Emerson Copeland Scroll YHV 2P Series Application Manuallines Download

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Copeland Scroll

™

Variable Speed Compressors

YHV0182P* to YHV0382P*

Application Guidelines

Summary of Contents for Copeland Scroll YHV 2P Series

Page 1: ...Copeland Scroll Variable Speed Compressors YHV0182P to YHV0382P Application Guidelines ...

Page 2: ...esign features 10 2 4 6 Oil recovery 10 2 5 Dimensions 11 3 Installation 12 3 1 Compressor and drive handling 12 3 1 1 Compressor transport and storage 12 3 1 2 Compressor positioning and securing 12 3 1 3 Installation location 12 3 1 4 Compressor mounting parts 13 3 2 Compressor brazing procedure 13 3 3 Suction line accumulators 14 3 4 Filter screens 15 3 5 Mufflers 15 3 6 Sound shell 15 3 7 Insu...

Page 3: ... 10 Shell temperature 26 5 11 Pump down cycle 26 5 12 Refrigerant floodback and oil dilution 27 5 13 Minimum run time 27 5 14 Oil level 28 6 Maintenance repair 29 6 1 Qualification of workers 29 6 2 Preparation and working procedure 30 6 3 Disassembling system components 30 6 4 Provisions of legislation and leak check requirements 30 6 5 Exchanging the refrigerant 31 6 6 Replacing a compressor 31 ...

Page 4: ...nstructions and conform to the corresponding provisions of legislation For relevant standards please refer to the Manufacturer s Declaration available at www climate emerson com en gb NOTE Emerson marks all A2L scroll compressors with a sticker for flammable refrigerants Systems using such refrigerants must comply with applicable legislation and regulations such as but not limited to EN378 It rema...

Page 5: ...rotection must be observed 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 ...

Page 6: ... 6 6 8 6 8 3 13 1 12 8 15 8 15 4 Table 1 Heating capacity in kW at below conditions Conditions Evaporating dew temperature 7 C Condensing dew temperature 50 C Suction gas superheat 5 K Condenser sub cooling 5 K Ambient temperature 35 C NOTE R452B and R454B are classified as A2L mildly flammable refrigerants NOTE The drive ED3 is not covered in detail in this document for more information on the mo...

Page 7: ...mpressor and drive connections prior to starting the compressor to avoid miswiring or powered reverse situation Both situations could potentially cause compressor damage NOTE For the latest list of matched pairs ED3 with YHV 2P please refer to the ED3 User Manual June 2019 version or contact the Application Engineering department at Emerson 2 2 Variable speed advantages The variable speed scroll i...

Page 8: ... 3 Compressor nomenclature 2 4 Application considerations 2 4 1 Qualified refrigerant and oil Oil recharge values can be taken from Copeland Scroll compressors brochures or Copeland brand products Select software available at www climate emerson com en gb Compressors YHV0182P YHV0252P YHV0382P Qualified refrigerant R452B and R454B Copeland brand products standard oil Emkarate RL 32 3MAF Table 4 Qu...

Page 9: ... a typical evaporator expansion valve configuration a minimum stable superheat of at least 5 K is required In the same way the superheat at the compressor suction must always stay below a maximum limit specified by Emerson depending on the model and for which the operating envelope is defined YHV 2P compressors operating envelopes depend on the running speed The envelope limitations are mainly rel...

Page 10: ...AGL_HP_VS_YHV2P_E_Rev0 7 Figure 4 Application envelope for YHV0182P 9E9 using R452B and R454B Figure 5 Application envelope for YHV0252P 9E9 using R452B and R454B ...

Page 11: ...polation 2400 5400 Linear interpolation 2400 7200 Figure 6 Application envelope and legend for YHV0382P 4E9 using R452B and R454B Legend YHV0382P 9X9 No drive limitation rpm YHV0382P 9X9 ED3020A rpm 1200 5400 1200 3600 1800 5400 1800 3600 2400 5400 2400 3600 2400 7200 2400 4500 Not shown 2400 7200 Figure 7 Application envelope and legend for YHV0382P 9X9 using R452B and R454B ...

Page 12: ... possible for no longer than 30 minutes but the user must be aware that unloading noise from the compressor can occur In this area the speed limits according to the evaporating temperatures in the envelope should be respected The qualified application envelopes will change with the compressor speed At all operating conditions the minimum and maximum speed limits according to Figures 4 to 7 have to...

Page 13: ...ge line temperature In the transition phase DLT control and superheat control have to be balanced by the system controller The superheat at compressor inlet should be reduced gradually to 0 K As the demand to move to DLT control depends eg on system design such as compressor insulation and ambient temperature there is no specified line at which this will happen 2 4 5 Design features The variable s...

Page 14: ... 11 2 5 Dimensions The external dimensions of YHV 2P compressors are shown in Figures 10 11 below Figure 10 External dimensions of compressor models YHV0182P and YHV0252P Figure 11 External dimensions of compressors YHV0382P ...

Page 15: ...brication at start up 3 1 2 Compressor positioning and securing IMPORTANT Handling damage Compressor malfunction Only use the lifting eyes whenever the compressor requires positioning Using discharge or suction connections for lifting may cause damage or leaks The compressor should be kept vertical during handling The discharge connection plug should be removed first before pulling the suction con...

Page 16: ... oxygen free nitrogen through the system at very low pressure during brazing Nitrogen displaces the air and prevents the formation of copper oxides in the system If allowed to form the copper oxide material can later be swept through the system and block screens such as those protecting capillary tubes thermal expansion valves and accumulator oil return holes Contamination or moisture Bearing fail...

Page 17: ...on components such as suction accumulators Irrespective of system charge oil dilution may occur if large amounts of liquid refrigerant repeatedly flood back to the compressor during e g normal off cycles defrost varying loads Due to Copeland Scrolls inherent ability to handle liquid refrigerant in flooded start and defrost cycle operation an accumulator is not required for durability in most syste...

Page 18: ...eded particular attention shall be paid to the electrostatic charge of the insulation material which could be a potential ignition source 3 7 Insulation material Insulation material is typically used in a system to insulate the suction line suction accumulator expansion valve bulb or discharge line thermostat When choosing the insulation material particular attention shall be paid to its electrost...

Page 19: ...mpressor to a system care must be taken to ensure that the piping is properly designed A scroll compressor makes both a rocking and twisting motion and enough flexibility must be provided in the pipe lines to allow starting stopping and steady state running of the compressor without transmitting excessive stress into any line attached to the unit In a split system the most important goal is to ens...

Page 20: ...cal equipment WARNING Ignition source in a potentially flammable atmosphere Fire hazard Any work on the energized terminals in the compressor terminal box could 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 Mechanic...

Page 21: ... leads to the identified compressor terminals will ensure proper rotation direction Figure 17 Terminal box and correct electrical installation NOTE For recommendations about cable dimensions please refer to the ED3 User Manual June 2019 version Figure 18 Electrical connections for compressor terminal and terminal cover When installing YHV 2P compressors in a system the following measures must be t...

Page 22: ...to original equipment wiring diagrams Electrical connections must be made by qualified electrical personnel Earth leakage current Danger of electric shock The combination of compressor and drive can cause both AC and DC earth leakage current To protect against both kinds of leakage current it is recommended to use an AC DC sensitive RCD on the power supply side The combination of YHV 2P compressor...

Page 23: ...stem type Figure 20 Wiring diagram for YHV 2P with single phase drive For the three phase matched pairs of YHV 2P with ED3 drive the following circuit diagrams can be used Power circuit Control circuit Legend B1 System controller F4 LP switch Q1 Main switch K2 Contactor optional D Drive assembly RCD Residual current device type B or B F1 F6 7 8 Fuses S1 Auxiliary switch F3 HP limiter Grey optional...

Page 24: ...xternal crankcase heater to be mounted on the compressor Instead the ED3 drive has a programmable feature that will utilize the motor windings to provide up to 50 Watts DC of heating to serve as a crankcase heater The crankcase heating function activation is recommended when the system charge exceeds the refrigerant charge limit indicated in Table 7 below Compressor Refrigerant charge limit YHV018...

Page 25: ...e minimum absolute pressure is 0 5 bar a discharge temperature control is mandatory to stop the compressor not exceeding the maximum discharge temperature see chapter 4 5 4 5 Discharge gas temperature protection IMPORTANT Overheating and inadequate lubrication Compressor damage YHV 2P compressors must be equipped with an external discharge gas temperature protection A good system control should pr...

Page 26: ...EN 60034 1 at a differential voltage of 1000 V plus twice the nominal voltage Since high voltage tests lead to premature ageing of the winding insulation further additional tests of that nature are not recommended However if it has to be done for any reason it shall not be made with the compressor charged with refrigerant Carry out the test with a lower voltage as described above Disconnect all el...

Page 27: ...ressure zones of the scroll compressor would need to be respected System high pressure section o define the system high side PS compressor high side PS o separate 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 side or add an external check valve to protect the in...

Page 28: ...ere 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 CAUTION Low suction pressure operation Compressor damage Do not operate with a restricted suction Do not operate with the low pressure cut out bridged Do not operate the compressor...

Page 29: ... capacity units NOTE For more information about this topic please refer to the ED3 User Manual June 2019 version 5 8 Starting sound During the very brief start up a clicking sound resulting from initial contacting of the spirals is audible this is normal Due to the design of the Copeland Scroll compressors the internal compression components always start unloaded even if system pressures are not b...

Page 30: ...oil dilution test During the system testing and under all possible operation conditions the evaporating temperature and the bottom shell temperature shall be recorded The bottom shell temperature together with the evaporating temperature gives an indication whether liquid refrigerant is returning or diluted in the compressor oil sump The compressor sump temperature must remain in the green safe ar...

Page 31: ...pped with any oil sight glass 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 ...

Page 32: ...ntially toxic or flammable atmospheres Ensure that the leak detection equipment being used is suitable for use with all applicable refrigerants No person carrying out work in relation to a refrigeration system which involves exposing any pipe work shall use any sources of ignition in such a manner that it may lead to the risk of fire or explosion All possible ignition sources shall be kept suffici...

Page 33: ...ailable 2 Flush system with inert gas dry nitrogen Compressed air or oxygen shall not be used for purging refrigerant systems 3 Disassemble components with a cutting tool 4 Drain recover and dispose of compressor oil as appropriate To disconnect Using a pipe cutting tool cut off the suction and discharge lines in such a manner that the new compressor can easily be re connected into the system Heat...

Page 34: ...ome plugged This will result in starvation of oil to the new compressor and a second failure Remove the refrigerant and oil completely from the replaced compressor 6 6 1 Compressor replacement In the case of A2L refrigerant compressor replacement 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 the case of a...

Page 35: ...gen OFDN Open the system with a cutting tool and flush the entire system with OFDN Disassemble the compressor with a cutting tool Drain and recover compressor oil properly Flush the compressor with OFDN for a few minutes The compressor should be returned free of oil and with connections open do not close connections with plugs Properly collect and secure the oil Provide information about the quant...

Page 36: ...oil sample should be taken and tested for moisture Sight glass moisture indicators currently available can be used with the HFC refrigerants and lubricants however the moisture indicator will just show the moisture presence in the refrigerant The actual moisture level of POE would be higher than the sight glass indicates This is due to the high hygroscopicity of the POE oil To determine the actual...

Page 37: ... external sensors are properly connected and still working discharge temperature sensor and high pressure switch Drive cooling For air cooled drives make sure that the airflow is not obstructed EMI filter Check all the wiring and check for loose or burned contacts on the board Compressor Make sure the compressor is running within the envelope Check the winding resistances from the compressor motor...

Page 38: ...of a functioning protection system can be the result For sizing information please consult with Contactor manufacturer data sheet If the application of the compressor is changed the contactor sizing should be rechecked Check for unbalanced voltage High discharge pressure suction pressure For high discharge pressure Check for system leaks Check the system design Make sure the discharge line is corr...

Page 39: ...es within the acceptable superheat range published by Emerson The Scroll compressor runs continuously Excessive cooling heating load or inadequate insulation Check the load design make sure that proper insulation is applied Correct it as necessary Control circuit inoperative Check the thermostat measure the temperature of the room and compare with the thermostat replace or re calibrate the thermos...

Page 40: ...ed technical information Please visit www climate emerson com en gb for free download of Application Guidelines and Technical Information Additional technical information C30 11 0419 E NTC Mounting Recommendations ED3 User Manual June 2019 version Performance and technical data The latest version of Copeland brand products Select software with performance data and technical data is available from ...

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