Emerson Copeland YF05K1E, Application Manuallines

Page 1: ...Copeland Scroll Compressors for Refrigeration Applications YF05K1E to YF15K1E Application Guidelines ...

Page 2: ... parts 8 3 3 Brazing procedure 8 3 3 1 General brazing procedure 9 3 3 2 Brazing procedure for YF 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 3 7 1 Exces...

Page 3: ...rting 22 5 5 Charging 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 Disa...

Page 4: ...AGL_Ref_ST_YFK1E_EN_Rev01 8 References 31 Appendix 1 Tightening torques 32 DISCLAIMER 32 ...

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Page 6: ...sors are 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 app...

Page 7: ...le standards and the maximum refrigerant charge shall not be exceeded If a flammable atmosphere is detected immediately take all 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 p...

Page 8: ...4 2 43 2 43 14 4 TFDN YF15K1E 3 06 2 88 3 12 3 12 3 10 17 1 TFDN Table 1 YF K1E model overview for LT applications with A1 refrigerants Compressor Cooling capacity kW Displacement m3 h Motor R454C R455A R454A YF05K1E 0 93 1 04 1 20 5 9 TFDN YF06K1E 1 15 1 28 1 48 7 3 TFDN YF07K1E 1 27 1 40 1 64 8 0 TFDN YF09K1E 1 56 1 74 2 02 9 9 TFDN YF10K1E 1 86 2 05 2 40 11 8 TFDN YF13K1E 2 27 2 49 2 93 14 4 TF...

Page 9: ...w GWP containing HFO s have a low chemical stability inpresenceof airorhumidity Thesamelevels of cleanliness dryness and evacuation of the refrigerant circuit are required as in HFC POE applications including the use of filter dryers NOTE R454C R455Aand R454A are classified as A2L mildly flammable refrigerants Compressors YF05K1E to YF15K1E Qualified refrigerants R404A R407A R407F R448A R449A R454...

Page 10: ...r g 50 C 6 4 0 6 Table 5 Maximum allowable 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 PE...

Page 11: ...dels BOM versions GDW and GDZ Compressor A 3 0 mm B mm C 3 0 mm D mm E mm F mm Ø G mm Ø H mm Ø I mm Ø J mm YF05K1E 368 8 343 8 244 5 280 163 1 69 6 1 2 3 4 165 8 3 8 YF06K1E YF07K1E 391 4 366 4 264 4 302 6 185 7 75 3 1 2 3 4 165 8 3 8 YF09K1E 405 1 380 1 277 1 316 4 198 4 88 1 2 3 4 165 8 3 8 YF10K1E to YF15K1E 442 409 6 296 7 340 9 225 2 79 6 1 2 7 8 185 5 3 8 Table 7 Dimensions of YF K1E compres...

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: ...arts 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 ...

Page 14: ...terial from flowing into it 3 3 2 Brazing procedure for YF 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 compres...

Page 15: ...g 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 YF K1E compressor systems that are to be operated below atmospheric pressure The following precautions must be observe...

Page 16: ...oad 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 cycles NOTE Please refer to the accessories and spare parts li...

Page 17: ...perheat is maintained and has theabilitytocopewithall likelyconditionsand highloads Relianceonprotectors will cause inadequate 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 desig...

Page 18: ...ure and recommendations hereunder Assembly of the discharge line thermostat Install the discharge line thermostaton the discharge tube 120 mm from top cap Snap the retainer clip over the tube and onto the thermostat The thermostatshould be placed on the discharge tube so that its body is in upward position on a horizontal tube installation Ensure that the thermostatis not tilted The wire mustnot b...

Page 19: ...ckage can result in compressor failure 3 11 Mufflers Gas flow through scroll compressors is continuous with relatively low pulsation External mufflers may not be required on Copeland scroll compressors Due to system variability individual tests should be conducted by the system manufacturer to verify acceptable levels of sound and vibration If adequate attenuation is not achieved use a muffler wit...

Page 20: ... the oil could wash the oil off the bearings and moving parts and could lead to local overheating and compressor failure The system piping must be carefully designed to ensure sufficient refrigerant gas velocity so that oil returns to the compressor at all times and conditions Individual piping diameter calculation depends on the refrigerant properties pressure mass flow and density Once a new sys...

Page 21: ...xpansion device s The bottom shell temperature should be measured accurately The thermo probe must be insulated well and positioned on the opposite sideof the sight glass or at an angle of 90 clockwisefrom the suction inlet with view on the top 3 16 Liquid injection The use of liquid injection is mandatory for all YF K1E compressors in low temperature applications with R404A R407A R407F R448A R449...

Page 22: ... the insulated capillary tube and the compressor top is 3 mm Figure 15 DTC valve overview Figure 16 DTC valve assembly The DTC valves are supplied with a thermo protection cap which is applied to the top of the compressor Before starting the compressor ensure that there is liquid refrigerant in front of the DTC valve inlet Otherwise the valve could be damaged 3 18 Suction line accumulator Due to C...

Page 23: ...trical shock hazard Shut off power supply before undertaking any task on electrical equipment WARNING Ignition source in a potentially flammable atmosphere Fire hazard In applications with A2L refrigerants the electrical connection of the scroll compressors is not an ignition source during normal operation but could become one if not installed properly according to installation instructions Ensure...

Page 24: ...nition Do not touchthe energized terminals with a tool or cable when the compressor is energized Compressorsoperatingwithflammablerefrigerantsshalluseonly thequalified terminal box supplied with the compressor CAUTION Mechanical stress or shock Overheating Terminal Fusite damageand leakage Mechanical stress and shocks to the Fusite must be avoided as they could damage the glass and or ceramic This...

Page 25: ... compressor is charged with flammablerefrigerant WARNING Conductor cables Electrical shock 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 t...

Page 26: ...The compressor high side and low side maximum allowable pressures PS values 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 connec...

Page 27: ...essure gauge on the access valves and not on 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...

Page 28: ...ease in input power 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 YF K1E compressors to attain the published performance are 16 hours at the standard conditio...

Page 29: ...m 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 protection In a failuremode thedischargegas temperaturesc...

Page 30: ...AC drives A number 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 proportional...

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: ...ammable refrigerant 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 and R449A 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 refrigerant systems...

Page 33: ...om the replaced compressor 6 5 1 Compressor 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 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 ...

Page 34: ...gen 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 local rules and regulations Use a proper cardboard box package when preparing t...

Page 35: ...ure 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 moisturecontentof thelubricant samples have to be ta...

Page 36: ...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 tools resources copeland select software Spare parts and accessories Visit www ...

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...

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