Copeland YAD K1 Series Manual

AE4-1491
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3-15 Ton YAD*K1 and YPD*K1 Copeland™ Scroll Compressors
IMPORTANT SAFETY INFORMATION ................. 2
Responsibilities, Qualifications and Training.................. 2
Terminal Venting and Other Pressurized System
Hazards ............................................................................. 3
Flammable Refrigerant Hazards...................................... 3
Electrical Hazards ............................................................. 3
Hot Surface and Fire Hazards .......................................... 3
Lifting Hazards .................................................................. 3
POE Oil Hazards ................................................................ 3
Precautions ....................................................................... 3
Signal Word Definitions ................................................... 4
INTRODUCTION................................................ 5
Nomenclature................................................................... 5
Digital Compressor Operation......................................... 5
How it Works .................................................................... 5
APPLICATION CONSIDERATIONS ..................... 5
Operating Envelope ......................................................... 5
Scroll Temperature Protection ........................................ 6
Shell Temperature............................................................ 6
Pressure Fluctuations....................................................... 6
Long Pipe Lengths / High Refrigerant Charge ................ 6
Suction and Discharge Fittings ........................................ 7
System Tubing Stress ....................................................... 7
Solenoid Valve and Coil.................................................... 7
Accumulators.................................................................... 7
Off-Cycle Migration Control ............................................ 7
Crankcase Heaters............................................................ 7
Pump Out Cycle ................................................................ 7
Reversing Valves............................................................... 7
Start Up and Shut Down .................................................. 8
Discharge Check Valve ..................................................... 8
Compressor Cycling.......................................................... 8
Sound Characteristics....................................................... 9
High Pressure Control ...................................................... 9
Low Pressure Control ....................................................... 9
Contaminant Control ....................................................... 9
Oil Type ............................................................................. 9
Power Factor ..................................................................10
Manifolded Compressor Replacement .........................10
Modulation Control........................................................10
APPLICATION TESTS...................................... 10
Performance Modeling ..................................................11
Refrigerant Flow Control ...............................................11
ASSEMBLY LINE PROCEDURES ..................... 11
Assembly Line Brazing Procedure .................................11
Unbrazing System Components ....................................11
© 2023 Copeland LP

TABLE OF CONTENTS

Removing Compressors .................................................12
Pressure Testing .............................................................12
Assembly Line System Charging Procedure .................12
'Hipot' (AC High Potential) Motor Testing ....................12
Final Run Test .................................................................12
SERVICE PROCEDURES ................................. 12
Field Replacement..........................................................12
Removing Oil...................................................................13
Electrical..........................................................................13
Compressor Replacement After a Motor Burn ............13
Manifolded Compressor Replacement .........................13
Start-Up of a New or Replacement Compressor..........13
Modulation Troubleshooting ........................................13
Refrigerant Retrofits ......................................................14
Modulation Valve Replacement Procedure .................14
Modulation Valve Replacement Procedure .................14
Copeland Scroll Compressor Functional Check............15
Figures & Tables............................................. 16
Figure 1 - Scroll Tube Fitting Brazing ............................16
Figure 2 - Digital Modulation Cycle ..............................17
Figure 3 - Compressor Capacity Graph ........................17
Figure 4: Digital Scroll Cross Section: YAD32-115 &
YPD76-129 ......................................................................18
Figure 5: Digital Scroll Cross Section: YAD130-174 &
YPD145-192 ....................................................................18
Figure 6: Operating Envelope: YAD32-50 .....................19
Figure 7: Operating Envelope: YAD57-86 .....................19
Figure 8: Operating Envelope: YAD98-115 ...................20
Figure 9: Operating Envelope: YAD130-174.................20
Figure 10: Operating Envelope: YPD76.........................21
Figure 11: Operating Envelope: YPD110-145 ...............21
Figure 12: Operating Envelope: YPD163-192 ...............22
Figure 13: Crankcase Heater Location: YAD32-50 .......22
Figure 14: Crankcase Heater Location: YAD57-115 &
YPD76-129 ......................................................................22
Figure 15: Crankcase Heater Location: YAD130 &
YPD145 ............................................................................23
Figure 16: Crankcase Heater Location: YAD147-174 &
YPD163-192 ....................................................................23
Figure 17: Oil Dilution Chart ..........................................24
Figure 18: Tandem Piping Example: YAD32-115 &
YPD76-129 ......................................................................24
Figure 19: Modulation Troubleshooting.......................25
Figure 20: Digital Nomenclature ...................................25
Table 1: Torque Values ..................................................26
Table 2: Compressor Features.......................................27
Table 3: Refrigerant Charge Limits................................27
1
October 2023