Emerson Copeland YB45K1E Instruction Manual

Copeland™Scroll Compressors
for Refrigeration Applications
YB12K1E to YB45K1E
Application Guidelines

AGL_Ref_ST_YBK1E_EN_Rev03
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 variations ..................................................................................................................4
2.4 Application range ...............................................................................................................4
2.4.1 Qualified refrigerants and oils ................................................................................4
2.4.2 Application limits.....................................................................................................4
2.4.3 PED category 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 for YB*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 System protection for operation below atmospheric pressure.........................................10
3.6 Crankcase heater.............................................................................................................11
3.7 Discharge gas temperature protection.............................................................................12
3.7.1 Excessive discharge gas temperatures ...............................................................12
3.7.2 Discharge line thermostat.....................................................................................13
3.8 Internal pressure relief valve............................................................................................14
3.9 Discharge check valve.....................................................................................................14
3.10 Filter screens ...................................................................................................................14
3.11 Mufflers ............................................................................................................................14
3.12 Sound shell ......................................................................................................................14
3.13 Insulation material............................................................................................................14
3.14 Sound and vibration.........................................................................................................15
3.15 Compressor oil return, oil balancing, refrigerant floodback and oil dilution tests ............15

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3.16 Suction 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 Motor protection...............................................................................................................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 System strength-pressure test .............................................................................21
5.2 Compressor tightness test...............................................................................................22
5.3 System evacuation...........................................................................................................22
5.4 Preliminary checks –Pre-starting....................................................................................22
5.5 Charging procedure .........................................................................................................23
5.6 Run-in time.......................................................................................................................23
5.7 Initial start-up ...................................................................................................................23
5.8 Rotation direction.............................................................................................................23
5.9 Starting sound..................................................................................................................24
5.10 Deep vacuum operation...................................................................................................24
5.11 Shell temperature.............................................................................................................24
5.12 Pumpdown cycle..............................................................................................................24
5.13 Minimum run time ............................................................................................................25
5.14 Shut-off sound..................................................................................................................25
5.15 Supply frequency and voltage .........................................................................................25
5.16 Oil level ............................................................................................................................25
6Maintenance & repair...................................................................................... 26
6.1 Qualification of workers....................................................................................................26
6.2 Preparation and work procedure .....................................................................................27
6.3 Disassembling system components ................................................................................27
6.4 Replacing a compressor..................................................................................................27
6.4.1 Compressor replacement.....................................................................................27
6.4.2 Start-up of a new or replacement compressor.....................................................28
6.4.3 Compressor return procedure..............................................................................28
6.5 Exchanging the refrigerant...............................................................................................29
6.6 Lubrication and oil removal..............................................................................................29
6.7 Oil additives .....................................................................................................................30
7Dismantling & disposal................................................................................... 31
8References....................................................................................................... 31

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

AGL_Ref_ST_YBK1E_EN_Rev03 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 the product 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 Emerson as other considerations may apply.
1 Safety instructions
Copeland scroll compressors are manufactured according to the latest relevant European, UK and
US 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 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 the applicable 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 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 when
working with these types of refrigerants –please check the 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.
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.

2 AGL_Ref_ST_YBK1E_EN_Rev03
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.
▪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.
NOTE: For systems using A1 refrigerants (R404A, R407A, R407F, R448A and R449A) the
flammable refrigerant sticker is not of application and should be removed from the
compressor.
Additional requirements and statements for A2L-refrigerant compressors/systems:
▪Only competent personnel (as specified in EN 13313) qualified for flammable refrigerant
handling are 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.
▪When planning and building systems with such refrigerants, a risk assessment and
corresponding precautions for risk mitigation must be taken by the system designer.
Special attention must be paid to flammability when dealing with A2L refrigerants.
▪The maximum refrigerant charge is specified in standards such as, but not limited to
EN 378, EN 60335-2-40 and EN 60335-2-89. 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.
Use personal safety equipment. Safety goggles, gloves, protective
clothing, safety boots and hard hats should be worn where necessary.
1.3 General instructions
WARNING
Pressurized system! Serious personal injuries and/or system
breakdown! Accidental system start before complete set-up must be avoided.
Never leave the system unattended without locking it out electrically when it is
under 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 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) lubricants
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, some polymers, eg, PVC/CPVC and polycarbonate.
IMPORTANT
Transit damage! Compressor malfunction! Use original packaging. Avoid
collisions and tilting.

AGL_Ref_ST_YBK1E_EN_Rev03 3
2 Product description
2.1 Compressor range
These application guidelines cover Copeland scroll compressor models YB*K1E for medium
temperature refrigeration applications. YB*K1E scroll compressors can be operated with either A1
or 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**/TFDN
YB17K1E
4.41
4.34
4.71
4.44
4.44
4.05
2.85
2.64
2.28
PFZN**/TFDN
YB21K1E
5.62
5.53
6
5.66
5.66
5.15
3.63
3.36
2.9
PFZN**/TFDN
YB24K1E
6.28
6.18
6.71
6.33
6.33
5.75
4.06
3.91
3.36
PFZN**/TFDN
YB31K1E
7.92
7.79
8.45
7.98
7.98
7.29
5.14
4.89
4.21
TFDN
YB36K1E
9.45
9.28
10.1
9.52
9.52
8.62
6.09
5.82
5.01
TFDN
YB45K1E
11.90
11.65
12.65
11.95
11.95
10.90
7.70
7.32
6.32
TFDN
* 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 R407C and R134a refrigerants only.
Table 1: YB*K1E model overview for MT applications with A1 refrigerants
Compressor
Cooling capacity* (kW)
Motor
R454C
R455A
R454A
R1234yf
YB12K1E
2.76
2.93
3.31
1.84
PFZN**/TFDN
YB17K1E
3.89
4.15
4.64
2.6
PFZN**/TFDN
YB21K1E
4.92
5.22
5.91
3.29
PFZN**/TFDN
YB24K1E
5.55
5.88
6.6
3.71
PFZN**/TFDN
YB31K1E
6.95
7.4
8.32
4.67
TFDN
YB36K1E
8.23
8.78
9.93
5.47
TFDN
YB45K1E
10.40
11.10
12.50
7.00
TFDN
* 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 refrigerant only.
Table 2: YB*K1E model overview for MT applications with A2L refrigerants
2.2 Nomenclature
The model designation contains the following technical information about the compressor:
Figure 1: Nomenclature

4 AGL_Ref_ST_YBK1E_EN_Rev03
2.3 BOM variations
The BOM (bill of material) marking at the end of the compressor designation indicates the different
compressor layouts and details. YB*K1E compressors are available in the following BOM versions:
BOM
Suction and discharge
connections
T-Box
Mounting
parts
Features
GBS
Brazing stub tubes
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 refrigerant blends have a significant temperature glide. It is essential
that the glide of the refrigerant blends be carefully considered when adjusting
pressure and superheat controls.
IMPORTANT
Refrigerant blends with low GWP containing HFO’s have a low chemical
stability in presence of air or humidity. The same levels of cleanliness, 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
YB12K1E to YB45K1E*
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 from the compressor nameplate or from Copeland Select software
available at www.climate.emerson.com/en-gb.
2.4.2 Application limits
CAUTION
Inadequate lubrication! 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.
For application envelopes and technical data, please refer to Copeland Select software available at
www.climate.emerson.com/en-gb.

AGL_Ref_ST_YBK1E_EN_Rev03 5
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 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 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 (litres)
Internal free
volume
HP side (litres)
YB12K1E
23.5 bar(g)
38 bar(g)
50 °C
4.1
0.5
YB17K1E
23.5 bar(g)
38 bar(g)
50 °C
4.2
0.5
YB21K1E
23.5 bar(g)
38 bar(g)
50 °C
4.3
0.5
YB24K1E
23.5 bar(g)
38 bar(g)
50 °C
4.8
0.5
YB31K1E
23.5 bar(g)
38 bar(g)
50 °C
6.4
0.6
YB36K1E
23.5 bar(g)
38 bar(g)
50 °C
6.4
0.6
YB45K1E
23.5 bar(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 when the product of "pressure
relative to the environment" by "related internal free volume" (P x V) 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.
Additionally, a distinction must be made between refrigerants of fluid group 1 (flammable) and fluid
group 2 (non-flammable). The YB*K1E compressors covered in these guidelines can be operated
with either A1 or A2L refrigerants. Consequently, identical compressor models may be subject to
different PED categories depending on the refrigerant used.
Compressor range
Refrigerant
Fluid group
PED category
YB12K1E to YB45K1E
R454C, R455A, R454A,
R1234yf
1
II
R404A, R407A, R407F,
R448A, R449A, R407C,
R513A, R134a, R450A
2
I
Table 6: PED category based on refrigerant used and fluid group

6 AGL_Ref_ST_YBK1E_EN_Rev03
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
YB45K1E
442
409.6
225.2
296.7
79.6
185.5
260.5
254.9
124.7
44
Table 7: Dimensions of YB*K1E compressors
Compressor
Suction
(inch)
Discharge
(inch)
YB12K1E
3/4"
1/2"
YB17K1E
3/4"
1/2"
YB21K1E
3/4"
1/2"
YB24K1E
7/8"
1/2"
YB31K1E
7/8"
1/2"
YB36K1E
7/8"
1/2"
YB45K1E
7/8"
1/2"
Table 8: Connection sizes of YB*K1E compressors
NOTE: The connection in blue colour is an additional connection for paralleling models (BOM
version GCG).

AGL_Ref_ST_YBK1E_EN_Rev03 7
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 handling equipment according to weight. Keep in the upright
position. Respect stacking loads according to Figure 3. 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 3: 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.
For YB*K1E compressors, as oil might spill out of the suction connection located low on the shell,
the suction connection plug must be left in place until the compressor is set into the unit.
No object, eg, a swaging tool should be inserted deeper than 51 mm into the suction tube as it might
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_Rev03
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
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 the hard mountings (bolt M8) are
recommended. The mounting torque should be 27 ± 1 Nm.
See Copeland spare parts & accessories catalogue 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 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 "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 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.

AGL_Ref_ST_YBK1E_EN_Rev03 9
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 5 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 recommended for
applications with A1 refrigerants and mandatory for applications with flammable A2L 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.
▪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 YB*K1E 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 "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 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 port 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, eg, OM* TraxOil from Alco Controls, please refer to the
product documentation when brazing the connection adaptor.
: Brazing areas
Figure 5: Brazing areas

10 AGL_Ref_ST_YBK1E_EN_Rev03
3.4 Pressure safety controls
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.
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
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.climate.emerson.com/en-gb/tools-resources.
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.
YB*K1E compressors used in R454C, R455A, R454A and R1234yf systems could be operated below
atmospheric pressure. In that case special requirements for safety and tightness apply and the
following precautions must be observed:
▪Check all the critical points on the system and 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 3.7 "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 only one of them is not complied with, the
compressors shall not be operated below atmospheric pressure.

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3.6 Crankcase heater
WARNING
Ignition source in a potentially flammable atmosphere! Fire hazard! The
crankcase heater, as specified by Emerson (see spare parts catalogue), is not
an ignition source during normal operation in A2L systems but could become
one if 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 9. This requirement is independent from system type and
configuration.
Compressor model
Refrigerant
charge limit
(kg)
Crankcase heater
Position
Height
(mm)
YB12K1E to YB17K1E
1.4
10 - 40
YB21K1E
1.5
YB24K1E & YB45K1E
1.6
Table 9: Refrigerant charge limits & crankcase heater position
The initial start-up in the field is a very critical moment 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 Copeland spare parts & accessories catalogue available at
www.climate.emerson.com/en-gb/tools-resources to select the correct crankcase heater model.
Caution: Crankcase heaters must be properly grounded!
For installation, the manufacturer/installer shall follow the recommendations mentioned below.
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. 6).
▪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. 7 & 8).
▪Avoid having the assembly heater inclined (Fig. 9).
▪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.
▪The presence of the heater shall be made evident by the posting of caution signs or markings at
appropriate locations.

12 AGL_Ref_ST_YBK1E_EN_Rev03
Figure 6 Figure 7 Figure 8 Figure 9
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 Discharge gas temperature protection
CAUTION
Inadequate lubrication! Scroll set damage! All YB*K1E 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 brand compressors.
The maximum discharge gas temperature is 130 °C for all YB*K1E compressors.
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 line thermostat has the
function of a compressor protection device; it is not designed to control the operating
envelope. For compressor envelope control, an additional control device or regulation must
be used.
3.7.1 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.

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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 thermostat with clamp
Technical data of the discharge line thermostat
Compressor
YB*K1E
Voltage
120-240 V AC
Maximum amperage
5 A / 240 V
Operating temperatures
Open
129 °C (± 4 K)
Close
101 °C (± 8 K)
Wire insulation maximum temperature
150 °C
Clips for tube
ø 12.7 mm (1/2")
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 discharge line thermostat on the
discharge tube 120 mm from top cap.
▪Snap the retainer clip over the tube and onto
the thermostat.
▪The thermostat should be placed on the
discharge tube so that its body is in upward
position on a horizontal tube installation.
▪Ensure that the thermostat is not tilted.
▪The wire must not be in contact with the top
cap of the compressor or the discharge tube.
Care should be taken to route wires so that
they do not come into contact with sharp
objects.
▪To avoid any impact on tripping temperature
by the ambient, the discharge line thermostat
must be insulated.
▪Wrap thermal insulation around the pipe left
and right of the thermostat and secure it with
plastic straps.
▪Wrap a second layer of insulation around the
first one and around the thermostat and
secure it with plastic straps.

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3.8 Internal pressure relief valve
There is an internal pressure relief valve on YB*K1E compressors. It opens at a differential pressure
of 28 bar ± 3 bar between high- and low-pressure sides. A high-pressure protection must be provided
by the system manufacturer/installer for each system and according to EN 378-2, clause 6.2.6.2. The
IPR valve is a safety device, not an HP switch. It is not designed for repeated operation and there is
no guarantee that it will reset correctly if it does have repeated operation.
3.9 Discharge check valve
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
compressor after shutdown.
NOTE: This check valve cannot be used with recycling pumpdown because it is not entirely
leak-proof.
3.10 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.
3.11 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 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 cm to maximum 45 cm from the compressor 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.
3.12 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).
Please see Copeland spare parts & accessories catalogue at www.climate.emerson.com/en-
gb/tools-resources to check the available sound shell kits according to compressor model.
3.13 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 A2L
applications, particular attention shall be paid to its non-electrostatic properties, as it could be a
potential ignition source.

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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 cracks which could lead to refrigerant leakage.
This situation must be avoided by the system manufacturer/installer. To this end, the pipework must
be carefully designed when connecting a scroll compressor to a system.
A scroll compressor makes both a rocking and twisting
motion and enough flexibility must be provided in the
pipework to allow starting, stopping and steady state running
of the compressor without transmitting excessive stress into
any line attached to the unit. In a split system, the most
important goal is to 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 rotational motion that can transmit a transient noise
along the lines. This may be particularly pronounced in
compressors using a three-phase motor due to their
inherently higher starting torque. This phenomenon, like the one described previously, can easily be
avoided by using standard line isolation techniques.
The sound level of a system is the result of design, quality and application. Scroll compressors sound
power levels generally increase with the compressor model capacity and the condition pressure ratio.
3.15 Compressor oil return, oil balancing, refrigerant floodback and oil dilution tests
CAUTION
Inadequate lubrication! Bearing and moving parts destruction! Ensure
adequate oil return from the system into the compressor at any time. No liquid
refrigerant return to the compressor. Liquid refrigerant dilutes the oil, could
wash the oil off the bearings and moving parts and could lead to overheating
and compressor failure.
The system piping must be 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 refrigerant properties, pressure level, mass flow, and density.
Once a new system design is set and assembled, a functional test is required. The functional test
includes a qualification for the general system oil return, a refrigerant floodback test and an oil dilution
test. Systems with multiple compressors (two, three, or more) require additional oil balancing
qualification between the parallel compressors.
A sample compressor equipped with an external oil sight tube can be ordered from Emerson for lab
testing.
Records of the evaporating temperature and the bottom shell temperature shall be taken with a high
sampling rate during the entire oil return or oil balance testing and under all tested conditions. The
liquid level in the sight tube has to be observed and recorded too. Testing conditions shall include
defrost and varying loads. If the system is reversible, the tests should be conducted in both operation
modes.
System engineers should review the system design and operation to identify the critical conditions
and to check oil return, oil balancing, liquid floodback and oil dilution. For discussion of 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 minimum mass
flow and minimum density of suction gas in continuous and frequent start/stop cycling.
Figure 11: Example of suction tube design