Related Manuals for Emerson COPELAND YBD36K1E
Summary of Contents for Emerson COPELAND YBD36K1E
- Page 1 Application Guidelines ™ Copeland Scroll Digital Compressors for Refrigeration Applications YBD17K1E to YBD36K1E...
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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 Variation ........................3 2.4 Application range ....................... - Page 3 3.14 Insulation material ......................15 3.15 Sound and vibration ......................16 3.16 Compressor oil return, oil balancing and floodback tests ..........16 3.17 Suction line accumulator ....................17 Electrical connection ..................18 4.1 General recommendations....................18 4.2 Electrical installation ......................18 4.3 Terminal box ........................
- Page 4 6.5.1 Compressor replacement ..................30 6.5.2 Start-up of a new or replacement compressor ............. 30 6.5.3 Compressor return procedure for A2L systems ........... 31 6.6 Lubrication and oil removal ....................31 6.7 Oil additives ........................32 Dismantling & disposal ................... 33 References .......................
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Page 6: About These Guidelines
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 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. -
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. ▪... -
Page 8: Product Description
YBD*K1E compressor models are available in the following BOM versions: Suction and discharge Mounting T-Box Features connections parts Single compressor Brazing stub tubes IP54 Without Extra tube for paralleling Table 3: BOM designation Please refer to the Emerson price list for more details. AGL_Ref_DG_YBDK1E_E_Rev01... -
Page 9: Application Range
Table 4: Qualified refrigerants and oil Oil recharge values can be taken from the compressor nameplate or from Copeland Select software available at www.climate.emerson.com/en-gb. NOTE: For systems using A1 refrigerants (R404A, R407A, R407F, R448A, R449A, R407C, R513A, R134a or R450A) the flammable refrigerant sticker is not of application and can be removed from the compressor. -
Page 10: Dimensions
the calculation of the PED category, a differentiation must be made between the high- and low- pressure sides. The highest of the calculation results is considered to determine the PED category. YBD*K1E scroll compressors can be operated with both A1 and A2L refrigerants. To determine the PED category a distinction is made between refrigerants of fluid group 1 (flammable) and fluid group 2 (non-flammable). -
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 mechanical or handling equipment according to weight. Keep in the upright position. -
Page 12: Mounting Parts
If the compressors are mounted in tandem or used in parallel, then the hard mountings (bolt M8) are recommended. The mounting torque should be 27 ± 1 Nm. See Emerson spare parts software for reference. Standard mounting parts for YBD*K1E – Soft mountings Alternative mounting parts for YBD*K1E –... -
Page 13: General Brazing Procedure
When working on a refrigerant-filled system, make sure to follow the safety and working instructions given in Chapter 6 "Maintenance & repair". Only compressor models officially approved by Emerson in the qualified configuration may be used for parallel applications. For YBD*K1E compressors in parallel applications with passive oil management, additional precautions shall be taken before brazing the oil and gas equalization ports. -
Page 14: Pressure Safety Controls
Emerson requires that YBD*K1E compressors be fitted with a low-pressure control, with no service valve between the low-pressure side and the pressure control. - Page 15 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 Spare Parts list available at www.climate.emerson.com/en-gb/tools- resources to select the correct crankcase heater model. Caution: Crankcase heaters must be properly grounded! For installation, the manufacturer/installer shall follow the recommendations mentioned below.
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Page 16: Discharge Gas Temperature Protection
Electrical connection ▪ Connect the crankcase heater according to the compressor application guidelines. ▪ The crankcase heater must be connected only to its rated voltage. ▪ The metal braid of the heater must be connected to a suitable earthing terminal. ▪... -
Page 17: Discharge Temperature Sensor Ntc
Similar installation and insulation techniques should be used as described above in section 3.6.2 "Discharge line thermostat". NOTE: For compressor accessories selection, please refer to the Emerson Spare Parts Software, available at www.climate.emerson.com/en-gb/tools-resources. Internal pressure relief valve There is an internal pressure relief valve on YBD*K1E compressors. -
Page 18: Discharge Check Valve
Emerson recommends adding a suitable gas-tight external check valve in the discharge line of the YBD*K1E digital scroll compressors for all parallel applications, to avoid any refrigerant gas flow through the digital scroll during standstill. -
Page 19: External Solenoid Valve Installation - General Recommendations
NOTE: In case of compressor exchange, Emerson recommends replacing the high-cycle digital solenoid valve and coil at the same time. If the digital solenoid valve is defective, it is always good practise to exchange both the solenoid valve and the coil. -
Page 20: Filter Screens
Figure 15: Control valve pipe connection for compressor without sound shell Emerson has developed digital solenoid tubing kits for compressors with brazing stub tubes and 24 V or 230 V coils. The kits are optimized for fitting with or without sound shell and are valid for all compressor sizes using an external visible solenoid valve. -
Page 21: Sound And Vibration
(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 Emerson 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 22: Suction Line Accumulator
▪ In all systems: to test liquid flood-back, all possible transient operation conditions in the system should be checked, eg, compressor frequent start/stop, compressor start after long off time with migration, defrost, switching between the operation modes in reversible systems, load changes, fans or pumps cycling at low load and more. -
Page 23: Electrical Connection
For safety reasons, Emerson recommends that the electrical installation be executed in compliance with standard EN 60204-1 and/or other standards and regulations of application when dealing with A2L mildly flammable refrigerants such as R454C, R455A, R454A and R1234yf. -
Page 24: Terminal Box
Three-phase compressors (TF*) with internal motor protection: Power circuit Control circuit Motor terminal connections Three-phase compressors are connected to the T1, T2 and T3 connections Legend B1 ....System controller K1 ... Contactor B3 ....Discharge gas thermostat Q1 ... Main switch F1, F6…F8 Fuses R2 ... -
Page 25: Motor Insulation
Cable glands have an influence on the protection class of the terminal box. Emerson strongly recommends using appropriate cable glands according to EN 50262 in order to reach the rated protection class. Examples of correct electrical installations are shown in Figure 20 below. -
Page 26: Start-Up & Operation
5.1.1 Compressor strength-pressure test The compressor has been strength-pressure tested in the Emerson factory. Therefore, it is not necessary for the system manufacturer/installer to strength-pressure test the compressor again. Scroll compressors are divided into two pressure zones. The compressor high-side and low-side maximum allowable pressures PS have to be respected at all times. -
Page 27: Compressor Tightness Test
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 Emerson factory. All compressors get a factory holding charge of dry air (about 1 to 2.5 bar, relative pressure). An intact holding charge serves as a proof of quality against penetrating moisture. -
Page 28: Charging Procedure
Charging procedure WARNING Air/A2L 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 A2L refrigerants. Make sure all connections are tight to avoid leakage. Make sure to fill with pure A2L refrigerant. -
Page 29: Pressure Fluctuations
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 30: Minimum Run Time
5.14 Minimum run time Emerson recommends a maximum of 10 starts per hour. There is no minimum off time because scroll compressors start unloaded, even if the system has unbalanced pressures. The most critical consideration is the minimum run time required to return oil to the compressor after start-up. -
Page 31: Controlling The Digital Scroll
During the system development phase, adequate oil return from the system to the compressor should be evaluated and qualified. For this purpose, a sample compressor for lab testing, equipped with an external oil sight tube, is available from Emerson. See also information in section 3.16 "Compressor oil return, oil balancing and floodback tests". - Page 32 capacity regulation is a dynamic process, the average power consumption can be calculated with the following method: = (P x Proportion of loaded time) + (0.1 x P x Proportion of unloaded time) where: = Digital scroll average power consumption = Compressor power input operation point = Maximum power input in the table of the application envelope Example: Cooling capacity requirement = 40 %, P...
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Page 33: Maintenance & Repair
Maintenance & repair WARNING Conductor cables! Electrical shock! 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: Qualification Of Workers
Qualification of workers Personnel working on the maintenance, repair and decommissioning of an A2L refrigerant system shall be adequately trained. Any work procedure affecting safety shall only be executed by qualified and trained personnel in compliance with national or other equivalent certification systems. Examples of such work procedures are: ▪... -
Page 35: Exchanging The Refrigerant
Exchanging the refrigerant WARNING Air/A2L mixture in a potentially flammable or explosive atmosphere! Fire and explosion hazard! For applications with A2L refrigerants, air/A2L mixture in the refrigeration system must be avoided in any case. Make sure that the system is filled with pure A2L refrigerant. In the event that the refrigerant needs replacing, the charge should be recovered using A2L-qualified refrigerant recovery unit and recycling bottles. -
Page 36: Compressor Return Procedure For A2L Systems
Since POE holds moisture more readily than mineral oil it is more difficult to remove it through the use of vacuum. The compressors supplied by Emerson contain oil with low moisture content, which may rise during the system assembling process. Therefore, it is recommended that a properly sized filter-drier be installed in all POE systems. -
Page 37: Oil Additives
Oil additives Although Emerson cannot comment on any specific product, from our own testing and past experience, we do not recommend the use of any additives to reduce compressor bearing losses or for any other purpose. -
Page 38: Dismantling & Disposal
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.com/en-gb/tools-resources for an online version of the Emerson spare parts and accessories software. AGL_Ref_DG_YBDK1E_E_Rev01... -
Page 39: Appendix1: Tightening Torques
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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