Emerson YHV0182P, YHV0382P User manual
Application Guidelines
Copeland Scroll
™
Variable Speed Compressors
YHV0182P* to YHV0382P*
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About these guidelines ................................................................................................ 1
1 Safety instructions ............................................................................................ 1
1.1 Icon explanation ................................................................................................................. 1
1.2 Safety statements .............................................................................................................. 2
1.3 General instructions ........................................................................................................... 2
2 Product description .......................................................................................... 3
2.1 General information about Copeland Scroll™ compressors ............................................. 3
2.2 Variable speed advantages ............................................................................................... 4
2.3 Compressor and drive nomenclature ................................................................................. 5
2.4 Application considerations ................................................................................................. 5
2.4.1 Qualified refrigerant and oil .................................................................................... 5
2.4.2 Admissible temperature and relative humidity ranges ........................................... 6
2.4.3 Application limits & operating envelopes ................................................................ 6
2.4.4 Discharge line temperature control mode ............................................................ 10
2.4.5 Design features .................................................................................................... 10
2.4.6 Oil recovery .......................................................................................................... 10
2.5 Dimensions ...................................................................................................................... 11
3 Installation ....................................................................................................... 12
3.1 Compressor and drive handling ....................................................................................... 12
3.1.1 Compressor transport and storage ...................................................................... 12
3.1.2 Compressor positioning and securing .................................................................. 12
3.1.3 Installation location ............................................................................................... 12
3.1.4 Compressor mounting parts ................................................................................. 13
3.2 Compressor brazing procedure ....................................................................................... 13
3.3 Suction line accumulators ................................................................................................ 14
3.4 Filter screens ................................................................................................................... 15
3.5 Mufflers ............................................................................................................................ 15
3.6 Sound shell ...................................................................................................................... 15
3.7 Insulation material ............................................................................................................ 15
3.8 Reversing valves .............................................................................................................. 15
3.9 Sound and vibration ......................................................................................................... 16
4 Electrical connection ...................................................................................... 17
4.1 General recommendations............................................................................................... 17
4.2 Electrical installation ........................................................................................................ 17
4.3 Wiring diagrams ............................................................................................................... 19
4.3.1 Motor windings ..................................................................................................... 21
4.3.2 Protection devices ................................................................................................ 21
4.3.3 Crankcase heating function .................................................................................. 21
4.4 Pressure protection devices ............................................................................................ 21
4.4.1 High-pressure protection ...................................................................................... 21
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4.4.2 Low-pressure protection ....................................................................................... 22
4.5 Discharge gas temperature protection ............................................................................. 22
4.6 High-potential testing ....................................................................................................... 23
5 Start-up & operation ........................................................................................ 24
5.1 Strength pressure test ...................................................................................................... 24
5.1.1 Compressor strength-pressure test ...................................................................... 24
5.1.2 System strength-pressure test ............................................................................. 24
5.2 Compressor tightness test ............................................................................................... 24
5.3 Preliminary checks – Pre-starting .................................................................................... 25
5.4 Charging procedure ......................................................................................................... 25
5.5 Run-in time ....................................................................................................................... 25
5.6 Initial start-up ................................................................................................................... 26
5.7 Start-and-stop routine ...................................................................................................... 26
5.8 Starting sound .................................................................................................................. 26
5.9 Deep vacuum operation ................................................................................................... 26
5.10 Shell temperature ............................................................................................................. 26
5.11 Pump-down cycle ............................................................................................................. 26
5.12 Refrigerant floodback and oil dilution ............................................................................... 27
5.13 Minimum run time ............................................................................................................ 27
5.14 Oil level ............................................................................................................................ 28
6 Maintenance & repair ...................................................................................... 29
6.1 Qualification of workers .................................................................................................... 29
6.2 Preparation and working procedure ................................................................................. 30
6.3 Disassembling system components ................................................................................ 30
6.4 Provisions of legislation and leak check requirements .................................................... 30
6.5 Exchanging the refrigerant ............................................................................................... 31
6.6 Replacing a compressor .................................................................................................. 31
6.6.1 Compressor replacement ..................................................................................... 31
6.6.2 Start-up of a new or replacement compressor ..................................................... 31
6.6.3 Compressor return procedure .............................................................................. 32
6.7 Lubrication and oil removal .............................................................................................. 32
6.8 Oil additives ..................................................................................................................... 33
7 Troubleshooting .............................................................................................. 34
8 Dismantling & disposal ................................................................................... 37
9 Reference list of related technical information ............................................. 37
DISCLAIMER ............................................................................................................... 37
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About these guidelines
The purpose of these guidelines is to provide guidance in the application of Copeland Scroll™
compressors and Emerson motor control drives 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 and motor control drives. The performance and reliability of the
product may be impacted if the product is not used according to these guidelines or 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 and Emerson motor control drives are manufactured according to the
latest relevant European safety standards. Particular emphasis has been placed on the user’s safety.
The YHV*2P compressors and drives are intended for installation in systems in accordance with the
European Machinery directive MD 2006/42/EC, the Pressure Equipment Directive PED 2014/68/EU,
the Low Voltage Directive LVD 2014/35/EU and the Electromagnetic Compatibility Directive
EMC 2014/30/EU. 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. For relevant standards
please refer to the Manufacturer’s Declaration, available at www.climate.emerson.com/en-gb.
NOTE: Emerson marks all A2L scroll compressors with a sticker for flammable refrigerants.
Systems using such refrigerants must comply with applicable legislation and regulations
such as but not limited to EN378. It remains the user’s responsibility to select products
compliant with legislation and regulations applicable for its application.
The Material Safety Datasheet (MSDS) for individual A2L refrigerants shall be checked and
considered when working with such refrigerants. The MSDS is provided by the gas supplier.
These instructions shall be retained throughout the lifetime of the compressor and the drive.
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.
Danger of fire
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.
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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 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, EN 60335-2-40 and EN 60335-2-89. The system designer shall implement all
safety measures defined by the applicable standards and not exceed the maximum
refrigerant charge.
▪ 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.
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
get in touch 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 POE! Material damage! POE lubricant must be handled
carefully and the proper protective equipment (gloves, eye protection, etc.)
must be used at all times. POE 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 General information about Copeland Scroll™ compressors
The Scroll compressor has been under development at Emerson since 1979. It is the most efficient
and durable compressor Emerson has ever developed for air conditioning, refrigeration and heating
applications.
These application guidelines deal with the YHV*2P variable speed Copeland Scroll
compressors for use with R452B and R454B. These compressors have a speed range of 1200 to
7200 revolutions per minute, corresponding to 20 up to 120 Hz. They are intended for use either in
air-source or geothermal residential heat pump applications. They feature a three-phase brushless
permanent magnet (BPM) motor which is controlled by an Emerson ED3 motor control drive, referred
to as the "ED3 drive" or "drive" throughout these guidelines.
Compressor
Heating capacity for R452B/ R454B [kW]
2400 rpm
3000 rpm
4500 rpm
5400rpm
YHV0182P
3.3/ 3.2
4.2/ 4.1
6.4/ 6.2
7.7/ 7.5
YHV0252P
4.6/ 4.4
5.7/ 5.4
8.7/ 8.3
10.5/ 10.1
YHV0382P
6.8/ 6.6
8.6/ 8.3
13.1/ 12.8
15.8/ 15.4
Table 1: Heating capacity in kW at below conditions
Conditions:
Evaporating dew temperature ..... -7 °C Condensing dew temperature .. 50 °C
Suction gas superheat ................. 5 K Condenser sub-cooling ............. 5 K
Ambient temperature ................... 35 °C
NOTE: R452B and R454B are classified as A2L (mildly flammable) refrigerants.
NOTE: The drive ED3 is not covered in detail in this document, for more information on the
motor control drive please refer to the ED3 User Manual (June 2019 version).
Figure 1: ED3 drive and YHV*2P compressor
The YHV*2P compressors with protection code "E" are sold as matched pairs with the ED3 drive,
designed in accordance with EN 60335-1, as listed in Table 2. The motor protection is implemented
in the ED3 drive.
The matched pairs have been designed for maximum efficiency and reliability. The drive will power
the compressor, control the compressor running speed, provide compressor and drive protection and
communicate with the master controller in ModBus RTU protocol. The drive requires cooling and is
typically installed in the unit near the compressor. To optimize drive efficiency and to limit
electromagnetic interferences, external chokes must be connected to the single-phase and threephase drives.
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Compressor
Drive
Drive power
supply
Package code
ED3 Modbus [318]
# OneEmerson [205]
YHV0252P-9E9
ED3018B/BU
3~/ 400V/ 50Hz
6
YHV0252P-9E9
ED3015A/AU
1~/ 230V/ 50Hz
10
YHV0182P-9E9
ED3015A/AU
1~/ 230V/ 50Hz
11
YHV0252P-9E9
ED3020A/AU
1~/ 230V/ 50Hz
12
YHV0182P-9E9
ED3013B/BU
3~/ 400V/ 50Hz
17
YHV0382P-9E9
ED3020A/AU
1~/ 230V/ 50Hz
22
YHV0382P-4E9
ED3022B
3~/ 400V/ 50Hz
28
Table 2: Matched pairs ED3 with YHV*2P
The YHV*2P compressors with protection code "X" (see chapter 2.3) listed in Table 3 are sold as
unprotected compressors. They are dedicated for use with a third-party drive. The motor protection
is under the responsibility of the system manufacturer/installer.
Compressor
YHV0182P-9X9
YHV0252P-9X9
YHV0382P-4X9
YHV0382P-9X9
Table 3: Unprotected YHV*2P compressors
A third-party control system must include discharge temperature
protection, current overload
protection, and a soft
start and stopping routine. Stator heat control is also recommended for optimal
performance and reliability. It should also include the operating map parameters. Contact the
Application Engineering department at Emerson for compressor motor
specifications and speed
adjustment requirements.
It is important to ensure correct wiring at both the
compressor and drive connections prior to
starting the compressor to avoid miswiring or powered reverse situation. Both situations could
potentially cause compressor damage.
NOTE: For the latest list of matched pairs ED3 with YHV*2P please refer to the ED3 User
Manual (June 2019 version) or contact the Application Engineering department at Emerson.
2.2 Variable speed advantages
The variable speed scroll is a key component in the variable capacity system. A variable capacity
system will use less electrical energy by minimizing on-off cyclical losses, maximizing heat
exchanger efficiency by operating at part load during a majority of the total operating hours, and by
operating with reduced airflow rates and blower power.
The variable speed scroll and drive are suitable for a variety of "best-in-class" applications. Both may
be used in other types of applications provided that the envelope and other operating restrictions are
met. The primary benefit of this product is to substantially reduce electrical energy consumption and
associated expenses.
Additionally, a variable speed scroll offers the capability of controlling space and domestic hot water
temperature to ranges exceeding simple on-off control, improving overall comfort levels inside the
building. The onboard electronics embedded in the drive greatly reduce the possibility of operation
outside the designed parameters which in turn increases overall system reliability.
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Figure 2: Variable speed solution to follow the building heat demand
2.3 Compressor and drive nomenclature
The compressor and drive model designation contains the following technical information:
Figure 3: Compressor nomenclature
2.4 Application considerations
2.4.1 Qualified refrigerant and oil
Oil recharge values can be taken from Copeland Scroll compressors brochures or Copeland™ brand
products Select software available at www.climate.emerson.com/en-gb.
Compressors
YHV0182P, YHV0252P, YHV0382P
Qualified refrigerant
R452B and R454B
Copeland brand
products standard oil
Emkarate RL 32 3MAF
Table 4: Qualified refrigerant and oil
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2.4.2 Admissible temperature and relative humidity ranges
The Scroll compressor must comply with the ambient temperature and humidity ranges specified in
Table 5 below, both for storage and in operation.
Compressor
model
Min / max relative humidity
Min / max ambient temperatures
in storage or at standstill
in operation
YHV*2P
30 / 95%
No condensing
-35 °C / 50 °C
-35 °C / 60 °C
Table 5: Acceptable ambient temperature and humidity ranges for the compressor
Compressor
PS
High-pressure side
PS
Low-pressure side
TS
Low-Pressure side
PED
category
YHV*2P
49 bar(g)
28 bar(g)
-35 °C
2
Table 6: Maximum allowable pressure
2.4.3 Application limits & operating envelopes
CAUTION
Inadequate lubrication! Compressor breakdown! Copeland Scroll
compressors are qualified for operation inside the envelope published by
Emerson. The envelope is defined according to Emerson’s testing and
experience. Operating a compressor outside the envelope might lead to
compressor failure which would be the heat pump manufacturer’s
responsibility. 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. In the same way, the superheat at the compressor
suction must always stay below a maximum limit specified by Emerson,
depending on the model and for which the operating envelope is defined.
YHV*2P compressors operating envelopes depend on the running speed. The envelope limitations
are mainly related to lubrication and power limitation.
The lower right boundary of the operating envelope is the minimum compression ratio required to keep
the scrolls loaded. Operation below this boundary could
result in the compressor intermittently
loading and unloading and noisy operation.
The upper left boundary of the envelope represents the maximum compression ratio. If the operating
condition approaches this boundary the compressor discharge temperature will begin to
approach
the maximum scroll temperature allowed
by the discharge line temperature sensor – see details in
chapter 4.5 "Discharge gas temperature protection". The temperature sensor must signal the drive or
system unit controller to shut down if the discharge line temperature exceeds the specified temperature
on the operating envelope.
For DLT-control mode with YHV*2P compressors in the upper left boundary of the envelope, please
also refer to chapter 2.4.4 "Discharge line temperature control mode".
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Figure 4: Application envelope for YHV0182P-9E9 using R452B and R454B
Figure 5: Application envelope for YHV0252P-9E9 using R452B and R454B
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Legend
YHV0382P-4X9 No drive limitation
(rpm)
YHV0382P-4X9 + ED3018B
(rpm)
1200
1200 1800
1800
2400-5400
2400-4500
2400-7200
Linear interpolation
Linear interpolation
2400-5400
Linear interpolation
2400-7200
Figure 6: Application envelope and legend for YHV0382P-4E9 using R452B and R454B
Legend
YHV0382P-9X9 No drive limitation
(rpm)
YHV0382P-9X9 + ED3020A
(rpm)
1200-5400
1200-3600
1800-5400
1800-3600
2400-5400
2400-3600
2400-7200
2400-4500
Not shown
2400-7200
Figure 7: Application envelope and legend for YHV0382P-9X9 using R452B and R454B
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NOTE: For matched pairs with smaller drives, please check the application envelopes in
Copeland™ brand products Select software at www.climate.emerson.com/en-gb.
Please note the following about operating envelopes:
▪ Before compressor start with the matched pair of YHV*2P and ED3, the pressure difference in
the system has to be below 10 bar. If the pressure difference is reduced by opening the
expansion valve, care must be taken to avoid liquid flood back to the compressor – also see
chapter 3.3 "Accumulators" and Figure 16.
▪ An oil return test for the system must be performed. If required, the system design should be
improved to ensure sufficient oil return from the system to the compressor – also see chapter
5.14 "Oil level".
▪ At start-up the system should be able to bring the compressor to a point inside the envelope as
fast as possible and to keep the compressor running there. Running outside the envelope is not
allowed. Emerson’s recommendation is to start with a speed of 3000 rpm and to freeze the
speed for minimum 30 seconds or longer until the system is in stable operation – see Figure 8
"Ramp up".
▪ Running/oscillating the compressor in and out of the envelope borders is not allowed and should
be avoided.
▪ Running the compressor below the envelope at low condensing temperatures is possible for no
longer than 30 minutes but the user must be aware that unloading noise from the compressor
can occur. In this area the speed limits according to the evaporating temperatures in the
envelope should be respected.
▪ The qualified application envelopes will change with the compressor speed. At all operating
conditions the minimum and maximum speed limits according to Figures 4 to 7 have to be
respected. With changing operating conditions the speed limits have to be determined by linear
interpolation between the limits given in Figures 4 to 7 – also see speed limits animation in
Select software available at www.climate.emerson.com/en-gb.
▪ Fast speed changes can cause instable control, eg, on the superheat control. Per Emerson
experience speed changes should be in the range of 10 to 60 rpm/s depending on the system
reaction.
▪ The user should adequately take care of controlling the envelope.
▪ To stop the compressor, reduce the speed to 3000 rpm then stop the compressor – see Figure 8
"Controlled shutdown".
Figure 8: Ramp-up and controlled shutdown
NOTE: Before first start, each drive has to be configured according to the compressor model.
NOTE: The ED3 drive overload protection aims at protecting the drive and the compressor. It
cannot be used in the system as an operating envelope limitation. For more details on the
overload protection refer to the ED3 User Manual (June 2019 version).
rpm
0
3000
Speed control
Controlled
shutdown
rpm
0
3000
Ramp up
Speed control
720
Min 30s
Hold
ED3
System Controller
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2.4.4 Discharge line temperature control mode
In the lower part of the envelope (Control Suction Superheat) shown below the suction gas at the
compressor inlet has to be superheated without liquid droplets. For superheat requirements please
also refer to chapter 2.4.3 "Application limits & operating envelopes".
Figure 9: Schematics of expansion valve control mode
In the upper part of the envelope (DLT Control) with operation at low evaporating and high
condensing with superheat control mode, the discharge temperature will exceed the limit of 125 °C
inside the application envelope – also see chapter 3.3 "Suction line accumulators". In this area, the
expansion valve of the evaporator is to be controlled not by superheat but by the discharge line
temperature so that some liquid droplets return to the compressor to cool it down. The discharge line
temperature DLT must be controlled to stay between minimum 115 °C and maximum 125 °C.
The move from superheat control to DLT control is demand-driven by the discharge line temperature.
In the transition phase DLT control and superheat control have to be balanced by the system
controller. The superheat at compressor inlet should be reduced gradually to 0 K. As the demand to
move to DLT control depends, eg, on system design such as compressor insulation and ambient
temperature, there is no specified line at which this will happen.
2.4.5 Design features
The variable speed scroll YHV*2P has a number of design features that improve efficiency and
reliability.
All the YVH* models are equipped with a positive displacement oil pump to ensure an adequate
supply of oil to the bearing system throughout the operating speed range.
The motor in the variable speed scroll is a three-phase, brushless permanent magnet (BPM) design
coupled with a rotor embedded with high energy magnets. The input voltage is a series of +DC pulses,
spaced in time to create an alternating current frequency.
2.4.6 Oil recovery
For oil return the exact parameters for an oil recovery cycle need to be evaluated for each system by
oil return tests, as they may differ depending on system application. Please contact
and review with
Application Engineering at Emerson for any
desired changes to this oil recovery cycle requirements.
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