Emerson Copeland Scroll YH16K1E, Application Manuallines

Page 1: ...Copeland Scroll Compressors for Heat Pump Applications YH04K1E to YH16K1E Application Guidelines ...

Page 2: ...dling 7 3 1 1 Transport and storage 7 3 1 2 Positioning and securing 7 3 1 3 Installation location 7 3 2 Mounting parts 8 3 3 Brazing procedure 8 3 3 1 General brazing procedure 9 3 3 2 Brazing procedure for YH 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 Crankcase heater 10 3 6 Discharge gas tempe...

Page 3: ...tion direction 22 5 9 Starting sound 22 5 10 Deep vacuum operation 22 5 11 Shell temperature 22 5 12 Pumpdown cycle 23 5 13 Minimum run time 23 5 14 Shut off sound 23 5 15 Supply frequency and voltage 23 5 16 Oil level 24 6 Maintenance repair 25 6 1 Qualification of workers 25 6 2 Preparation and work procedure 26 6 3 Disassembling system components 26 6 4 Provisions of legislation leak check requ...

Page 4: ...AGL_HP_ST_YHK1E_E_Rev02 9 References 33 DISCLAIMER 33 ...

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Page 6: ...ions and conform to the corresponding provisions of legislation NOTE Emerson marks all compressors that are qualified for A2L refrigerants with a sticker indicating the usage of flammable refrigerants Systems using such refrigerants must comply with any and all applicable legislation and regulations such as but not limited to EN 378 Ensuring compliance remains the user s responsibility The Materia...

Page 7: ...tection must be observed 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 system start before complete set up must be avoided Never leave the system unattended without locking it out electrically when it is...

Page 8: ... overview operation at 7 C 50 C 10 K 0 K The YH K1E compressors have one scroll compression set driven by a three phase induction motor The scroll set is mounted at the upper end of the rotor shaft of the motor The rotor shaft axis is in the vertical plane 2 2 Nomenclature The model designation contains the following technical information about the compressor Figure 1 Nomenclature of YH K1E compre...

Page 9: ...of at least 5 K is required For application envelopes and technical data please refer to Copeland brand products Select software available at www climate emerson com en gb 2 4 3 PED category and maximum allowable pressure PS The YH K1E compressor models covered in these guidelines are PED Class II according to the Pressure Equipment Directive PED 2014 68 EU The pressure PS is the maximum allowable...

Page 10: ...3 0 mm D mm E mm Ø G inch YH04K1E 364 6 338 5 165 8 244 5 69 6 3 4 YH06K1E 387 2 361 1 185 7 264 4 75 3 YH07K1E 400 9 374 9 198 4 277 1 YH09K1E 418 391 9 215 4 294 1 7 8 Table 5 Dimensions for compressor models YH04K1E to YH09K1E NOTE The connection in blue colour is an additional connection for paralleling models ...

Page 11: ...Ø A inch B mm YH11K1E YH13K1E 1 2 124 7 YH16K1E 3 4 131 0 YH11K1E YH13K1E paralleling ready 3 4 124 7 YH16K1E paralleling ready 3 4 131 0 Table 6 Dimensions for compressor models YH11K1E to YH16K1E NOTE The connection in blue colour is an additional connection for paralleling models ...

Page 12: ...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 plu...

Page 13: ... 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 Do n...

Page 14: ...g procedure for YH 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 models officially approved by Emerso...

Page 15: ...elow atmospheric pressure Emerson requires that YH K1E compressors be fitted with a low pressure control with no service valve between the low pressure side and the pressure control For hermetically sealed system in case the approved application envelope is below atmospheric pressure the following rules shall be observed valid only for hermetically sealed systems see safety standards for definitio...

Page 16: ...cording to compressor size and required wattage Check the compressor application guidelines for crankcase heater connection and operation Position the crankcase heater between the lower cover and the lower bearing weld projection Fig 7 Fit the heater horizontally around the crankcase ensuring that it is in close contact with the compressor housing along the entire length Avoid having the heating p...

Page 17: ...ntrol an additional control device or regulation must be used 3 6 1 Excessive discharge gas temperature A few of the possible consequences of excessive discharge gas temperatures are listed below Since the oil circulates in the system with the refrigerant it is subjected to high discharge gas temperatures If the discharge gas temperature becomes too high the so called cooking effect will occur hea...

Page 18: ...ipe left and right of the thermostat and secure it with plastic straps Wrap a second layer of insulation around the first one and around the thermostat and secure it with plastic straps 3 7 Internal pressure relief valve An internal pressure relief valve is provided on Copeland Scroll compressor models YBD K1E It opens at a differential pressure of 28 bar 3 bar between high and low pressure sides ...

Page 19: ...nition source 3 12 Insulation material Insulation material is commonly used in a system to insulate the suction line suction accumulator expansion valve bulb or discharge line thermostat When choosing the insulation material particular attention shall be paid to its non electrostatic properties as it could be a potential ignition source 3 13 Sound and vibration WARNING Vibrations Creation of a fla...

Page 20: ...Testing conditions shall include defrost and varying loads If the system is reversible the tests should be conducted in both operation modes System engineers should review the system design and operation to identify the critical conditions and to check oil return oil balancing and liquid floodback Typically the following situations should be considered In single compressor systems to check oil ret...

Page 21: ...n an accumulator is not required in most systems To determine if a suction line accumulator is required the system designer must check this with an appropriate test scenario See Chapter 3 14 Compressor oil return oil balancing and floodback tests If an accumulator is used the oil return orifice should be from 1 to 1 4 mm in diameter for all YH K1E models depending on compressor size and compressor...

Page 22: ...e Protect cable and wires against sharp edges 4 2 Electrical installation WARNING Conductor cables Electrical shock Shut off power supply before undertaking any task on electrical equipment WARNING Ignition source in a potentially flammable atmosphere Fire hazard The electrical connection of the scroll compressors is not an ignition source during normal operation but could become one when not inst...

Page 23: ...n the compressor is energized Compressors operating with flammable refrigerants shall use only the qualified terminal box supplied with the compressor 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 ...

Page 24: ...ential testing CAUTION Internal arcing Motor destruction Do not carry out high voltage or insulation 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 voltage of 1000V plus twice the nominal voltage Since high voltage tests lead to premature...

Page 25: ...RNING High pressure Personal injuries Consider personal safety requirements and refer to test pressures prior to test CAUTION System contamination Bearing malfunction Use only dry inert gases for example nitrogen for leak testing DO NOT USE other industrial gases The compressor has been leak pressure tested in the Emerson factory Therefore it is not necessary for the system manufacturer installer ...

Page 26: ...e and compound gauges fitted correctly charged with refrigerant compressor electrical isolator location position 5 5 Charging procedure WARNING Air A2L refrigerant mixture in a potentially flammable or explosive atmosphere Fire and explosion hazard Only use filling equipment designed and approved for use and operation with A2L refrigerants Make sure all connections are tight to avoid leakage Make ...

Page 27: ...rises when the compressor is energized allows verification of proper rotation direction There is no negative impact on durability caused by operating three phase Scroll compressors in the reversed direction for a short period of time under one hour but oil may be lost Oil loss can be prevented during reverse rotation if the tubing is routed at least 15 cm above the compressor After several minutes...

Page 28: ... the minimum suction pressure allowed by the operating envelope 5 13 Minimum run time Emerson recommends a maximum of 10 starts per hour There is no minimum off time because scroll compressors start unloaded even if the system has unbalanced pressures The most critical consideration is the minimum run time required to return oil to the compressor after start up To establish the minimum run time a ...

Page 29: ...rom the system to the compressor should be evaluated and qualified For this purpose a sample compressor for lab testing equipped with an external oil sight tube is available from Emerson The BOM GCG version contains a stub tube connection 7 8 22 2 mm for paralleling on the compressor housing at oil level height If an oil regulator is used the oil level should be set within the top half of the oil ...

Page 30: ...flammable atmosphere Ensure that the leak detection equipment being used is suitable for use with all applicable refrigerants Personnel performing work on a refrigeration system that involves exposing the pipework shall avoid using any ignition source in a way that could lead to a fire or explosion hazard All sources of ignition shall be kept sufficiently far from the site of installation repair r...

Page 31: ...rogen Compressed air or oxygen shall not be used for purging refrigerant systems 3 Disassemble components with a cutting tool 4 Drain recover and dispose of compressor oil as appropriate Figure 17 Tube connecting areas To disconnect Using a pipe cutting tool cut off the suction and discharge lines in such a manner that the new compressor can easily be re connected into the system Heat joint areas ...

Page 32: ...essor replacement 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 the case of a motor burnout the majority of contaminated oil will be removed with the compressor The rest of the oil is cleaned through the use of suction and liquid line filter driers A 1...

Page 33: ...ckage when preparing the compressor for shipment Place warning icons on each side and on the top of the box Mention the following message on the box Warning Flammable A2L or A3 refrigerant compressor for analysis The compressor shipment must be kept in the upright position mark it accordingly If more than one compressor must be returned each compressor must be packed individually NOTE Check with y...

Page 34: ... POE would be higher than the sight glass indicates This is due to the high hygroscopicity of the POE oil To determine the actual moisture content of the lubricant samples have to be taken from the system and analysed 6 8 Oil additives Although Emerson cannot comment on any specific product from our own testing and past experience we do not recommend the use of any additives to reduce compressor b...

Page 35: ...ternal compressor mechanical damage Refrigeration migration When the compressor is switched off for a long period refrigerant can condense in the crankcase If the compressor body is colder than the evaporator refrigerant will move from the evaporator to the compressor crankcase Refrigerant migration normally occurs when the compressor is installed in a cold area A crankcase heater and or a pumpdow...

Page 36: ...sually the consequence of oversized selection of the expansion valve or incorrect bulb sensor mounting The valve may freeze up in the open position due to accumulation of debris in the system For a system with very short refrigeration lines a suction line accumulator is recommended Compressor operating outside the design limits Check the compressor suction and discharge pressures while it is runni...

Page 37: ...the number of cycles to maximum 10 per hour Low gas velocity System gas velocity changes depending on temperature and load capacity control In low load conditions gas velocity may not be high enough to return oil to the compressor Low discharge pressure Low ambient temperature Fit a fan cycling control system Refrigerant undercharge Check the system for leaks Observe sight glass for bubbles if fit...

Page 38: ...www climate emerson com en gb tools resources for an online version of the Emerson spare parts and accessories software DISCLAIMER 1 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 2 Emerson Climate Technologies ...

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