Copeland YH23K1G Instruction Manual

Copeland™Scroll Compressors
for R290 Heat Pump Applications
YH23K1G to YH38K1G
Application Guidelines

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About these guidelines ...............................................................................................1
1Safety instructions...........................................................................................1
1.1 Icon explanation............................................................................................................... 2
1.2 Safety statements ............................................................................................................ 2
1.3 General instructions......................................................................................................... 3
2Product description .........................................................................................4
2.1 Compressor range ........................................................................................................... 4
2.2 Nomenclature................................................................................................................... 4
2.3 BOM Variations................................................................................................................ 5
2.4 Application range ............................................................................................................. 5
2.4.1 Qualified refrigerants and oils .............................................................................. 5
2.4.2 Application limits................................................................................................... 5
2.4.3 PED category and maximum allowable pressure PS .......................................... 6
2.5 Dimensions ...................................................................................................................... 7
3Installation........................................................................................................8
3.1 Compressor handling....................................................................................................... 8
3.1.1 Transport and storage.......................................................................................... 8
3.1.2 Positioning and securing...................................................................................... 8
3.1.3 Installation location............................................................................................... 8
3.2 Mounting parts ................................................................................................................. 8
3.3 Brazing procedure............................................................................................................ 9
3.3.1 General brazing procedure................................................................................... 9
3.3.2 Brazing procedure for YH*K1G compressors in parallel applications................ 10
3.4 Pressure safety controls ................................................................................................ 10
3.4.1 High-pressure protection.................................................................................... 10
3.4.2 Low-pressure protection..................................................................................... 11
3.5 System protection for operation below atmospheric pressure....................................... 11
3.6 Crankcase heater........................................................................................................... 12
3.7 Soft starters.................................................................................................................... 13
3.8 Discharge gas temperature protection........................................................................... 13
3.8.1 Excessive discharge gas temperatures ............................................................. 14
3.8.2 Discharge temperature sensor NTC .................................................................. 14
3.9 Internal pressure relief valve.......................................................................................... 14
3.10 Discharge check valve................................................................................................... 14
3.11 Filter screens ................................................................................................................. 15
3.12 Mufflers .......................................................................................................................... 15
3.13 Sound shell .................................................................................................................... 15
3.14 Insulation material.......................................................................................................... 15
3.15 Reversing valves............................................................................................................ 15
3.16 Sound and vibration....................................................................................................... 16

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3.17 Compressor oil return, oil balancing, refrigerant flood-back and oil dilution tests......... 16
3.18 Suction line accumulator................................................................................................ 17
4Electrical connection.....................................................................................18
4.1 General recommendations............................................................................................. 18
4.2 Electrical installation ...................................................................................................... 18
4.3 Terminal box .................................................................................................................. 19
4.3.1 Terminal box –IP54 GCZ, GCY and GCW........................................................ 20
4.3.2 Terminal box –Metal IP65 JCE and JCD .......................................................... 20
4.4 Motor insulation.............................................................................................................. 21
4.5 Motor protection............................................................................................................. 21
4.6 High potential testing ..................................................................................................... 21
5Start-up & operation.......................................................................................23
5.1 Strength-pressure test ................................................................................................... 23
5.1.1 Compressor strength-pressure test.................................................................... 23
5.1.2 System strength-pressure test ........................................................................... 23
5.2 Compressor tightness test ............................................................................................. 24
5.3 System evacuation......................................................................................................... 24
5.4 Preliminary checks –Pre-starting.................................................................................. 24
5.5 Charging procedure ....................................................................................................... 25
5.6 Run-in time..................................................................................................................... 25
5.7 Initial start-up ................................................................................................................. 25
5.8 Rotation direction........................................................................................................... 25
5.9 Starting sound................................................................................................................ 26
5.10 Deep vacuum operation................................................................................................. 26
5.11 Shell temperature........................................................................................................... 26
5.12 Pumpdown cycle............................................................................................................ 26
5.13 Minimum run time .......................................................................................................... 27
5.14 Shut-off sound................................................................................................................ 27
5.15 Supply frequency and voltage ....................................................................................... 27
5.16 Oil level .......................................................................................................................... 27
6Maintenance & repair.....................................................................................29
6.1 Qualification of workers.................................................................................................. 29
6.2 Preparation and work procedure ................................................................................... 30
6.3 Disassembling system components .............................................................................. 30
6.4 Exchanging the refrigerant............................................................................................. 31
6.5 Replacing a compressor................................................................................................ 31
6.5.1 Compressor replacement................................................................................... 31
6.5.2 Start-up of a new or replacement compressor................................................... 31
6.5.3 Compressor return procedure............................................................................ 32
6.6 Lubrication and oil removal............................................................................................ 32

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6.7 Oil additives ................................................................................................................... 33
7Dismantling & disposal..................................................................................34
8References......................................................................................................34
Appendix 1: Tightening torques...............................................................................35
DISCLAIMER ..............................................................................................................35

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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.
Besides the support they provide, the instructions listed herein are also critical for the proper and
safe functioning of the compressors. The performance and reliability of the product may be impacted
if it is not used according to these guidelines or is misused.
These application guidelines cover stationary applications only. For mobile applications, please
contact the Application Engineering department at Copeland as other considerations may apply.
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.
YH*K1G compressors are intended for installation in systems in accordance with the following
directives and regulations:
Machinery Directive MD 2006/42/EC
Supply of Machinery (Safety) Regulation 2016
Pressure Equipment Directive PED 2014/68/EU
Pressure Equipment (Safety) Regulation 2008
Low Voltage Directive LVD 2014/35/EU
Electrical Equipment (Safety) Regulation 2016
They may be put to service only if they have been installed in systems according to instructions and
conform to the corresponding provisions of legislation.
In order to keep the system compliant with the ATEX Directive 99/92/EC, all accessories to be fitted
on the compressor, eg, oil level regulator, crankcase heater, discharge line thermostat, shall comply
with the ATEX Directive 2014/34/EU Zone 2. If one of these accessories does not comply, the
complete system will lose its compliance with the ATEX Directive 99/92/EC and therefore can be
operated only in a non-flammable environment.
NOTE: Only dedicated compressors are allowed to be used with flammable refrigerants.
Copeland 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 must comply with any and all applicable
legislation and regulations. Ensuring compliance remains the user’s responsibility.
The Material Safety Datasheet (MSDS) of each individual refrigerant shall be considered –please
check this document provided by the gas supplier.
These instructions shall be retained throughout the lifetime of the compressor.
You are strongly advised to follow these safety instructions.

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1.1 Icon explanation
WARNING
This icon indicates instructions to
avoid personal injury and material
damage.
Fire hazard
This icon indicates a risk of flammable
atmosphere.
High voltage
This icon indicates operations with a
danger of electric shock.
CAUTION
This icon indicates instructions to
avoid property damage and possible
personal injury.
Danger of burning or frostbite
This icon indicates operations with a
danger of burning or frostbite.
IMPORTANT
This icon indicates instructions to
avoid malfunction of the compressor.
Explosion hazard
This icon indicates operations with a
danger of explosion.
NOTE
This word indicates a
recommendation for easier operation.
Danger of explosive atmosphere
This icon indicates a risk of explosive
atmosphere.
1.2 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. Only
competent personnel (as specified in EN 13313) qualified for flammable refrigerant
handling is permitted to commission, initiate and maintain the compressor/refrigeration
systems; 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
EN 378 and EN 60335-2-40. The system designer shall implement all safety measures
defined by the applicable standards and the maximum refrigerant 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.
▪Electrical connections must be made by qualified electrical personnel.
▪All valid standards for connecting electrical and refrigeration equipment must be
observed.
▪The national legislation and regulations regarding personnel protection must be observed.
Use personal safety equipment. Safety goggles, gloves,
protective clothing, safety boots and hard hats should be worn where
necessary.

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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 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 must be used.
WARNING
High shell temperature! Burning! Do not touch the compressor until it has
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 PAG! Material damage! Poly-alkylene glycol (PAG) lubricant
must be handled carefully and the proper protective equipment (gloves, eye
protection, etc.) must be used at all times. Refrigerant oil must not come into
contact with 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.

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2 Product description
2.1 Compressor range
These application guidelines cover Copeland scroll compressor models according to Table 1 for
R290 heat pump applications.
Compressor
Heating
capacity*
(kW)
Displacement
(m3/h)
Motor
YH23K1G
22.3
29.2
TFD
YH28K1G
26.7
35.4
TFD
YH33K1G
31.9
42.4
TFD
YH38K1G
36.8
48.3
TFD
Table 1: Model overview for R290 heating applications
* Refrigerant dew temperature, evaporating temperature: -7 °C; condensing temperature: 50 °C; suction gas
superheat:5 K; liquid sub-cooling: 4 K; frequency: 50 Hz
2.2 Nomenclature
The model designation contains the following technical information about the compressors:
Figure 1: Nomenclature

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2.3 BOM Variations
The BOM (bill of material) number at the end of the compressor designation indicates the different
compressor layouts and details. The YH*K1G compressor models are available in the following BOM
versions:
BOM
Suction and
discharge
connections
T-Box
Mounting
parts
Features
GCZ
Braze
IP54
Without
Single use
JCE
Braze
IP65
Without
GCY
Braze
IP54
Without
Tandem/trio use with brazing stub tube
for gas and oil equalization
JCD
Braze
IP65
Without
GCW
Braze
IP54
Without
Tandem use with brazing stub tube for
gas and oil equalization line & extra
connection for gas equalization line
(GEL for variable speed tandemization)
Table 2: BOM designation
Please refer to the Copeland price list for more details.
Compressor versions BOM JCE and JCD contain an IP65 terminal box, which complies with ATEX
Directive 94/9/EC part II 3G. The compressor label conforms to the ATEX Directive 2014/34/EU
specifications and to the harmonized standard series EN 60079. The ATEX marking for applications
in gas explosive atmosphere Zone 2 locations is as follows:
▪ATEX Directive 94/9/EC part: II 3G
▪Standard part (EN 60079-0, EN 60079-15): Ex nA IIA T2
The Declaration of Conformity is available from the manufacturer upon request.
2.4 Application range
2.4.1 Qualified refrigerants and oils
NOTE: R290 is classified as A3 (highly flammable) refrigerant.
Compressors
YH23K1G, YH28K1G, YH33K1G and YH38K1G
Qualified refrigerants
R290
Copeland standard oil
Zerol RFL68-EP (PAG)
Table 3: YH*K1G - qualified refrigerants and oils
Oil recharge values can be taken from Copeland Select software available at www.
copeland.com/en-gb.
2.4.2 Application limits
CAUTION
Inadequate lubrication! Compressor breakdown! Copeland scroll
compressors are qualified for operation inside the envelope published by
Copeland. The envelope is defined according to Copeland’s testing and
experience. Operating a compressor outside the envelope might lead to
compressor failure which would be the heat pump manufacturer’s
responsibility.
Low superheat! Liquid floodback and compressor breakdown! The
superheat at the compressor suction inlet must always be sufficient to ensure
that no refrigerant droplets enter the compressor. For a typical evaporator
expansion valve configuration a minimum stable superheat of at least 5 K is
required.