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Summary of Contents for Emerson Copeland YB56K1G
- Page 1 Application Guidelines Copeland Scroll Compressors ™ for R290 Applications YB56K1G to YB97K1G...
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Page 2: Table Of Contents
About these guidelines ....................1 Safety instructions .................... 1 1.1 Icon explanation ......................... 1 1.2 Safety statements ......................2 1.3 General instructions ......................2 Product description ..................3 2.1 Compressor range ......................3 2.2 Nomenclature ........................3 2.3 BOM variations ........................3 2.4 Application range ....................... - Page 3 Electrical connection ..................17 4.1 General recommendations....................17 4.2 Electrical installation ......................17 4.3 Terminal box ........................18 Terminal box – IP54 ..................... 19 4.3.1 Terminal box – IP65 ..................... 19 4.3.2 4.4 Motor insulation ........................ 20 4.5 Motor protection ....................... 20 4.6 High-potential testing .......................
- Page 4 Appendix 1: Tightening torques ................34 DISCLAIMER ....................... 34 AGL_Ref_ST_YBK1G_EN_Rev01...
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Page 6: About These Guidelines
About these guidelines The purpose of these guidelines is to provide guidance in the application of Copeland™ scroll compressors in users’ systems. They are intended to answer the questions raised while designing, assembling and operating a system with these products. Besides the support they provide, the instructions listed herein are also critical for the proper and safe functioning of the compressors. -
Page 7: Safety Statements
Safety statements ▪ Refrigerant compressors must be employed only for their intended use. The system has to be labelled according to the applicable standards and legislation. ▪ Only qualified and authorized RACHP (refrigeration, air conditioning and heat pump) personnel are permitted to install, commission and maintain this equipment. Only competent personnel (as specified in EN 13313) qualified for flammable refrigerant handling is permitted to commission, initiate and maintain the compressor/refrigeration systems using flammable refrigerant;... -
Page 8: Product Description
Product description Compressor range These application guidelines cover Copeland scroll compressor models YB*K1G for medium temperature refrigeration applications. YB*K1G scroll compressors are operated with A3 refrigerants. Cooling capacity* Compressor Motor (kW) YB56K1G 12.5 YB64K1G 14.9 YB81K1G 17.7 YB97K1G 20.9 * Refrigerant dew temperature, evaporating temperature: -10 °C; condensing temperature: 45 °C; suction gas superheat: 10 K;... -
Page 9: Application Range
Application range 2.4.1 Qualified refrigerant and oil Compressors YB*K1G Qualified refrigerant R290 Qualified oil (factory PAG RLF 68 EP charged) Servicing oil PAG RLF 68 EP Table 3: Qualified refrigerant and oil Oil recharge values can be taken from the compressor nameplate or from Copeland Select software available at www.copeland.com/en-gb/tools-resources. -
Page 10: Dimensions
Dimensions Figure 2: External dimensions – Front and top views Compressors (mm) (mm) (mm) (mm) (mm) YB56K1G & YB64K1G 533.8 501.8 277.3 245.6 93.0 YB81K1G & YB97K1G 551.5 519.5 295.0 263.4 92.6 Table 6: Dimensions of compressors YB*K1G with BOM GCZ & GCY and IP54 T-Box NOTE: The connection in blue colour is an additional connection for paralleling models (only on models with BOM GCY). -
Page 11: Installation
Installation WARNING High pressure! Injury to skin and eyes possible! Be careful when opening connections on a pressurized item. Compressor handling 3.1.1 Transport and storage WARNING Risk of collapse! Personal injuries! Move compressors only with appropriate handling equipment according to weight. Keep in the upright position. -
Page 12: Mounting Parts
Mounting parts The compressors are designed to be mounted on vibration absorber grommets. The grommets dampen the start-up surge of the compressor and minimise sound and vibration transmission to the compressor base during operation. The metal sleeve inside is a guide designed to hold the grommet in place. -
Page 13: General Brazing Procedure
3.3.1 General brazing procedure Copeland scroll compressors have copper-plated steel suction and discharge stub tubes. These stub tubes are far more robust and less prone to leaks than copper tubes. Make sure the brazing procedures are carried out in an appropriate manner taking into account the different thermal properties of steel and copper. -
Page 14: Pressure Safety Controls
Pressure safety controls Pressure protection devices to be used in ATEX Zone 2 locations must comply with the ATEX directive requirements. Non ATEX-certified pressure protection devices shall NOT be used in ATEX Zone 2 locations. ATEX-approved pressure protection devices are available from Alco Controls. Please refer to the dedicated "Product Guide for R290". -
Page 15: Crankcase Heater
▪ Additional warning notices shall be affixed to any system equipped with shut-off valves. The warnings must contain instructions to open the shut-off valves completely after each repair or maintenance work. The compressors may only be energized when the safety measures (high- and low-pressure cut-outs and discharge temperature cut-out) have been checked and verified to be operational. -
Page 16: Soft Starters
Assembly instructions ▪ Choose the appropriate model according 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. -
Page 17: Excessive Discharge Gas Temperatures
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. -
Page 18: Discharge Check Valve
Assembly of the discharge line thermostat ▪ Install the discharge line thermostat on the discharge tube 120 mm from top cap. ▪ Snap the retainer clip over the tube and onto the thermostat. ▪ The thermostat should be placed on the discharge tube so that its body is in upward position on a horizontal tube installation. -
Page 19: Sound Shell
3.12 Sound shell Copeland has qualified sound shell kits for the compressor model range YB*K1G versions GCZ (IP54, single compressor) and GCY (IP54, parallel compressor). The sound shell material selected by Copeland is not an ignition source with respect to the electrostatic charges for R290 according to clause 7.4 of EN 60079-0, 2017. -
Page 20: Suction Line Accumulator
test. Systems with multiple compressors (two, three, or more) require additional oil balancing qualification between the parallel compressors. A sample compressor equipped with an external oil sight tube can be ordered from Copeland for lab testing. Records of the evaporating temperature and the bottom shell temperature shall be taken with a high sampling rate during the entire oil return or oil balance testing and under all tested conditions. - Page 21 If an accumulator is used, the oil-return orifice should be from 1 to 1.4 mm in diameter for all YB*K1G models depending 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.
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Page 22: Electrical Connection
Electrical connection General recommendations WARNING Conductor cables! Electrical shock hazard! 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 compressor is not an ignition source during normal operation in A3-refrigerant systems but could become one if not installed properly according to installation instructions. -
Page 23: Terminal Box
The recommended wiring diagrams for the YB*K1G range of compressors are shown hereunder: Power circuit Control circuit Motor terminal connections Three-phase compressors are connected to the T1, T2 and T3 connections Legend B1 ....System controller K1, K2 ..Contactors B3 .... -
Page 24: Terminal Box - Ip54
4.3.1 Terminal box – IP54 YB*K1G compressors with BOM GCZ (single compressor) and BOM GCY (tandem-ready compressor) are supplied with an IP54 terminal box. This terminal box variation cannot be applied in an ATEX environment. Figure 16: IP54 T-Box and correct electrical installation with cable gland 4.3.2 Terminal box –... -
Page 25: Motor Insulation
torque of 4 - 4.4 Nm and the ground connection between the cover and the body of the terminal box with a torque of 1.8 - 2 Nm. Assemble the cable gland M25 with a torque of 9.8 - 10 Nm. The cable gland is designed for cable diameters of 10 to 17 mm –... - Page 26 CAUTION Internal arcing! Motor destruction! Do not perform high-voltage or insulation tests if the compressor housing is under vacuum. Copeland 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 1000 V plus twice the nominal voltage.
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Page 27: Start-Up & Operation
Start-up & operation WARNING Diesel effect! System explosion! The mixture of air and oil at high temperature can lead to an explosion. Avoid operating with air. WARNING Air/flammable refrigerant mixture! Creation of a flammable atmosphere! Make sure the atmosphere is non-flammable before starting the system. Ensure that the system contains only refrigerant. -
Page 28: Compressor Tightness Test
Compressor tightness test WARNING High pressure! Personal injuries! Consider personal safety requirements and refer to test pressures prior to test. IMPORTANT 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 Copeland factory. -
Page 29: Charging Procedure
Charging procedure WARNING Air/R290 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 A3 refrigerant. Make sure all connections are tight to avoid leakage. Make sure to fill with pure R290 refrigerant. -
Page 30: Start-Up And Shut-Off Sound
caused by operating three-phase Copeland scroll compressors in the reverse 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 of operation in reverse, the compressor protection system will trip due to high motor temperature. -
Page 31: Shell Temperature
5.12 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 135 °C – see section 3.8 "Discharge gas temperature protection". In a failure mode, the discharge gas temperatures can get even higher. - Page 32 If an oil regulator is used the oil level should be set within the top half of the oil regulator sight glass. BOM versions GCY, JCD and 9J3 contain a stub tube connection 1 3/8" (35.3 mm) for paralleling on the compressor housing at oil level height.
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Page 33: Maintenance & Repair
Maintenance & repair WARNING Conductor cables! Electrical shock hazard! Follow the lockout/tag out procedure and the national regulations before undertaking any maintenance or service work on the system. Use compressor with grounded system only. Screwed electrical connections must be used in all applications. Refer to original equipment wiring diagrams. Electrical connections must be made by qualified electrical personnel. -
Page 34: Disassembling System Components
If any work is to be conducted on the refrigeration systems or any associated parts, appropriate fire extinguishing equipment shall be provided. Dry powder or CO fire extinguishers are considered appropriate. Confirm that appropriate fire extinguishing equipment is available near the work area. Prior to starting to work on systems containing flammable refrigerants, safety checks are necessary to ensure that the risk of ignition is minimized. -
Page 35: Replacing A Compressor
It is not necessary to replace the refrigerant unless contamination, for example due to an error such as topping up the system with a non-condensable gas or incorrect refrigerant, is suspected. To verify correct refrigerant composition, a sample can be taken for chemical analysis. A check can be made during shutdown by comparing the refrigerant temperature and pressure using precision measurements at a location in the system where liquid and vapour phases are present and when the temperatures have stabilised. -
Page 36: Compressor Return Procedure
6.5.3 Compressor return procedure For all systems with A3 refrigerant, if a compressor has to be returned to the manufacturer for analysis, the refrigerant and the oil must be thoroughly removed. For the shipping process, all compressor connections must remain open and warning stickers for flammable refrigerant must be placed on the shipping box. -
Page 37: Oil Additives
installed in all PAG systems. This will maintain the moisture level in the oil to less than 50 ppm. If PAG oil is charged into a system, it is recommended that its moisture content be no higher than 50 ppm. Figure 22: Absorption of moisture in POE/PAG oil vs mineral oil in ppm by weight at 25 °C and 50 % relative humidity (h= hours) If the moisture content of the oil in a refrigeration system reaches unacceptably high levels, corrosion... -
Page 38: Dismantling & Disposal
Dismantling & disposal Removing oil and refrigerant: ▪ Do not disperse in the environment. ▪ Use the correct equipment and method of removal. ▪ Dispose of oil and refrigerant in compliance with national legislation and regulations. Dispose of compressor in compliance with national legislation and regulations. References Application Guidelines and Technical Information: Please visit... - Page 39 3. Emerson does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any Emerson product remains solely with the purchaser or end user.
- Page 40 The Emerson logo is a trademark and service mark of Emerson Electric Co. Emerson Climate Technologies Inc. is a subsidiary of Emerson Electric Co. Copeland is a registered trademark and Copeland Scroll is a trademark of Emerson Climate Technologies Inc.. All other trademarks are property of their respective owners.
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