Compressor Return Procedure; Lubrication And Oil Removal - Emerson Copeland YB56K1G Application Manuallines

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.
The recommendations and procedure below shall be followed:
▪ During the entire working procedure continuously check if the ambient atmosphere is flammable.
If a flammable atmosphere is detected, immediately cut off the power supply and ventilate the
working space.
▪ Resume working after the atmosphere is no longer dangerous.
▪ Recover the refrigerant from the system using a suitable recovery unit. During this action, the
compressor crankcase heater could be energized – immediately de-energize in case a flammable
or explosive atmosphere is detected.
▪ Recover to 3 mbar absolute pressure or lower. For best results and to recover also the refrigerant
dissolved in the oil, run the recovery unit two or three times as necessary. Both the refrigerant
and the oil must be thoroughly removed.
▪ Flush the whole system with oxygen-free dry nitrogen.
▪ Open the system with a cutting tool and flush the entire system with dry nitrogen again.
▪ Disassemble the compressor with a cutting tool. Drain and recover compressor oil properly. Purge
the compressor with dry nitrogen 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 the compressor for shipment. Place
warning icons
the box: "Warning! Flammable A3 refrigerant compressor for analysis".
▪ The compressor must be kept in the upright 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 applying to such
shipments are complied with.
6.6

Lubrication and oil removal

WARNING
Air/R290 flammable refrigerant mixture in a flammable or explosive
atmosphere! Fire and explosion hazard! Use suitable recovery unit and
recycling bottles also for oil disposal as A3 refrigerant may still be dissolved in
the oil.
CAUTION
Chemical reaction! Compressor destruction! Do not mix up ester oils with
mineral oil and/or alkyl benzene.
The compressor is supplied with an initial oil charge. The standard oil for use with YB*K1G
compressors is a polyalkylene glycol (PAG) lubricant RLF 68 EP. See nameplate for original oil
charge shown in litres. A field recharge is from 0.05 to 0.1 litre less.
PAG oil has a similar hygroscopic behaviour to that of POE oils. Only brief exposure to ambient air
is needed for POE to absorb sufficient moisture to make it unacceptable for use in a refrigeration
system. Since PAG holds moisture more readily than mineral oil it is more difficult to remove it
through the use of vacuum. However, in systems with PAG oil, the same measures as in systems
with POE oil can be used to prevent moisture ingress and to remove moisture (for example,
minimizing the contact with air, using appropriate vacuuming methods, using a filter-dryer, etc.). The
compressors supplied by Copeland contain oil with low moisture content, which may rise during the
system assembling process. Therefore, it is recommended that a properly sized filter-dryer be
AGL_Ref_ST_YBK1G_EN_Rev01
on each side and on the top of the box. Mention the following message on
31