Fax 971 4 886 54 65 mea sales emerson com ASIA PACIFIC Suite 2503 8 25 F Exchange Tower 33 Wang Chiu Road Kowloon Bay Kowloon Hong Kong Tel 852 2866 3108 Fax 852 2520 6227 CZECH REPUBLIC Hajkova 22 CZ 133 00 Prague Tel 420 733 161 651 Fax 420 271 035 655 Pavel Sudek emerson com SPAIN PORTUGAL C Pujades 51 55 Box 53 ES 08005 Barcelona Tel 34 93 412 37...