Copeland YB12K1E User manual

Copeland™Scroll Compressors
for Refrigeration Applications
YB12K1E to YB36K1E
Application Guidelines

AGL_Ref_ST_YBK1E_EN_Rev01
About these guidelines..............................................................................................1
1Safety instructions..........................................................................................1
1.1 Icon explanation................................................................................................. 1
1.2 Safety statements............................................................................................... 2
1.3 General instructions............................................................................................ 2
2Product description ........................................................................................3
2.1 Compressor range.............................................................................................. 3
2.2 Nomenclature.................................................................................................... 3
2.3 BOM Variation................................................................................................... 4
2.4 Application range............................................................................................... 4
2.4.1 Qualified refrigerants and oils..................................................................... 4
2.4.2 Application limits ...................................................................................... 4
2.4.3 PEDcategory and maximum allowable pressure PS...................................... 5
2.5 Dimensions ....................................................................................................... 6
3Installation.......................................................................................................7
3.1 Compressor handling.......................................................................................... 7
3.1.1 Transport and storage............................................................................... 7
3.1.2 Positioning and securing............................................................................ 7
3.1.3 Installation location................................................................................... 7
3.2 Mounting parts................................................................................................... 8
3.3 Brazing procedure.............................................................................................. 8
3.3.1 General brazing procedure........................................................................ 9
3.3.2 Brazing procedure forYB*K1E compressors in parallel applications ................. 9
3.4 Pressure safety controls.....................................................................................10
3.4.1 High-pressure protection..........................................................................10
3.4.2 Low-pressure protection...........................................................................10
3.5 Protection of A2L refrigerant systems operating below atmospheric pressure .............10
3.6 Crankcase heater..............................................................................................11
3.7 Discharge gas temperatureprotection..................................................................12
3.7.1 Excessive discharge gas temperatures.......................................................12
3.7.2 Discharge line thermostat.........................................................................12
3.8 Internal pressure relief valve...............................................................................13
3.9 Discharge check valve.......................................................................................13
3.10Filterscreens....................................................................................................14
3.11Mufflers............................................................................................................14
3.12Sound shell......................................................................................................14
3.13Insulationmaterial.............................................................................................14
3.14Sound and vibration...........................................................................................14
3.15Compressor oil return,oilbalancing, floodback and oil dilution tests..........................15

AGL_Ref_ST_YBK1E_EN_Rev01
3.16Suction line accumulator.....................................................................................16
4Electrical connection ....................................................................................17
4.1 General recommendations..................................................................................17
4.2 Electrical installation..........................................................................................17
4.3 Terminal box.....................................................................................................19
4.4 Motor insulation.................................................................................................20
4.5 Motorprotection................................................................................................20
4.6 High-potential testing .........................................................................................20
5Start-up & operation......................................................................................21
5.1 Strength-pressure test........................................................................................21
5.1.1 Compressor strength-pressure test ............................................................21
5.1.2 Systemstrength-pressure test...................................................................21
5.2 Compressor tightness test ..................................................................................22
5.3 System evacuation............................................................................................22
5.4 Preliminarychecks –Pre-starting.........................................................................22
5.5 Charging procedure...........................................................................................23
5.6 Run-in time.......................................................................................................23
5.7 Initial start-up....................................................................................................23
5.8 Rotationdirection..............................................................................................23
5.9 Starting sound ..................................................................................................24
5.10Deep vacuum operation.....................................................................................24
5.11Shell temperature..............................................................................................24
5.12Pumpdowncycle...............................................................................................24
5.13Minimum run time..............................................................................................25
5.14Shut-off sound ..................................................................................................25
5.15Supply frequency and voltage.............................................................................25
5.16Oil level............................................................................................................25
6Maintenance & repair....................................................................................26
6.1 Qualificationof workers......................................................................................27
6.2 Preparation and work procedure..........................................................................27
6.3 Disassembling system components......................................................................27
6.4 Exchanging the refrigerant..................................................................................28
6.5 Replacing a compressor.....................................................................................28
6.5.1 Compressor replacement..........................................................................28
6.5.2 Start-up of a new or replacement compressor..............................................28
6.5.3 Compressor return procedure....................................................................29
6.6 Lubrication and oil removal .................................................................................29
6.7 Oil additives......................................................................................................30
7Dismantling & disposal.................................................................................31
8References....................................................................................................31

AGL_Ref_ST_YBK1E_EN_Rev01
Appendix 1: Tightening torques ..............................................................................32
DISCLAIMER.............................................................................................................32

AGL_Ref_ST_YBK1E_EN_Rev01 1
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.
Besidesthe support they provide, the instructionslisted herein are also critical for the proper and
safe functioning of the compressors. The performance and reliability of the product may be impacted
if the productis not used according to these guidelines or is misused.
These application guidelines cover stationary applications only. For mobile applications, please
contactthe Application Engineering department at Emerson as otherconsiderations mayapply.
1 Safety instructions
Copeland scroll compressors are manufactured according to the latest relevant US and European
safety standards. Particular emphasis has been placed on the user’s safety.
YB*K1E compressors are intended for installation in systems in accordance with the European
Machinery Directive MD 2006/42/EC, the Pressure Equipment Directive PED2014/68/EU and the
Low Voltage Directive LVD 2014/35/EU. They maybe putto service onlyif they have been installed
in systemsaccording to instructions and conformto the corresponding provisions of legislation.
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. They mustcomply with any and all applicable
legislation and regulations. Ensuringcompliance remains the user’s responsibility.
The Material Safety Datasheet (MSDS) for the individual refrigerant shall be considered when
working with these typesof refrigerant –please check the document provided by the gassupplier.
These instructions shall be retained throughout the lifetime of the compressor.
You are strongly advised to follow these safety instructions.
1.1 Icon explanation
WARNING
This icon indicates instructions to
avoid personal injury and material
damage.
Fire hazard
This icon indicatesa risk of flammable
atmosphere.
High voltage
This icon indicates operations with a
dangerof electricshock.
CAUTION
This icon indicates instructions to
avoid property damage and possible
personal injury.
Danger ofburning or frostbite
This icon indicates operations with a
dangerof burning or frostbite.
IMPORTANT
This icon indicates instructions to
avoid malfunction of the compressor.
Explosion hazard
This icon indicates operations with a
dangerof explosion.
NOTE
This word indicates a
recommendation for easier operation.
Danger of explosive atmosphere
This icon indicatesa risk of explosive
atmosphere.

2 AGL_Ref_ST_YBK1E_EN_Rev01
1.2 Safetystatements
▪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, commissionand maintain this equipment.
▪Electrical connections must be made by qualified electrical personnel.
▪All valid standards for connecting electrical and refrigeration equipment must be
observed.
▪Thenationallegislationandregulationsregardingpersonnelprotectionmustbeobserved.
Additional requirements and statements for A2L-refrigerant compressor/systems:
▪Only competentpersonnel (as specified in EN 13313) qualified for flammable refrigerant
handling is permitted to commission, initiate and maintain the compressor/refrigeration
systems using flammable refrigerant; non-trained personnel,including the user, are not
allowed to do so and must call on an expert.
▪The maximum refrigerant charge is specified in standards such as, but not limited to
EN378, EN 60335-2-40 and EN 60335-2-89. The system designershall implement allsafety
measures defined by the applicable standards and the maximumrefrigerant charge shall
not be exceeded.
▪If a flammable atmosphere is detected, immediately take all necessary precautions to
mitigate the risk as determined in the risk assessment.
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!Accidentalsystemstartbeforecompleteset-upmustbeavoided.
Never leave the system unattended without locking it out electrically when it is
on vacuum and has no refrigerant charge,when it has a holding charge of
nitrogen, or when the compressor service valves are closed.
WARNING
System breakdown! Personal injuries! Only approved refrigerants and
refrigeration oils mustbe used.
WARNING
High shell temperature! Burning! Do not touch the compressor and piping
until they have cooled down.Ensure that other materials in the area of the
compressor do not come into contact with it. Lock and mark accessible
sections.
CAUTION
Overheating! Bearing damage! Do not operate compressor without
refrigerant charge or without it being connected to the system.
CAUTION
Contact with refrigerant oil! Material damage! Polyolester(POE) lubricant
must be handled carefully and the proper protective equipment(gloves,eye
protection,etc.) mustbe used at all times. Refrigerantoil mustnot come into
contactwith any surface or material that it might damage, including without
limitation, certain polymers, eg,PVC/CPVC and polycarbonate.
IMPORTANT
Transit damage! Compressor malfunction! Use original packaging.Avoid
collisions and tilting.

AGL_Ref_ST_YBK1E_EN_Rev01 3
2 Product description
2.1 Compressor range
These application guidelines cover Copeland scroll compressor models YB*K1E for medium
temperaturerefrigerationapplications.YB*K1EscrollcompressorscanbeoperatedwithbothA1and
A2L refrigerants.
Compressor
Cooling capacity* (kW)
Motor
R404A
R407A
R407F
R448A
R449A
R407C
R513A
R134a
R450A
YB12K1E
3.15
3.1
3.36
3.17
3.17
2.87
2.02
1.9
1.64
PFZN**/
TFMN
YB17K1E
4.41
4.34
4.71
4.44
4.44
4.05
2.85
2.64
2.28
PFZN**/
TFMN
YB21K1E
5.62
5.53
6
5.66
5.66
5.15
3.63
3.36
2.9
PFZN**/
TFMN
YB24K1E
6.28
6.18
6.71
6.33
6.33
5.75
4.06
3.91
3.36
PFZN**/
TFMN
YB31K1E
7.92
7.79
8.45
7.98
7.98
7.29
5.14
4.89
4.21
TFMN
YB36K1E
9.45
9.28
10.1
9.52
9.52
8.62
6.09
5.82
5.01
TFMN
Table 1: YB*K1E model overview for MT applications withA1 refrigerants
Compressor
Cooling capacity* (kW)
Motor
R454C
R455A
R454A
R1234yf
YB12K1E
2.76
2.93
3.31
1.84
PFZN**/TFMN
YB17K1E
3.89
4.15
4.64
2.6
PFZN**/TFMN
YB21K1E
4.92
5.22
5.91
3.29
PFZN**/TFMN
YB24K1E
5.55
5.88
6.6
3.71
PFZN**/TFMN
YB31K1E
6.95
7.4
8.32
4.67
TFMN
YB36K1E
8.23
8.78
9.93
5.47
TFMN
Table 2: YB*K1E model overview for MT applications withA2L refrigerants
* Refrigerant dew temperature, evaporating temperature: -10 °C; condensing temperature: 45 °C; suction gas
superheat: 10 K; liquid sub-cooling: 0 K; frequency: 50 Hz
** Single-phase models are released for use with R454C, R407C and R134a refrigerants only.
2.2 Nomenclature
The model designationcontains the following technical information aboutthe compressor:
Figure 1: Nomenclature

4 AGL_Ref_ST_YBK1E_EN_Rev01
2.3 BOM Variation
The BOM (bill of material) numberat the end of the compressor designation indicates the different
compressor layouts and details. YB*K1E compressor models are available in the following BOM
versions:
BOM
Suction and discharge
connections
T-Box
Mounting
parts
Features
GBS
Brazing stubtubes
IP54
Without
Single compressor
GCG
Extra tube for paralleling
Table 3: BOM designation
Please refer to the Emerson price list for more details.
2.4 Application range
2.4.1 Qualified refrigerants and oils
IMPORTANT
Some refrigerantblendshave a significant temperature glide. It is essential
that the glide ofthe refrigerant blendsbe carefully considered when adjusting
pressure and superheat controls.
IMPORTANT
Refrigerant blends with low GWP containing HFO’s have a low chemical
stabilityinpresenceofairorhumidity.Thesamelevelsofcleanliness,dryness
and evacuation of the refrigerant circuit are required as in HFC & POE
applications, including the use of filter dryers.
NOTE: R454C, R455A, R454A and R1234yf are classified as A2L (mildly flammable)
refrigerants.
Compressors
YB12K1Eto YB36K1E*
Qualified refrigerants
R454C,R455A,R454A, R1234yf
R404A, R407A,R407F,R448A, R449A,
R407C,R513A,R134a & R450A
Qualified oil (factory
charged)
RL32 3MAF
Servicing oil
RL32 3MAF
* Single-phase models are released for use with R454C, R407C and R134a refrigerants only.
Table 4: Qualified refrigerants and oil
Oil recharge values can be taken fromthe 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 refrigerantsticker is not of application and can be
removed from the compressor.
2.4.2 Application limits
CAUTION
Inadequate lubrication! Compressor breakdown! The superheat at the
compressorsuctioninletmustalwaysbesufficienttoensurethatnorefrigerant
droplets enter the compressor. For a typical evaporator-expansion valve
configuration a minimumstable superheatof at least 5 K is required.
For application envelopes and technicaldata, please refer to Copeland Selectsoftware available at
www.climate.emerson.com/en-gb.

AGL_Ref_ST_YBK1E_EN_Rev01 5
2.4.3 PED category and maximum allowable pressure PS
The nameplate of the compressor containsinformation about the maximumallowable pressure PS,
the minimum and maximumallowed temperature TS, the internal free volume and the fluid groups
of the refrigerants qualified for the compressor model range. Values are given for the two existing
pressure ranges onlow- and high-pressure side.
Compressor
PS
Low-pressure
side
PS
High-pressure
side
TS max.
Low-pressure
side
Internal free
volume
LP side (litres)
Internal free
volume
HP side (litres)
YB12K1E
23.5bar(g)
38 bar(g)
50 °C
4.1
0.5
YB17K1E
23.5bar(g)
38 bar(g)
50 °C
4.2
0.5
YB21K1E
23.5bar(g)
38 bar(g)
50 °C
4.3
0.5
YB24K1E
23.5bar(g)
38 bar(g)
50 °C
4.8
0.5
YB31K1E
23.5bar(g)
38 bar(g)
50 °C
6.4
0.6
YB36K1E
23.5bar(g)
38 bar(g)
50 °C
6.4
0.6
Table 5: Maximum allowable pressures, temperatures and internal free volumes
The PED category is assigned according to the Pressure Equipment Directive PED 2014/68/EU.
Requirements apply to the relevant pressure levels in the compressor if a limitvalue for the product
of pressure relative to the environment and relevant internal free volume is exceeded. For the
calculation of the PED category, a differentiation must be made between the high- and low-pressure
sides. The highestof the calculation results is considered to determine the PED category.
YB*K1E scroll compressors can be operated with both A1 and A2L refrigerants. To determinethe
PED category a distinction is made between refrigerants of fluid group 1 (flammable) and fluid
group 2 (non-flammable).As a result, identicalcompressor models maybe subject to different PED
categories depending on the refrigerantused.
Compressorrange
Refrigerant
Fluid group
PED class
YB*K1E
R454C, R455A,R454A,
R1234yf
1
2
R404A, R407A, R407F,
R448A, R449A, R407C,
R513A, R134a,R450A
2
1
Table 6: PED class based on refrigerantused

6 AGL_Ref_ST_YBK1E_EN_Rev01
2.5 Dimensions
Figure 2
Compressor
A ± 3.0
(mm)
B
(mm)
C ± 3.0
(mm)
D
(mm)
E
(mm)
Ø F
(mm)
G
(mm)
H
(mm)
I
(mm)
X
(°)
YB12K1E
364.6
338.5
165.8
244.5
69.6
165.8
247.5
252.8
115.5
49
YB17K1E
387.2
361.1
185.7
264.4
75.3
165.8
247.5
252.8
115.5
49
YB21K1E
400.9
374.9
198.4
277.1
75.3
165.8
247.5
252.8
115.5
49
YB24K1E
418
391.9
215.4
294.1
75.3
165.8
247.5
252.8
115.5
49
YB31K1E
442
409.6
225.2
296.7
79.6
185.5
260.5
254.9
124.7
44
YB36K1E
442
409.6
225.2
296.7
79.6
185.5
260.5
254.9
124.7
44
Table 7: Dimensions ofYB*K1E compressors
Compressor
Suction
(inch)
Discharge
(inch)
YB12K1E
¾"
½"
YB17K1E
¾"
½"
YB21K1E
¾"
½"
YB24K1E
⅞"
½"
YB31K1E
⅞"
½"
YB36K1E
⅞"
½"
Table 8: Connectionsizes of YB*K1E compressors
NOTE: The connectionin blue colour is an additional connection for paralleling models (with
BOM GCG).

AGL_Ref_ST_YBK1E_EN_Rev01 7
3 Installation
WARNING
High pressure! Injury to skinand eyes possible! Be careful when opening
connections on a pressurized item.
3.1 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. Respect stacking loads according to Figure 3. Checkthe
tilting stability and if needed take action to ensure the stability of the stacked
loads. Keep the packaging dryat all times.
Respect the maximum number of identical packages which may be stacked on one
another, where "n" is the limiting number:
▪Transport: n = 1
▪Storage: n = 2
Figure 3: Maximum stacking loads for transport and storage
The compressortilt angle should not exceed 30° during transport and handling.This will prevent oil
from exiting through the suction stub. A tilt angleof maximum45° is allowed for a very short time.
Tilting the compressor more than 45° mightaffect its lubrication atstart-up.
NOTE: The compressor is pre-chargedwith dry airto avoid any moisture contamination.
3.1.2 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 compressorshould be keptvertical during handling.
The discharge connection plug should be removed first before pulling the suction connection plug to
allow the dry air pressure inside the compressor to escape. Pulling the plugs in this sequence
prevents oil mist from coating the suction tube making brazing difficult. The copper-coated steel
suction tube should be cleaned before brazing.
The plugs mustberemovedaslateaspossiblebeforebrazingsothattheairhumiditydoesnotaffect
the oil characteristics.
For YB*K1E compressors, as oil mightspill out of the suction connection located low on the shell,
the suctionconnection plug must be left in place until the compressor is set into the unit.
No object,eg, a swaging toolshould beinserted deeper than 51 mminto the suction tubeas itmight
damage the suction screen and motor.
3.1.3 Installation location
Ensure the compressors are installed on a solid level base. For single-compressor applications, the
compressor tilt angle during operation should not exceed 15° to allow adequate lubrication. For
multiple-compressor parallel configurations, the compressors must be positioned completely
vertically on a totally horizontal surface or rail.

8 AGL_Ref_ST_YBK1E_EN_Rev01
3.2 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
compressorbase during operation. The metal sleeve inside is a guide designed to hold the grommet
in place. It is not designedas a load-bearingmember, and applicationof excessive torque to the
bolts can crush the sleeve. Its inner diameter is approximately 8.5 mm to fit,eg, an M8 screw. The
mounting torque should be 13 ± 1 Nm. It is critically important that the grommet is not compressed.
If the compressorsare mounted in tandemor 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 YB*K1E –Soft mountings
Alternative mounting parts for YB*K1E–Hard mountings
Figure 4: Mounting parts
3.3 Brazing procedure
WARNING
Air/flammable refrigerant mixture! Creation of a potentially flammable
atmosphere! Fire hazard! Remove allrefrigerant before opening the system.
When working on a refrigerant-filled system, make sure to follow the safety
and working instructionsgiven in Chapter 6 "Maintenance & repair".
WARNING
High temperature! Burning! Proceed with caution when brazing system
components. Do not touch the compressor until it has cooled down. Ensure
that other materials in the area of thecompressordo not comeinto contact
with it.
CAUTION
Blockage! Compressorbreakdown! Maintain a flow of oxygen-free nitrogen
through the system at very low-pressure during brazing.Nitrogen displaces
the air and prevents the formation of copperoxidesin the system. If allowed
to form, the copperoxidematerialcan later be swept through the systemand
block screens such as those protecting capillary tubes, thermal expansion
valves, and accumulator oil return orifices.
Contaminationor moisture! Bearing failure! Do not remove the connection
plugs until the compressor is set into the unit. This minimises any entry of
contaminantsand moisture.

AGL_Ref_ST_YBK1E_EN_Rev01 9
3.3.1 General brazingprocedure
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.Duetothedifferentthermalpropertiesofsteeland
copper, brazing procedures should be carried out in an
appropriate manner.
Referto Figure 5 and procedure below forthe brazing of
the stub tube connections of a scrollcompressor.
▪Flushing oxygen-free nitrogen through the piping during the brazing process is recommended for
applicationswithA1 refrigerants and mandatory for applicationswith flammable A2L refrigerants.
▪The copper-coated steel tubes on scroll compressorscan be brazed in approximately the same
manneras any coppertube.
▪Recommended brazing materials: any Silfos material is recommended, preferably with a
minimum of 5 % silver. However, 0% silver is acceptable.
▪Be sure tube fitting inner diameterand tube outer diameter are clean prior to assembly.
▪Using a double-tipped torch, apply heat in area 1.
▪As the tube approachesbrazing temperature, move the torch flame to area 2.
▪Heatarea 2untilbrazetemperatureis attained,movingthetorchup anddownandrotatingaround
the tube as necessary to heat the tube evenly. Add braze materialto the jointwhile moving the
torch around the joint to flow braze material around the circumference.
▪After the braze material flows around the joint, move the torch to heat area 3. This will draw the
braze material down into the joint. The time spentheating area 3 should be minimal.
▪As with any brazed joint, overheating maybe detrimental to the final result.
NOTE: Since the discharge stub contains a check valve, care must be taken not to overheat
it to prevent brazing material fromflowinginto it.
3.3.2 Brazing procedure for YB*K1E compressors inparallelapplications
WARNING
Air/flammable refrigerant mixture! Creation of a potentially flammable
atmosphere! Fire hazard! Remove allrefrigerant before opening the system.
When working on a refrigerant-filled system, make sure to follow the safety
and working instructionsgiven in Chapter 6 "Maintenance & repair".
Only compressor models officially approved by Emerson in the qualified configuration may be used
for parallel applications. For YB*K1E compressors in parallel applications with passive oil
management,additional precautions shallbe taken before brazing the oil and gas equalization ports.
The sequence shallbe asfollows:
First, install the compressors on the base frame and tilt the assemblyso that oil willnot be lost when
opening the cap. The gas and oil equalization line assembly should be ready for brazing at this point.
For new compressors, release the protective gas charge: the rubber plug from the discharge port of
the compressor has to be removed first, then the rubber plug fromthe oil port.
Most probably the oil port will be coated with some oil. It is mandatory to clean out the oil before
brazing.If theinnersurfaceiscontaminatedwithoilthebrazingmaterialwillnotadheretothesurface
and the joint will fail, generating leakage. The oil should be carefully wiped out with industrial
absorption paper.Industrialsolvents on a clean cloth can be used too butonly with great care.Note
that emery cloth will not remove the oil.
It is possible that the oil cannotbe completely cleaned out. In this case additional measures should
be taken. For instance, if a connection is coated with flux then the residualoilwill be removed when
brazing thanks to the applied heat.
If an active oil level control is to be used, eg, OM* TraxOil fromAlco Controls, pleasereferto the
product documentation when brazing the connection adaptor.
: Brazing areas
Figure 5: Brazingareas

10 AGL_Ref_ST_YBK1E_EN_Rev01
3.4 Pressure safetycontrols
3.4.1 High-pressure protection
Applicable regulations and standards, for example EN 378-2, shall be followed to apply appropriate
control and ensure that the pressure never exceeds the maximumlimit.
High-pressureprotectionisrequiredtostopthecompressoroperatingoutsidetheallowablepressure
limits. The high-pressure control must be installed correctly, which means that no service valve is
allowed between the compressor and the pressure protection.
The high-pressure cut-out setting shall be determined according to the applicable standard, the type
of system, the refrigerantand the maximumallowable pressure PS.
3.4.2 Low-pressure protection
CAUTION
Operation outside the application envelope!Compressor breakdown! A
low-pressure protection shall be fitted in the suction line to stop the
compressorwhen it operates outside the envelope limits.
Applicableregulationsandstandardsshallbefollowedtoapplyappropriatesafetycontrolandensure
that the pressure is always above the required minimum limit.
Low-pressureprotectionisrequiredtostopthecompressoroperatingoutsidetheallowableenvelope
limits. The low-pressure control must be installed correctly into the suction line, which means that no
service valve is allowed between the compressor and the pressure protection.
The minimum cut-out setting shall be determined according to the refrigerant and the allowed
operation envelope –see Select software at www.climate.emerson.com/en-gb/tools-resources.
3.5 Protection of A2L refrigerantsystems operatingbelowatmospheric pressure
WARNING
Operation below ambient pressure! Fire hazard! During operation below
atmospheric pressure, a flammable mixture can form inside the system.
Ensure system tightnessto preventany ingress of air.
Special requirements for safety and tightness applyto YB*K1E compressor systems that are to be
operated belowatmospheric pressure. The following precautionsmust be observed:
▪Check all the critical points on the systemand piping connections; tightnesshas to be ensured
also at very lowpressure.
▪Minimum absolute working pressure: 0.5 bar.
▪The installation of mechanical high-pressure and low-pressure cut-outs is mandatory. For
systems provided with a service shut-off valve on the discharge side of the compressor, only a
mechanical pressure cut-out shall be used. Electronic pressure limiters, which could cause
delayed sensor response,are not allowed.
▪The high- and low-pressure cut-outs must be installed correctly on the discharge and suction
lines, which means that no service valve is allowed between the compressor and the pressure
protection (refer to EN 378 or ISO 5149).
▪A discharge temperature control is mandatory to stop the compressor when the maximum
discharge temperature is exceeded –see section 3.7 "Discharge gas temperature
protection".
▪Additional warning notices shall be affixed to any system equipped with shut-off valves. The
warnings must contain instructionsto open the shut-off valves completely after each repair or
maintenance work. The compressorsmay 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.
NOTE:Ifany ofthe abovepointscannotbemet, thecompressorsmustnotbeoperatedbelow
atmospheric pressure!

AGL_Ref_ST_YBK1E_EN_Rev01 11
3.6 Crankcase heater
WARNING
Ignition source in a potentially flammable atmosphere! Firehazard! The
crankcase heater is not an ignition source during normal operation in A2L
systems but could become one when not installed properly according to
installation instructions.Ensure correct electrical and mechanical installation.
CAUTION
Overheating and burnout!Compressor damage! Never applypower to the
crankcase heater in free air, before the crankcase heater is installed on the
compressoror when it is not in complete contact with the compressor shell.
IMPORTANT
Oil dilution! Bearing malfunction! Turn the crankcase heateron 12 hours
before starting the compressor.
A crankcase heater is used to prevent refrigerant from migrating into the shell during standstill
periods. The installation of a crankcase heater is required when the system charge exceeds the
charge limits indicated in Table 9. This requirement is independent from system type and
configuration.
Compressormodel
Refrigerant
chargelimit
(kg)
Crankcase heater
Position
Height
(mm)
YB12K1E to YB24K1E
1.54
10 - 40
YB31K1E & YB36K1E
1.93
Table 9: Refrigerantcharge limits &crankcase heater position
The initial start-up in the field is a very critical momentfor any compressor because all load-bearing
surfacesare newand require a short break-in period to carry highloads under adverse conditions.
The crankcase heater must be turned on a minimum of 12 hours prior to starting the
compressor. This will prevent oil dilution and bearing stress on initial start-up. The crankcase
heater must remain energizedduringcompressor off cycles.
Caution: Crankcase heaters must be properly grounded!
For installation, the manufacturer/installer shallfollow the recommendations mentioned below.
Assembly instructions
▪Choose the appropriate model according to compressor size and required wattage.
▪Check the compressor application guidelines for crankcase heater connection and operation.
▪Positionthecrankcase heaterbetween the lowercoverand the lower bearing weld projection
(Fig. 6).
▪Fit the heater horizontally around the crankcase, ensuring that it is in close contact with the
compressorhousing along theentire length.
▪Avoid having the heating portion of the heaterin contactwith any weld projection (Fig. 7 & 8).
▪Avoid having the assembly heater inclined (Fig.9).
▪Close the lock and tighten the screw,torque: 2-3 Nm.
▪The excess clamp bracketmaybe trimmed. Sharp edgesmust not come into contact with wires.
▪The presence of the heater shall be made evidentby the posting of caution signs or markings at
appropriate locations.
Figure 6 Figure 7 Figure 8 Figure 9

12 AGL_Ref_ST_YBK1E_EN_Rev01
Electrical connection
▪Connect the crankcase heater according to the compressor application guidelines.
▪The crankcase heater mustbe connected onlyto its rated voltage.
▪The metal braid of the heatermustbe connected to a suitableearthing terminal.
▪Check the resistance according to the technical data.
▪Performan insulation test before start-up.
▪Electrical security and safety measures are to be provided on site.
3.7 Discharge gas temperature protection
CAUTION
Inadequate lubrication! Scroll set damage! All YB*K1E compressorsmust
be equipped with a discharge gastemperature protection.
A good system control shall prevent the system from operating outside the published operating
envelope and acceptable superheat range, whatever the climatic conditions and the capacity
demand. However, under some extreme operating conditions such as loss of charge or improper
control operation,the internal discharge gas temperature reached can cause compressor damage.
In order to ensure positive compressor protection, discharge gas temperature protection is required
for any applicationwith Copeland brand compressors.
The maximum discharge gastemperature is 130 °C for YB*K1E compressors.
Discharge gas temperature protection is the "fall-back" for failure ofthe system control. It is essential
that proper control of both the evaporating and condensing pressures and the superheat is
maintained and hastheabilitytocopewithalllikelyconditionsand highloads.Relianceonprotectors
will cause inadequate system performance and short cycling.
NOTE: The maximum discharge gas temperatures indicated in this chapter are validfor 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. For compressor envelope control, an additionalcontroldevice or regulationmust
be used.
3.7.1 Excessive discharge gas temperatures
A few of the possible consequencesof excessive discharge gastemperatures are listed below:
▪Since the oil circulates in the systemwith the refrigerant, it is subjected to high discharge gas
temperatures.If the discharge gastemperature becomestoo high,the so-called "cooking"effect
will occur (heating of oil under exclusion of air). Carbon deposits can form at points of high
temperature,forexampleonthevalves,oilchannels,oilfilters,etc.Theoillubricitywillbereduced
and a progressive wear process will occur whichwill prematurely damage the compressor.
▪The stability of the refrigerant can also be affected, particularly if traces of contaminant are
present.
The problems described above frequently occur simultaneously, particularly since the chemical
reaction speed approximately doubles with every 10 °C temperature rise. This directly leads to
chemical reactions of the oil with the refrigerant and the compounds extracted fromsealants and
insulation material. As a consequence,contaminants of various types, among them acids, will form
inside the system.
3.7.2 Discharge line thermostat
YB*K1E compressors have no internal discharge gas temperature protection. Therefore, an external
discharge line thermostat must be installed.
Figure 10: Discharge line thermostatwithclamp

AGL_Ref_ST_YBK1E_EN_Rev01 13
Technical data of the discharge line thermostat
Voltage
120-240 V AC
Maximum amperage
5 A / 240 V
Operating temperatures
Open
134 °C (± 4 K)
Close
106 °C (± 8 K)
Wire insulation maximum temperature
150 °C
Clips fortube
ø 12.7 mm (0.5")
Table 10:Discharge line thermostat –Technical data
To ensure proper functioning and to avoid false readings, the discharge line thermostat must be
installed and insulated according to the procedure and recommendations hereunder.
Assembly of the discharge line thermostat
▪Install the dischargelinethermostatonthe
discharge tube120mm fromtopcap.
▪Snap the retainerclip overthe tubeand onto
the thermostat.
▪The thermostatshould beplacedon the
discharge tubeso that its bodyis in upward
position ona horizontaltubeinstallation.
▪Ensure that the thermostatisnot tilted.
▪The wire mustnot bein contactwith the top
cap of thecompressororthedischargetube.
Careshouldbetaken to route wiresso that
they do not comeintocontactwith sharp
objects.
▪To avoid anyimpacton trippingtemperature
by the ambient,thedischargelinethermostat
mustbe insulated.
▪Wrap thermalinsulationaroundthepipe left
and right of the thermostatand secure itwith
plasticstraps.
▪Wrap a second layerof insulation aroundthe
firstone and aroundthethermostatand
secure it with plasticstraps.
3.8 Internal pressure reliefvalve
There is an internal pressure relief valve on YB*K1E compressors. It opensat a differentialpressure
of 28bar±3 barbetweenhigh-and low-pressuresides.Ahigh-pressureprotectionmustbeprovided
by thesystemmanufacturer/installerforeachsystemand accordingtoEN 378-2,clause6.2.6.2.The
IPR valve is a safety device,not an HP switch. It is not designed for repeated operation and there is
no guaranteethat it will reset correctly if it does haverepeated operation.
3.9 Discharge checkvalve
YB*K1E compressors contain an internal check valve on the discharge connection.The discharge
check valve prevents the high-pressure discharge gas from flowing rapidly back through the
compressoraftershutdown.
NOTE: This check valve cannot be used with recycling pumpdown because it is not entirely
leak-proof.

14 AGL_Ref_ST_YBK1E_EN_Rev01
3.10 Filterscreens
CAUTION
Screen blocking! Compressor breakdown! Use screens with at least
0.6 mm openings.
The use of filter screensfiner than 30 x 30 mesh (0.6 mmopenings) anywhere in the systemshould
be avoided with these compressors.Field experience has shown that finer mesh screens used to
protect thermal expansion valves, capillary tubes or accumulators can become temporarily or
permanently plugged with normalsystem debris and block the flow of either oil or refrigerant to the
compressor. Such blockage can result in compressor failure.
3.11 Mufflers
Gas flow through scroll compressors is continuous with relatively low pulsation.External mufflers
may not be required on Copeland scroll compressors. Due to system variability, individual tests
should be conducted by the system manufacturer to verify acceptable levelsof sound and vibration.
If adequate attenuation isnot achieved,use a muffler with a larger cross-sectional area to inlet area
ratio. A ratio of 20:1 to 30:1 is recommended. A hollowshell muffler will work quite well. Locate the
muffler at minimum15 cm to maximum45 cm fromthe compressor for the mosteffective operation.
The fartherthemuffleris placedfromthecompressorwithintheseranges, themoreeffective.Choose
a muffler with a length of 10 to 15 cm.
3.12 Sound shell
For the selection of sound reduction material in A2L applications, attention shall be paid to the
electrostatic charge of the material, which could be a potential ignition source.
The standard Emerson sound shell material is not an ignition source for A2L refrigerants (R454C,
R455A, R454A and R1234yf).
NOTE: Please see Emerson spare parts software at www.climate.emerson.com/en-gb/tools-
resources to check the available soundshellkits according to compressor model.
3.13 Insulationmaterial
Insulation material is commonly used in a system to insulate the suction line, suction accumulator,
expansion valve bulb or discharge line thermostat. When choosing the insulation materialfor A2L
applications, particular attention shall be paid to its non-electrostatic properties, as it could be a
potential ignition source.
3.14 Sound and vibration
WARNING
Vibrations! Creation of a flammable atmosphere! Carefully check the
system for vibrations in applications with A2L refrigerants.
Vibrations during compressor operation can cause crackswhich could lead to refrigerant leakage.
This situation must be avoided bythe system manufacturer/installer. To this end, the pipework must
be carefully designed when connecting a scrollcompressor to a system.
A scroll compressor makes both a rocking and twisting
motion and enough flexibility must be provided in the
pipework to allowstarting, 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 goalis to ensure minimal vibration in all directions
to avoid transmitting vibrations to the structure to which the
lines are fastened.
Under some conditions, the Copeland scroll has a normal
starting rotationalmotion that cantransmit a transient noise
along the lines. This may be particularly pronounced in
compressors using a three-phase motor due to their
Figure 11: Example ofsuctiontube design

AGL_Ref_ST_YBK1E_EN_Rev01 15
inherently higherstarting torque. This phenomenon, like the one described previously, can easily be
avoided byusing standard line isolation techniques.
The sound levelofasystemis theresultofdesign, qualityand application.Scrollcompressorssound
powerlevelsgenerallyincreasewiththecompressormodelcapacityandtheconditionpressureratio.
3.15 Compressoroil return, oil balancing, floodback andoil dilutiontests
CAUTION
Inadequate lubrication! Bearing and moving parts destruction! Ensure
adequate oil return from the systeminto the compressor at any time. No liquid
refrigerant return to the compressor. Liquid refrigerant dilutes the oil, could
wash the oil off the bearingsand moving parts and could lead to overheating
and compressorfailure.
The systempiping mustbe carefully designed to ensure sufficient refrigerant gas velocity, so that oil
returns to the compressor at all times and conditions. Individual piping diameter calculation depends
on the refrigerantproperties, pressure level,mass flow, and density.
Once a new systemdesign is set and assembled, a functional testis required. The functional test
includes a qualification for the general systemoil return and a refrigerant floodback and oil dilution
test. Systems with multiple compressor applications (two, three, or more) require additional oil
balancing qualification between the parallelcompressors.
A sample compressor equipped with an external oil sighttube can be ordered fromEmerson for lab
testing.
Records ofthe evaporating temperature and the bottom shell temperature shallbe takenwith a high
sampling rate during the entire oil return or oil balance testing and under all tested conditions. The
liquid level in the sight tube has to be observed and recorded too. Testing conditions shallinclude
defrostand varyingloads.If thesystemisreversible,thetestsshouldbeconductedinbothoperation
modes.
System engineers should review the systemdesign and operation to identify the critical conditions
and to checkoilreturn, oil balancing,liquid floodbackand oil dilution.For discussionof individual test
results and system behaviour, eg, with regard to oil dilution, please contact the Application
Engineering department. Typically, the following situations should be considered:
▪In single compressor systems: to check oil return, testing conditions shall be at minimummass
flow and minimum density of suction gas in continuous and frequentstart-stop cycling.
▪In multiple compressor systems: to check oil return and oil balancing inthe tandem or trio,
testing conditions shall be at the cornerpoints of the systemapplication envelope in continuous
and frequentstart-stop-cycling.
▪In all systems: to test liquid floodback and oil dilution, all possible transientoperation conditions
in the systemshould be checked, eg,compressor frequentstart/stop,compressor start after long
off time with migration, defrost, switching between the operation modesin reversible systems,
load changes,fansorpumpscyclingatlowloadand more.To evaluatetherisk ofliquidfloodback
and oil dilution, please refer to the chart in Figure 12.
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 area, asshown in the chart in Figure 12 below. In case
of operation in the(red) unsafe area, adjustments are required in order to modify the system design,
refrigerant charge or superheat setting of the expansion device(s). The bottomshell temperature
should be measured accurately. The thermo-probe must be insulated well and positioned on the
opposite side of thesight glass or atan angle of 90° clockwise from the suction inlet with view on the
top.