Emerson Copeland YRH KTE Series, Application Manuallines

Page 1: ...Copeland Scroll Horizontal Compressors forTransport Applications YRH V KTE KTG Application Guidelines ...

Page 2: ... securing 7 3 1 3 Installation location maximum tilting and rotating angles 8 3 2 Mounting parts 8 3 3 Brazing procedure 8 3 4 Pressure safety controls 9 3 4 1 High pressure protection 9 3 4 2 Low pressure protection 9 3 5 System protection for operation below atmospheric pressure 10 3 6 Crankcase heater 10 3 7 Discharge gas temperature protection 11 3 7 1 External discharge line temperature senso...

Page 3: ...Shell temperature 22 5 11 Refrigerant migration 22 5 12 Pumpdown cycle 22 5 13 Minimum run time 23 5 14 Shut off sound 23 5 15 Supply frequency and voltage 23 5 16 Oil level 23 6 Maintenance repair 24 6 1 Qualification of workers 25 6 2 Preparation and work procedure 25 6 3 Disassembling system components 25 6 4 Exchanging the refrigerant 26 6 5 Replacing a compressor 26 6 5 1 Compressor replaceme...

Page 4: ...fety Regulation 2016 They may be put to service only if they have been installed in systems according to instructions and conform to the corresponding provisions of the applicable legislation NOTE Only dedicated compressors 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 refri...

Page 5: ... 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 on vacuum and has no re...

Page 6: ...ficantly higher requirements with regard to mechanical load system design general function tightness conditions of the electrical supply and many other details The qualification for the whole system and all individual requirements eg component selection piping piping layout fixation as well as a study about shock vibration and load requirements must be carried out by the system designer Emerson ca...

Page 7: ...ng pressure and superheat controls IMPORTANT R454C is a refrigerant blend with low GWP It contains HFO which has a low chemical stability in the presence of air or humidity The same levels of cleanliness dryness and evacuation in the refrigerant circuit are required as in HFC POE applications including the use of filter dryers IMPORTANT Both PAG polyalkylene glycol and POE polyolester oils are hyg...

Page 8: ...e nameplate of the compressor Safety is established in compliance with the relevant standards applicable to the given product 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 when the product of pressure relative to the environment by related internal free volume P x V exceeds given limits...

Page 9: ...6 AGL_AC_ST_YRH_EN_Rev01 2 6 Dimensions of YRH V KTE KTG compressors Figure 2 Front view Figure 3 Top view ...

Page 10: ...ransportation of YRH V KTE KTG compressors Compressor model L mm W mm H mm Gross weight kg Net weight kg YRH V KTE YRH V KTG 1175 1130 345 230 196 Table 5 Packaging dimensions for YRH V KTE KTG compressors transportation 3 1 2 Positioning and securing IMPORTANT Handling damage Compressor malfunction Only use the lifting eyes whenever the compressor requires positioning Do not use the discharge or ...

Page 11: ...led on a solid level base For the installation of horizontal scroll compressors the recommended direction is perpendicular to the vehicle direction see Figure 7 The maximum gradient is 7 for rotating angles and 15 for tilting angles see Figure 8 Figure 7 Compressor installation direction Figure 8 Rotating and tilting angles 3 2 Mounting parts YRH V KTE KTG horizontal scroll compressors can be moun...

Page 12: ...y to heat the tube evenly Add braze material to the joint while moving the torch around the joint to flow braze material around the circumference After the braze material flows around the joint move the torch to heat area 3 This will draw the braze material down into the joint The time spent heating area 3 should be minimal As with any brazed joint overheating may be detrimental to the final resul...

Page 13: ...valve on the discharge side of the compressor only a mechanical pressure cut out shall be used Electronic pressure limiters which could cause delayed sensor response are not allowed The high and low pressure cut outs must be installed correctly on the discharge and suction lines which means that no service valve is allowed between the compressor and the pressure protection refer to EN 378 or ISO 5...

Page 14: ...d on the discharge tube in upward position The wire must not be in contact with the top cap of the compressor or the discharge tube Care should be taken to route the wires so that they do not touch sharp objects To avoid any impact on tripping temperature by the ambient the discharge line sensor must be properly insulated Figure 10 Discharge line sensor with insulation 3 8 Internal pressure relief...

Page 15: ...g heating and defrost 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 To assess individual test results and system behaviour eg with regard to oil dilution please contact the Application Engineering department Typically the following situations should be considered gener...

Page 16: ...uld be from 1 to 1 4 mm in diameter for all YRH V KTE KTG models based on compressor size and compressor floodback results To protect this small orifice from plugging with system debris a large area protective screen no finer than 30 x 30 mesh 0 6 mm openings is required Tests have shown that a small screen with a fine mesh can easily become plugged causing oil starvation to the compressor bearing...

Page 17: ...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 if not installed properly according to installation instructions Ensure correct mechanical and electrical installation System capacitors may remain charged for several minutes after ...

Page 18: ...d create an ignition Do not touch the energized terminals with a tool or cable when the compressor is energized Compressors operating with flammable refrigerants shall use only the qualified 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 g...

Page 19: ...ed in these guidelines TX7 variable speed models do not have an internal protector For these TX7 models motor protection must be handled by setting the correct maximum current value in the inverter 4 6 Inverter operation The whole range of fixed speed horizontal scroll compressor models YRH72KTE KTG and YRH81KTE KTG are limited to operation at 50 to 60 Hz Variable speed models YRHV72KTE KTG and YR...

Page 20: ...ential testing WARNING High potential testing in a flammable atmosphere Fire hazard Make sure the atmosphere is non flammable before performing high potential testing DO NOT perform any high potential test when the compressor is charged with flammable refrigerant WARNING Conductor cables Electrical shock hazard Shut off power supply before high potential testing CAUTION Internal arcing Motor destr...

Page 21: ...ll electronic devices eg motor protection module fan speed control etc prior to testing Special attention should be paid when performing a high potential test and reading the Megohm resistance on A2L and A3 compressors as such tests can induce an electrical arc and cause a fire hazard For this reason compressors removed from a system with A2L or A3 refrigerant will need to have the oil drained and...

Page 22: ... with the compressor connected but in that case the two pressure zones of the scroll compressor need to be respected System high pressure section o Define the system high side PS compressor high side PS o Isolate the high and low pressure sections of the system by closing valves solenoid valves expansion valves or by other means o Use the internal check valve of the compressor on the discharge sid...

Page 23: ...ating seal could axially seal with the scroll set with the higher pressure on the floating seal Consequently until the pressures equalise the floating seal and scroll set can be held tightly together The highest demands are placed on the leak proof design of the installation and on the leak testing methods refer to eg EN 378 When working on systems already filled with refrigerant it may be necessa...

Page 24: ... system manufacturer installer must respect the charge limitations according to valid standards such as EN 378 5 6 Run in time Scroll compressors exhibit a slight decrease 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 ...

Page 25: ...ust be avoided In mobile applications a crankcase heater might not be effective due to lack of power This could lead to situations where there will be no voltage present during extended off cycle periods A pumpdown cycle in combination with a low leak check valve in the discharge line could be an alternative to reduce off cycle refrigerant migration to the compressor This extra low leak check valv...

Page 26: ...zes reverse rotation The residual momentary reversal of the scrolls at shut off will cause a clicking sound but it is entirely normal and has no effect on compressor durability 5 15 Supply frequency and voltage There is no general release for the fixed speed horizontal scroll compressor models YRH KTE KTG for use with variable speed AC drives Only frequencies from 50 to 60 Hz are acceptable If the...

Page 27: ...ts with inert gas before undertaking any work and before brazing WARNING Open flame in a potentially flammable or explosive atmosphere Fire and explosion hazard The area shall be checked with an appropriate refrigerant detector prior to and during work on the system to ensure the technician is aware of a potentially toxic or flammable atmosphere Ensure that the leak detection equipment being used ...

Page 28: ...en disassembling system components please follow the main steps described hereunder 1 Recover refrigerant and evacuate system using an A2L or A3 dedicated recovery unit and vacuum pump All the refrigerant shall be recovered to avoid significant release Ensure that the outlet of the vacuum pump is not close to any potential ignition source and that ventilation is available 2 Flush system with inert...

Page 29: ...ed compressor 6 5 1 Compressor replacement If an A2L or A3 refrigerant compressor is to be replaced 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 motor burnout the majority of the contaminated oil will be removed with the compressor The rest of the oil is cleaned through the use of suction and liq...

Page 30: ...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 must be kept in the horizontal position mark the box accordingly If more than one compressor have to be returned each compressor must be packed individually NOTE Check with the transport company that all the requirements ...

Page 31: ...t The actual moisture level of POE PAG would be higher than the sight glass indicates This is due to the high hygroscopicity of the POE and PAG oils To determine the actual moisture content of the lubricant samples have to be taken from the system and analysed NOTE YRH V KTE KTG horizontal scroll compressors are fitted with an internal oil pump 6 7 Oil additives Although Emerson cannot comment on ...

Page 32: ...ith national 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 ...

Page 33: ...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 assume responsibility for the selection use or maintenance of any product Responsibility for proper selection use and maintenanc...

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