Copeland YH23K1G Instruction Manual

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

AGL_HP_ST_YHK1G_EN_Rev00
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

AGL_HP_ST_YHK1G_EN_Rev00
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

AGL_HP_ST_YHK1G_EN_Rev00 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.
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.

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Figure 2: Application envelope for YH*K1G compressors
The models YH23/28K1G can run at the upper left highlited area with DLT control, not following the
5 K superheat.
For application envelopes and technical data, please refer to Copeland Select software available at
www.copeland.com/en-gb.
2.4.3 PED category and maximum allowable pressure PS
The nameplate of the compressor contains information about the maximum allowable pressure PS,
the minimum and maximum allowed temperatures TS, the internal free volume and the fluid groups
of the refrigerants qualified for the compressor model range. Values are given for both pressure
ranges on low- and high-pressure sides.
Compressor
PS
Low-
pressure side
PS
High-
pressure
side
TS max.
Low-
pressure
side
Internal free
volume
LP side
Internal free
volume
HP side
YH23K1G
30.4 bar(g)
50 bar(g)
55 °C
12.6 L
1.5 L
YH28K1G
30.4 bar(g)
50 bar(g)
55 °C
12.6 L
1.5 L
YH33K1G
30.4 bar(g)
50 bar(g)
55 °C
12.6 L
1.5 L
YH38K1G
30.4 bar(g)
50 bar(g)
55 °C
12.6 L
1.5 L
Table 4: 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 when the product of "pressure
relative to the environment" by "related internal free volume" (PxV) exceeds given limits.
When calculating the PED category, the high- and low-pressure sides have to be calculated
separately. The highest of the calculation results is considered.
Compressor range
Refrigerant
Fluid group
PED
class
YH*K1G
R290
1
3
Table 5: PED class based on refrigerant and fluid group used

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2.5 Dimensions
Figure 3: Dimensions of compressors YH*K1G with BOM GCZ and JCE (single)
BOM
A
(mm)
B
(mm)
C
(mm)
T-Box
GCZ
263.2
289
162.6
IP54
JCE
270.9
292.1
165.8
IP65
Table 6
Figure 4: Dimensions of compressors YH*K1G with BOM GCY, JCD and GCW (tandem/trio)
BOM
A
(mm)
Gas and oil
equalization*
Gas
equalization**
T-Box
GCY
263.2
Yes
No
IP54
JCD
270.9
Yes
No
IP65
GCW
263.2
Yes
Yes
IP54
Table 7

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3 Installation
WARNING
High pressure! Injury to skin and 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 5. Check the
tilting stability and if needed take action to ensure the stability of the stacked
loads. Keep the packaging dry at 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 5: Maximum stacking loads for transport and storage
The compressor tilt angle should not exceed 30° during transport and handling. This will prevent oil
from exiting through the suction stub. A tilt angle of maximum 45° is allowed for a very short time.
Tilting the compressor more than 45° might affect its lubrication at start-up.
NOTE: The compressor is pre-charged with dry air to 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 compressor should be kept vertical 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 must be removed as late as possible before brazing so that the air humidity does not affect
the oil characteristics.
No object, e.g., a swaging tool should be inserted deeper than 51 mm into the suction tube as it might
damage internal parts.
3.1.3 Installation location
These compressors shall be installed in Zone 2 locations, as defined by the ATEX directive, or in
non-hazardous atmospheres.
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.
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
compressor base during operation. The metal sleeve inside is a guide designed to hold the grommet

AGL_HP_ST_YHK1G_EN_Rev00 9
in place. It is not designed as a load-bearing member, and application of 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 compressors are mounted in tandem or used in parallel, then metal spacers between
compressor and rails are recommended, an M10 screw is applied and the mounting torque should
be between 45 to 55 Nm.
See Copeland spare parts software for references.
NOTE: For more information, please refer to Copeland spare parts and accessories software
available at www.copeland.com/en-gb/tools-resources for reference.
3.3 Brazing procedure
WARNING
Air/flammable refrigerant mixture! Creation of a potentially flammable
atmosphere! Fire hazard! Remove all refrigerant before opening the system.
When working on a refrigerant-filled system, make sure to follow the safety
and working instructions given in Chapter 6.
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 the compressor do not come into contact
with it.
CAUTION
Blockage! Compressor breakdown! 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 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 orifices.
Contamination or moisture! Bearing failure! Do not remove the connection
plugs until the compressor is set into the unit. This minimises any entry of
contaminants and moisture.
3.3.1 General brazing procedure
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. Due
to the different thermal properties of steel and copper,
brazing must be carried out in an appropriate manner.
Refer to Figure 6 and procedure below for the brazing of the
stub tube connections of a scroll compressor.
▪Flushing oxygen-free nitrogen through the piping during the brazing process is mandatory for
applications with flammable A3 refrigerants.
▪The copper-coated steel tubes on scroll compressors can be brazed in approximately the same
manner as any copper tube.
▪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 diameter and tube outer diameter are clean prior to assembly.
▪Using a double-tipped torch, apply heat in area 1.
▪As the tube approaches brazing temperature, move the torch flame to area 2.
▪Heat area 2 until braze temperature is attained, moving the torch up and down and rotating around
the tube as necessary to heat the tube evenly. Add braze material to the joint while 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 spent heating area 3 should be minimal.
Figure 6: Brazing areas

10 AGL_HP_ST_YHK1G_EN_Rev00
▪As with any brazed joint, overheating may be 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 from flowing into it.
3.3.2 Brazing procedure for YH*K1G compressors in parallel applications
WARNING
Air/flammable refrigerant mixture! Creation of a potentially flammable
atmosphere! Fire hazard! Remove all refrigerant before opening the system.
When working on a refrigerant-filled system, make sure to follow the safety
and working instructions given in Chapter 6.
WARNING
Oil high temperature! Burning and personal injuries! The high temperature generated
during the brazing process can exceeded the flash point of the oil and consequently lead
to the air-steam mixture ignition. Make sure to always keep the oil temperature below its
flash point, otherwise the oil will ignite in the presence of air. Do not braze the pipes with
oil inside to avoid reaching the flash point of the oil, which in the presence of air forms
flammable mixtures.
Only compressor models officially approved by Copeland in the qualified configuration may be used
for parallel applications. For YH*K1G compressors in parallel applications with passive oil
management, additional precautions shall be taken before brazing the oil and gas equalization ports.
The sequence shall be as follows:
First, install the compressors on the base frame and tilt the assembly so that oil will not 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 from the oil port.
Most probably the oil fitting will be coated with some oil. It is mandatory to clean out the oil before
brazing. If the inner surface is contaminated with oil the brazing material will not adhere to the surface
and the joint will fail, generating leakage. The oil should be carefully wiped out with industrial
absorption paper. Industrial solvents on a clean cloth can be used too but only with great care. Note
that emery cloth will not remove the oil.
It is possible that the oil cannot be completely cleaned out. In this case additional measures should
be taken. For instance, if a connection is coated with flux then the residual oil will be removed when
brazing thanks to the applied heat.
If an active oil level control is to be used, please refer to the product documentation when brazing
the connection adaptor.
3.4 Pressure safety controls
Pressure protection devices to be used in ATEX Zone 2 locations must comply with the ATEX
directive requirements. Non ATEX-certified pressure protection devices shall NOT be used in ATEX
Zone 2 locations.
ATEX-approved pressure protection devices are available from Alco Controls. Please refer to the
dedicated "Product Guide for R290".
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 maximum limit.
High-pressure protection is required to stop the compressor operating outside the allowable pressure
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 refrigerant and the maximum allowable pressure PS.

AGL_HP_ST_YHK1G_EN_Rev00 11
3.4.2 Low-pressure protection
CAUTION
Operation outside the application envelope! Compressor breakdown! A
low-pressure protection should be fitted in the suction line in order to stop the
compressor when it operates outside the envelope limits. Do not bridge or by-
pass the low-pressure limiter.
Applicable regulations and standards shall be followed to apply appropriate control and ensure that
the pressure is always above the required minimum limit.
Low-pressure protection is required to stop the compressor operating outside the allowable envelope
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.copeland.com/en-gb.
3.5 System protection for operation below atmospheric pressure
WARNING
Operation below atmospheric pressure! Fire hazard! During operation
below atmospheric pressure, a flammable mixture can form inside the system.
Ensure system tightness to prevent any ingress of air.
Compressors YH*K1G in R290 systems may be operated below atmospheric pressure only when
installed in hermetically sealed systems. For non-hermetically systems, the pressure must always be
above atmospheric pressure. The operating pressure must be limited as defined by the operation
envelope, refer to the technical documentation.
When systems operate with YH*K1G compressors below atmospheric pressure, the following
precautions must be observed:
▪Check all critical points on the system and the piping connections; tightness has to be ensured
also at very low pressure.
▪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 3.8 "Discharge gas temperature
protection".
▪Additional warning notices shall be affixed to any system equipped with shut-off valves. The
warnings must contain instructions to open the shut-off valves completely after each repair or
maintenance work. The compressors may 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: All of the above points must be fulfilled. If any of them cannot be met, the compressors
shall not be operated below atmospheric pressure.

12 AGL_HP_ST_YHK1G_EN_Rev00
3.6 Crankcase heater
WARNING
Ignition source in a potentially flammable atmosphere! Fire hazard! The
crankcase heater is not an ignition source during normal operation in A3
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 apply power to the
crankcase heater in free air, before the crankcase heater is installed on the
compressor or when it is not in complete contact with the compressor shell.
IMPORTANT
Oil dilution! Bearing malfunction! Turn the crankcase heater on 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 8. This requirement is independent from system type and
configuration.
Compressor model
Refrigerant
Refrigerant
charge limit
(kg)
Crankcase heater
Position
Height
YH*K1G
R290
3.3
53 to 59 mm
Table 8: Refrigerant charge limits for single application & crankcase heater position
The initial start-up in the field is a very critical period for any compressor because all load-bearing
surfaces are new and require a short break-in period to carry high loads 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 energized during compressor off cycles.
Please refer to the Spare Parts list available at www.copeland.com/en-gb/tools-resources to select
the correct crankcase heater model.
Crankcase heaters to be used in ATEX Zone 2 locations must comply with the ATEX Directive
requirements. Non ATEX-certified crankcase heaters shall NOT be used in ATEX Zone 2 locations.
NOTE: The crankcase heater presently available from Copeland is not ATEX-certified and can
only be used in non-flammable environments. In case the available crankcase heater has to
be ordered from Copeland, please refer to the Spare Parts list available at
www.copeland.com/en-gb/tools-resources for correct model selection.
Caution: Crankcase heaters must be properly grounded!
For installation, the manufacturer/installer shall follow 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.
▪Position the crankcase heater between the lower cover and the lower bearing weld projection
(Fig. 7).
▪Fit the heater horizontally around the crankcase, ensuring that it is in close contact with the
compressor housing along the entire length.
▪Avoid having the heating portion of the heater in contact with any weld projection (Fig. 8 & 9).
▪Avoid having the assembly heater inclined (Fig. 10).
▪Close the lock and tighten the screw, torque: 2-3 Nm.
▪The excess clamp bracket may be trimmed. Sharp edges must not come into contact with wires.

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▪The presence of the heater shall be made evident by the posting of caution signs or markings at
appropriate locations.
Figure 7 Figure 8 Figure 9 Figure 10
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.
▪Check the resistance according to the technical data.
▪Perform an insulation test before start-up.
▪Electrical security and safety measures are to be provided on site.
3.7 Soft starters
Copeland scroll fixed-speed compressors can generally be operated with soft starters. Soft starter
versions and sizes should be selected according to the soft starter manufacturer’s recommendations,
taking into consideration the compressor amps. Normally, the ramp-up time should not exceed
1 second.
Due to the inherent design of the Copeland scroll, the internal compression components start
unloaded, even if system pressures are not balanced. Since the compressor internal pressures are
balanced at start-up, low voltage starting characteristics are excellent, and starting components are
normally not required.
However, for extreme electrical conditions such as weak power supplies, single-phase soft starters
can be supplied on request by Copeland, while three-phase soft starters are available on the market.
3.8 Discharge gas temperature protection
CAUTION
Inadequate lubrication! Scroll set damage! All YH*K1G compressors must
be equipped with a discharge gas temperature 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 application with Copeland compressors.
The maximum discharge gas temperature is 135 °C for models YH*K1G covered in this guideline.
Discharge gas temperature protection is the "fall-back" for failure of the system control. It is essential
that proper control of both the evaporating and condensing pressures and the superheat is
maintained and has the ability to cope with all likely conditions and high loads. Reliance on protectors
will cause inadequate system performance and short cycling.
NOTE: The maximum discharge gas temperatures indicated in this chapter are valid for safe
operation within the approved application envelope. The discharge temperature protection
has the function of a compressor protection, it is not designed to control the operating
envelope. For compressor envelope control, an additional control device or regulation must
be used.

14 AGL_HP_ST_YHK1G_EN_Rev00
3.8.1 Excessive discharge gas temperatures
A few of the possible consequences of excessive discharge gas temperatures are listed below:
▪Since the oil circulates in the system with the refrigerant, it is subjected to high discharge gas
temperatures. If the discharge gas temperature becomes too high, the so-called "cooking" effect
will occur (heating of oil under exclusion of air). Carbon deposits can form at points of high
temperature, for example on the valves, oil channels, oil filters, etc. The oil lubricity will be reduced
and a progressive wear process will occur which will 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 from sealants and
insulation material. As a consequence, contaminants of various types, among them acids, will form
inside the system.
3.8.2 Discharge temperature sensor NTC
Compressors YH*K1G need an external discharge line temperature sensor. The correct reading of
this sensors is fundamental for discharge line temperature control. The sensor must guarantee good
accuracy and acceptable dynamic behavior.
General recommendations prescribed that the sensor must be installed in a copper sleeve, to
improve response time and to reduce setoff. The copper sleeve must be brazed on the surface of
the pipe.
Use thermal compound to improve the heat transfer from the sleeve to the sensor is strongly
recommended. The thermal compound must be approved for appropriate temperature ranges.
To reduce the impact of ambient temperature, the pipe including the sensor must be insulated.
Also protect the sensor from being removed from its position by transport, vibration or any other
incident.
Copeland recommended that the discharge temperature sensor be positioned 120 mm from the
compressor outlet.
Figure 11: Sensor installation
For NTC mounting recommendations please refer to Copeland assembly instructions
C30.11/0419/E.
3.9 Internal pressure relief valve
There is no internal pressure relief valve on YH*K1G compressors.
3.10 Discharge check valve
YH*K1G compressors contain an internal low leak check valve on the discharge connection. The
discharge check valve prevents the high-pressure discharge gas from flowing rapidly back through
the compressor after shutdown.
NOTE: This check valve cannot be used with recycling pump down because it is not entirely
leak-proof.

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3.11 Filter screens
CAUTION
Screen blocking! Compressor breakdown! Use screens with at least
0.6 mm openings.
The use of filter screens finer than 30 x 30 mesh (0.6 mm openings) anywhere in the system should
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 normal system debris and block the flow of either oil or refrigerant to the
compressor. Such blockage can result in compressor failure.
3.12 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 levels of sound and vibration.
If adequate attenuation is not 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 hollow shell muffler will work quite well. Locate the
muffler at minimum 15 to maximum 45 cm from the compressor discharge for the most effective
operation. The farther the muffler is placed from the compressor within these ranges, the more
effective. Choose a muffler with a length of 10 to 15 cm.
3.13 Sound shell
Copeland has qualified sound shell kits for the compressor model range YH*K1G.
NOTE: Refer to the Copeland spare parts & accessories catalogue at www.copeland.com/en-
gb/tools-resources to select the correct sound shell kits according to compressor model.
3.14 Insulation material
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 material for A3
applications, particular attention shall be paid to its non-electrostatic properties, as it could be a
potential ignition source.
3.15 Reversing valves
Since Copeland scroll compressors have a very high volumetric efficiency, their displacements are
lower than those of comparable capacity reciprocating compressors. As a result, Copeland
recommends that the capacity rating on reversing valves be no more than 1.5 to 2 times the nominal
capacity of the compressor in order to ensure proper operation of the reversing valve under all
operating conditions.
Caution: Reversing valve sizing must be within the guidelines of the valve manufacturer. The
pressure drop required to ensure valve shifting must be measured throughout the operating range of
the unit and compared to the valve manufacturer's data. Low ambient heating conditions with low
flow rates and low pressure drop across the valve can result in a valve not shifting. This can lead to
a condition where the compressor appears not to be pumping, ie, balanced pressures. It can also
cause elevated compressor sound levels.
During a defrost cycle, when the reversing valve abruptly changes the refrigerant flow direction, the
suction and discharge pressures will go outside of the normal operating envelope. The sound that
the compressor makes during this transition period is normal, and the duration of the sound will
depend on the heat exchanger (coil) volume, outdoor ambient, and system charge level. The
preferred method of mitigating defrost sound is to shut down the compressor for 20 to 30 seconds
when the reversing valve changes position going into and coming out of the defrost cycle. This
technique allows the system pressures to reach equilibrium without the compressor running. The
additional start-stop cycles do not exceed the compressor design limits, but suction and discharge
tubing design and contactor life should be evaluated.
The reversing valve solenoid should be wired so that the valve does not reverse when the system is
shut off by the operating thermostat in the heating or cooling mode. If the valve is allowed to reverse
at system shut-off, suction and discharge pressures are reversed to the compressor. This results in