` AE4-1494 November 2023

20-40 Ton YA*K1 and YP*K1 Copeland™ Scroll Compressors

TABLE OF CONTENTS
IMPORTANT SAFETY INFORMATION................. 2
Responsibilities, Qualifications and Training....... 2
Terminal Venting and Other Pressurized System
APPLICATION TESTS............................................. 10
Hazards ....................................................... 2
Flammable Ref rigerant Hazards ....................... 3 ASSEMBLY LINE PROCEDURES...................... 10
Electrical Hazards .......................................... 3 Installing the Compressor .................................. 10
Hot Surf ace and Fire Hazards .......................... 3 Mounting ......................................................... 11
Lif ting Hazards .............................................. 3 Suction and Discharge Fittings ........................... 11
POE Oil Hazards ........................................... 3 Assembly Line Brazing Procedure....................... 11
Precautions................................................... 3 Unbrazing System Components .......................... 11
Signal Word Definitions................................... 4 Removing Compressors .................................... 11
Pressure Testing .............................................. 11
INTRODUCTION................................................ 5
Assembly Line System Charging Procedure ......... 11
Nomenclature................................................ 5
'Hipot' (AC High Potential) Motor Testing .............. 12
Operating Envelopes ...................................... 5
Final Run Test.................................................. 12
High Pressure Control .................................... 5
Low Pressure Control ..................................... 5 SERVICE PROCEDURES ........................................ 12
Discharge Temperature Protection ................... 5 Field Replacement ............................................ 12
Shut Down Device ......................................... 6 Removing Oil ................................................... 12
Discharge Check Valve................................... 6 Electrical ......................................................... 12
Compressor Cycling ....................................... 6 Compressor Replacement After a Motor Burn ....... 12
Long Pipe Lengths / High Refrigerant Charge..... 6 Manifolded Compressor Replacement ................. 13
Suction and Discharge Fittings......................... 6 Start-Up of a New or Replacement Compressor .... 13
System Tubing Stress..................................... 7 Ref rigerant Retrofits .......................................... 13
Accumulators ................................................ 7
Off -Cycle Migration Control ............................ 7 Figures & Tables
Crankcase Heaters ........................................ 7 Figure 1 - Scroll Tube Fitting Brazing.......................... 14
Pump Down Cycle ......................................... 7
Figure 2 - YA YP Scroll Nomenclature ........................ 15
Pump Out Cycle ............................................ 7
Reversing Valves ........................................... 7 Figure 3 - Crankcase Heater Location......................... 15
Contaminant Control ...................................... 8 Figure 4 - Operating Envelope YA219K1 – YA275K1 .... 16
Oil Type ....................................................... 8 Figure 5 - Operating Envelope YA360K1, YA460K1...... 16
Power Factor Correction ................................. 8
Figure 6 - Operating Envelope YA233K1 – YA293K1 .... 17
Soft Starters .................................................. 8
Manifolded Compressors ................................ 9 Figure 7 -Operating Envelope YP385K1 – YP485K1..... 17
Figure 8 – Oil Dilution Chart ...................................... 18
VARIABLE SPEED OPERATION......................... 9
Introduction ..................................................... 9 Figure 9 – Variable Speed Output Frequency .............. 18
Operating Envelope………………………………..9
Drive Selection………………………………………9 Table 1 - Torque Values ........................................... 19
Electrical Requirements……………………………9
Starting and Ramp up………………………………9
Stopping…………………………………………...…..9
Vibration………………………………….……………9
OilRecoveryCycle…………………………………….9

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IMPORTANT SAFETY INFORMATION

Those involved in the design, manuf acture, and installation of a system, system purchasers, and service personnel may
need to be aware of hazards and precautions discussed in this section and throughout this document. OEMs integrating
the compressor into a system should ensure that their own employees follow this bulletin and provide any necessary safety
inf ormation to those involved in manuf acturing, installing, purchasing, and servicing the system.

Responsibilities, Qualifications and Training

• OEMs are responsible f or system design, selection of appropriate components, integration of this component into the
system, and testing the system. OEMs must ensure that staff involved in these activities are competent and qualif ied.
• OEMs are also responsible for ensuring that all product, service, and cautionary labels remain visible or are appropriately
added in a conspicuous location on the system to ensure they are clear to any personnel involved in the installation,
commissioning, troubleshooting or maintenance of this equipment.
• Only qualif ied and authorized HVAC or ref rigeration personnel are permitted to install, commission, troubleshoot and
maintain this equipment. Electrical connections must be made by qualif ied electrical personnel.
• Observe all applicable standards and codes f or installing, servicing, and maintaining electrical and ref rigeration
equipment.

Terminal Venting and Other Pressurized System Hazards

If a compressor’s electrical terminal pin loses its seal, pressurized oil, ref rigerant, and debris may spray
out. This is called “terminal venting”.
The ejected debris, oil, and refrigerant can injure people or damage property. The oil and refrigerant spray
can be ignited by electrical arcing at the terminal or any nearby ignition source, producing f lames that may p roject a
significant distance f rom the compressor. The distance depends on the pressure and the amount of refrigerant and oil
mixture in the system. The f lames can cause serious or f atal burns and ignite nearby materials.
Each compressor has a terminal cover or molded plug that covers electrical connections. The cover or plug helps to protect
against electric shock and the risks of terminal venting. If terminal venting occurs, the cover or plug helps contain the spray
of refrigerant and oil and reduces the risk of ignition. If ignition occurs, the plug or cover helps contain the flames. However,
neither the terminal cover nor the molded plug can completely eliminate the risk of venting, ignition, or electric shock.

See https://www.copeland.com/en-us/training-support/safety-resource-center/terminal-venting f or more details about

terminal venting.

Additionally, a compressor’s ref rigerant lines keep ref rigerant and oil under pressure. When removing or recharging
ref rigerant f rom this component during service, this can pose a pressurized f luid hazard.

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Flammable Refrigerant Hazards

If f lammable refrigerant is released from a system, an explosive concentration can be present in the air near the
system. If there is an ignition source nearby, a release of flammable refrigerant can result in a fire or explosion.
While systems using f lammable ref rigerant are designed to mitigate the risk of ignition if the ref rigerant is
released, f ire and explosion can still occur.
See https://www.copeland.com/en-us/training-support/safety-resource-center/flammable-refrigerants f or more inf ormation
on f lammable ref rigerant saf ety.

Electrical Hazards
Until a system is de-energized, and capacitors have been discharged, the system presents a risk of electric
shock.

Hot Surface and Fire Hazards

While the system is energized, and for some time after it is deenergized, the compressor may be hot. Touching
the compressor bef ore it has cooled can result in severe burns. When brazing system components during
service, the f lames can cause severe burns and ignite nearby combustible materials.

Lifting Hazards

Certain system components may be very heavy. Improperly lifting system components or the compressor can

result in serious personal injury. Use proper lif ting techniques when moving.

POE Oil Hazards

This equipment contains polyolester (POE) oils. Certain polymers (e.g., PVC/CPVC and polycarbonate) can be harmed if
they come into contact with POE oils. If POE oil contacts bare skin, it may cause an allergic skin reaction.

Precautions
• Always wear personal protective equipment (gloves, eye protection, etc.).

• Keep a f ire extinguisher at the jobsite at all times.

• Keep clear of the compressor when power is applied.

- IMMEDIATELY GET AWAY if you hear unusual sounds in the compressor. They can indicate that terminal pin
ejection may be imminent. This may sound like electrical arcing (sizzling, sputtering or popping). However, terminal
venting may still occur even if you do not hear any unusual sounds.
• Never reset a breaker or replace a blown f use without perf orming appropriate electrical testing
- A tripped breaker or blown fuse may indicate an electrical fault in the compressor. Energizing a compressor with an
electrical f ault can cause terminal venting. Perf orm checks to rule out an electrical f ault.

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• Disconnect power and use lock-out/tag-out procedures bef ore servicing.

- Bef ore removing the terminal cover or molded plug, check that ALL electrical power is disconnected from the unit.
Make sure that all power legs are open. (Note: The system may have more than one power supply .)
- Discharge capacitors f or a minimum of two minutes
- Always use control of hazardous energy (lock-out/tag-out) procedures to ensure that power is not reconnected while
the unit is being serviced.

• Allow time f or the compressor to cool bef ore servicing.

- Ensure that materials and wiring do not touch high temperature areas of the compressor.

• Keep all non-essential personnel away f rom the compressor during service.

• Remove ref rigerant from both the high and low side of the compressor. Use a recovery machine and cylinder designed
f or f lammable ref rigerants. Do not use standard recovery machines because they contain sources of ignition such as
switches, high and low pressure controls, and relays. Only vent the ref rigerant into the atmosphere if the system is in a
well-ventilated area.

• Never us a torch to remove the compressor. Only tubing cutters should be used.

• Use an appropriate lif ting device to install or remove the compressor.

• Never install a system and leave it unattended when it has no charge, a holding charge, or with the service valves closed
without electrically locking out the system.

• Always wear appropriate saf ety glasses and gloves when brazing or unbrazing system components.

• Charge the system with only approved ref rigerants and ref rigeration oils.

• Keep POE oils away from certain polymers (e.g., PVC/CPVC and polycarbonate) and any other surface or material that
might be harmed by POE oils. Proper protective equipment (gloves, eye protection, etc.) must be used when handling
POE lubricant. Handle POE oil with care. Ref er to the Saf ety Data Sheet (SDS) f or f urther details.
• Bef ore energizing the system:
1. Securely f asten the protective terminal cover or molded p lug to the compressor, and
2. Check that the compressor is properly grounded per the applicable system and compressor requirements.

Signal Word Definitions

The signal word explained below are used throughout the document to indicate saf ety messages.

DANGER indicates a hazardous situation which, if not avoided, will result in death or
DANGER serious injury.

WARNING indicates a hazardous situation which, if not avoided, could result in death or
WARNING serious injury.

CAUTION, used with the saf ety alert symbol, indicates a hazardous situation which, if not
CAUTION avoided, could result in minor or moderate injury

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High Pressure Control

WARNING
INTRODUCTION
A high pressure cut-out control must be used in all
The 20-to-40-ton YA*K1 and YP*K1 Copeland™ scroll applications.
compressors are designed for a variety of commercial The 20-to-40-ton Copeland scroll compressors do not
air conditioning and chiller applications. These have internal pressure relief valves. The system
compressors are intended only for refrigeration and air designer should determine the required high pressure
conditioning use and should not be used in any other value cutout f or the desired system and application.
applications. This bulletin describes the operating The high pressure control should have a manual reset
characteristics, design f eatures, and application f eature f or the highest level of system protection.
requirements f or these models.
If any type of discharge line shut-off valve is used, the
The YA*K1 scroll compressors are qualif ied with the high pressure control must be installed between the
R454B ref rigerant. compressor discharge f itting and the valve.
Compressors with rotalock discharge f ittings have a
The YP*K1 compressors are qualif ied with the R32 connection on the rotalock fitting for the high pressure
ref rigerant. cut-out switch connection.

For compressor accessories and service parts, please Compressors requiring certification to the Pressure
ref er to Copeland Mobile. Equipment Directive (PED):
The nameplate will be marked with a TS min which is
Ref erence the AE4-1430 Compressor Multiples bulletin def ined as the minimum allowable temperature. The
f or multiple compressor applications. For additional nameplate will also be marked with a TS max which is
bulletins and compressor information, please refer to def ined as the maximum allowable temperature (max
Copeland Mobile. design temperature, highest temp that can occur during
operation or standstill of the ref rigeration system or
during test under test conditions, specified by the
Nomenclature manuf acturer). Ref er to Copeland Mobile f or PED
specif ic inf ormation.
The model numbers of the Copeland scroll
compressors include the approximate nominal cooling Low Pressure Control
capacity operating at 60 Hz at standard operating
conditions. An example would be the YA460K1E-TED, A low pressure control is highly recommended for loss
which has 460,000 Btu/hr (134.8kWh) cooling capacity of charge protection and other system f ault conditions
at the AHRI high temperature air conditioning rating that may result in very low evaporating temperatures.
point. Note that the same compressor will have Loss of system charge will result in overheating and
approximately 5/6 of this capacity or 383,333 Btu/hr recycling of the motor overload protector. Prolonged
(112.3kWh) when operated at 50 Hz. See Figure 2 for operation in this manner could result in oil pump out and
more inf ormation regarding nomenclature. eventual bearing f ailure. The low pressure cut-out
setting will depend on the application type and
minimum expected evaporating temperature. The low
Operating Envelopes
pressure cut-out should be selected based on the
Figures 4 thru 7 illustrate the operating envelopes for specific application and expected operating conditions.
the YA*K1 and YP*K1 compressors with the respective A cut out setting no lower than 20 psig (1.4 bar) is
ref rigerant. The steady-state operating condition of the recommended.
compressor must remain inside the prescribed
operating envelope. Excursions outside of the envelope WARNING
should be brief and infrequent. Use of ref rigerants other
Compressor top cap temperatures can be very hot.
than the qualif ied ref rigerant voids the compressor UL Care must be taken to ensure that wiring or other
recognition and may increase the risk of malfunction materials which could be damaged by these
and serious injury or death. temperatures do not come into contact with these
potentially hot areas.
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Discharge Temperature Protection low ambient condenser f looding, or systems with

multiple heat exchangers are among some system
High discharge temperature protection is provided by a conf igurations that may require additional lubricant.
thermistor probe in the discharge plenum of the scroll. If the compressors have a sight glass f or oil level
The compressors use a negative temperature viewing, the oil level should always be checked during
coefficient (NTC) thermistor. The module M1-M2 OEM assembly, f ield commissioning, and f ield
contacts are opened if the internal discharge servicing. An estimation of the amount of additional
temperature exceeds saf e limits. Discharge lubricant to add to the compressor(s) when the circuit
temperature data are stored in the CoreSense module charge exceeds 20 pounds of refrigerant is as follows:
and can be made available to a system controller.
Single compressor application: 0.5 fluid ounce of oil per
Shut Down Device pound of ref rigerant.
All scrolls in this size range have f loating valve
technology to mitigate shut down noise. Since For multiple compressor applications, ref er to AE4-
Copeland scroll compressors are also excellent gas 1430 f or additional oil estimate for tandems and trios.
expanders, they may run backwards f or a brief period
af ter shutdown as the internal pressures equalize. The oil level must be carefully monitored during system
development, and corrective action should be taken if
Discharge Check Valve the compressor oil level f alls more than 2.4" (60 mm)
below the center of the sight-glass f or the YA219,
The compressors f eature a spring assist, disk-type YA275, YP233 and YP293 compressors. Corrective
check valve in the discharge f itting of the compressor action should be taken if the compressor oil level falls
to prevents the high pressure gas in the condenser from more than 2.0" (50 mm) below the center of the sight-
rapidly f lowing back through the compressor af ter glass f or the YA360, YA460, YP385 and YP485
shutdown. The check valve is not leak-proof. compressors. The compressor oil level should be
Perf ormance of the check valves f or pump down checked with the compressor "off" to avoid the sump
applications hasn't been evaluated at all pressure turbulence when the compressor is running.
dif ferentials. Low pressure dif ferentials may result in
unacceptable leak-back rates. An external discharge These compressors are available to the OEM with a
check valve should be considered in some applications. production sight-glass that can be used to determine
the oil level in the compressor in the end -use
Compressor Cycling application. These compressors are also available to
There is no set answer to how often scroll compressors the OEM with an oil Schrader f itting on the side of the
can be started and stopped in an hour, since it is highly compressor to add additional oil if needed because of
dependent on system conf iguration. There is no long lengths of piping or high ref rigerant charge. No
minimum off time because Copeland scroll attempt should be made to increase the oil level in the
compressors start unloaded, even if the system has sight-glass above the 3/4 f ull level. To accurately
unbalanced pressures. The most critical consideration determine the oil level, a sample compressor with a
is the minimum run time required to return oil to the sight tube may be ordered to perform oil balance and
compressor af ter startup. To establish the minimum run return testing. A sample compressor with a sight tube
time, obtain a sample compressor equipped with a sight must not be used in the f ield. A high oil level is not
tube (available from Copeland) and install it in a system sustainable in the compressor and the extra oil will be
with the longest connecting lines and highest internal pumped out into the system causing a reduction in
volume that the system may have. The minimum on system ef ficiency and a higher-than-normal oil
time becomes the time required f or oil lost during circulation rate.
compressor startup to return to the compressor sump
and restore a minimal oil level that will assure oil pick Suction and Discharge Fittings
up through the crankshaft. Cycling the compressor for The compressors have copper plated steel suction and
a shorter period than this, for instance to maintain very discharge or threaded rotalock fittings. See Figure 1 for
tight temperature control, will result in progressive loss assembly line and f ield brazing recommendations and
of oil and damage to the compressor. Table 1 f or rotalock torque requirements.
Long Pipe Lengths / High Refrigerant Charge System Tubing Stress
Some systems may contain higher than normal System tubing should be designed to keep tubing
ref rigerant charges. Systems with large reheat coils,
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stresses under the endurance limit of the copper tubing complete contact with the compressor shell. It's
type used (i.e., Type K, L, etc.). Start, stop and running important that the clamp screw is torqued to the range
(resonance) cases should be evaluated to ensure long shown in Table 1 to ensure adequate contact and to
term reliability. prevent heater burnout. Never apply power to the
heater in f ree air or before the heater is installed on the
For variable speed applications, the suction and compressor to prevent overheating and burnout.
discharge tubing must be evaluated to determine the
resonant f requencies. Once the resonant frequencies WARNING
are known, they can be shif ted to a desired range by
changing the mass of the line f or constant speed Crankcase heaters must be properly grounded to
applications or they can be avoided f or variable speed reduce the potential of a fire or shock hazard.
applications. Application engineering is available to
recommend additional tests and to evaluate test Pump Down Cycle
results. If a pump down cycle is required by the system
designer, a onetime pump down at the end of the
Accumulators cooling cycle is preferred over a recycling pump down.
The use of accumulators is very dependent on the Although not preferred, a recycling pump down cycle
application. The Copeland scroll compressor’s inherent can be used to minimize off-cycle refrigerant migration
ability to handle liquid ref rigerant during occasional to the compressor. The risk of a short cycling condition
operating f lood back situations make the use of an that can lead to oil pump out, excessive contactor wear,
accumulator unnecessary in most applications. The unnecessary energy use, and excessive low pressure
OEM is responsible for determining if an accumulator is cut-out switch cycles make recycling pump down
needed and the selection of the accumulator. undesirable. In lieu of the pump down cycles mentioned
Consideration f or additional oil needed f or the above, simply closing a liquid line solenoid valve when
accumulator should be taken. the compressor cycles off is a good, simple, and cost
ef f ective method of minimizing of f-cycle ref rigerant
Off-Cycle Migration Control migration.
Excessive migration of ref rigerant to the compressor Pump Out Cycle
during the of f-cycle can result in oil pump-out on start
up, excessive starting noise and vibration, bearing A pump out cycle has been successfully used by some
erosion, and broken scrolls if the hydraulic slugging manuf acturers of large rooftop units. After an extended
pressure is high enough. For these reasons, of f -cycle of f period, a typical pump out cycle will energize the
ref rigerant migration must be minimized. The f ollowing compressor for up to one second followed by an off time
three sections summarize of f-cycle migration of 5 to 20 seconds. This cycle is usually repeated a
techniques. second time, the third time the compressor stays on for
the cooling cycle.
Crankcase Heaters
Reversing Valves
Preventing ref rigerant migration to the compressor
during the off cycle is required. A crankcase heater can Since Copeland scroll compressors have very high
be used to mitigate ref rigerant migration to the volumetric ef ficiency, their displacements are lower
compressor during the off cycle. The initial start-up in than those of comparable capacity reciprocating
the f ield is a very critical period f or any compressor compressors.
because all load-bearing surfaces are new and require
a short break-in period to carry high loads under Reversing valve sizing must be within the guidelines of
adverse conditions. The crankcase heater must be the valve manuf acturer. Required pressure drop to
turned on a minimum of 12 hours prior to starting the ensure valve shifting must be measured throughout the
compressor. This will help prevent oil dilution and operating range of the unit and compared to the valve
bearing stress on initial startup. manuf acturer's data. Low ambient heating conditions
with low f low rates and low pressure drop across the
To properly install the crankcase heater, the heater valve can result in a valve not shifting. This can result
should be installed in the location illustrated in Figure in a condition where the compressor appears to be not
3. Tighten the clamp screw carefully, ensuring that the pumping (i.e., balanced pressures). It can also result in
heater is unif ormly tensioned along its entire length and elevated compressor sound levels.
that the circumference of the heater element is in
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f rom system manuf acturing processes which leave

During a def rost cycle, when the reversing valve solid or liquid contaminants in the evaporator coil,
abruptly changes the ref rigerant f low direction, the condenser coil, and interconnecting tubing plus any
suction and discharge pressures will go outside of the contaminants introduced during the f ield installation
normal operating envelope. The sound that the process. Molecular sieve and activated alumina are two
compressor makes during this transition period is f ilter-drier materials designed to remove moisture and
normal, and the duration of the sound will depend on mitigate acid f ormation. A 100% molecular sieve f ilter
the coil volume, outdoor ambient temperature, and can be used f or maximum moisture capacity. A more
system charge level. If the compressor is operating conservative mix, such as 75% molecular sieve and
during a def rost cycle the compressor should operate 25% activated alumina, should be used f or service
between 50-60Hz. The pref erred method of mitigating applications.
def rost sound is to shut down the compressor for 20 to
30 seconds when the reversing valve changes position Oil Type
going into and coming out of the def rost cycle. This Polyolester oil (POE) is used in YA*K1 and YP*K1
technique allows the system pressures to reach compressors. Please refer to Copeland publication 93-11
equilibrium without the compressor running. The f or specific POE oil grade in centistokes for each refrigerant.
additional start-stop cycles do not exceed the
compressor design limits, but suction and discharge See the compressor nameplate f or the original oil
tubing design should be evaluated.
charge. A complete recharge should be approximately
eight to ten f luid ounces (237-296ml) less than the
The reversing valve solenoid should be wired so that nameplate value. Please ref er to Copeland Mobile for
the valve does not reverse when the system is shut off model specific oil charge and recharge values. If
by the operating thermostat in the heating or cooling additional oil is needed in the field, there are multiple POE
mode. If the valve is allowed to reverse at system brands available at your local distributor and wholesalers.
shutoff, suction and discharge pressures are reversed
to the compressor. This results in pressures equalizing WARNING
through the compressor which can cause the
compressor to slowly rotate backwards until the
pressures equalize. This condition does not affect POE may cause an allergic skin reaction and must
compressor durability but can cause unexpected sound be handled carefully. Proper protective equipment
af ter the compressor is turned of f . (gloves, eye protection, etc.) must be used when
handling POE lubricant. POE must not come into
Contaminant Control contact with any surface or material that might be
harmed by POE, including, certain polymers (e.g.,
Manuf acturing processes have been designed to
minimize the introduction of solid or liquid PVC/CPVC and polycarbonate). Refer to the Safety
Data Sheet (SDS) located at Copeland Mobile for the
contaminants. Dehydration and purge processes
ensure minimal moisture levels in the compressor, and specific oil.
continuous auditing of lubricant moisture levels ensures
that moisture isn’t inadvertently introduced into the Power Factor Correction
compressor. However, due to the manuf acturing If power f actor correction is necessary in the end -use
processes, Copeland scroll compressors will contain a application, please see AE-1249 f or more inf ormation
miniscule amount of solid and liquid contaminants when on this topic.
they leave the f actory.
Soft Starters
During unit assembly and f ield servicing, compressors Sof t starters can be used with the compressors to
shouldn't be left open to the atmosphere for longer than reduce inrush current. Soft starters should be selected
f ive minutes. It is generally accepted that system in accordance with the sof t starter manuf acturer's
moisture levels should be maintained below 50 ppm. A recommendations, taking into consideration ambient
f ilter-drier is required on all POE lubricant systems to temperature, number of starts per hour, and
prevent solid particulate contamination, oil dielectric compressor amps. The maximum ramp up time should
strength degradation, ice formation, oil hydrolysis, and not exceed 3 seconds.
metal corrosion. It is the system designer’s
responsibility to make sure that the f ilter-drier is
adequately sized to accommodate the contaminants
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Manifolded Compressors motor overheating and reduced ef f iciency.

Tandem and trio compressor assemblies are available
f or purchase f rom Copeland. In lieu of purchasing the The normal ratio of the voltage/frequency should be
assembled tandem or trio, OEMs can purchase the kept constant below 60 Hertz. At f requencies higher
manif old-ready compressors and perform the assembly than 60 Hertz, the voltage/frequency ratio cannot be
in their f actory. Drawings of tandem and trio kept constant because the output voltage of the drive
compressor assemblies are available from Copeland by cannot be higher than the drive input voltage. Figure 9
contacting your Application Engineer. Part numbers for illustrates the voltage- f requency curves f or nominal
manif olds and other service parts are available by 230, 460, and 575 volt power supplies. Verif y the
contacting Application Engineering. Customers who acceptable speed range f or each compressor with the
choose to design and build their own manif olds for Copeland Application Engineer.
tandem and trio compressor assemblies are ultimately
responsible for the reliability of those manif old sets. Starting and Ramp Up
The starting f requency should be equal to or greater
Ref erence the AE-1430 bulletin f or inf ormation on than the minimum speed. After starting the compressor
multiple compressors applications and design at the minimum speed, the speed should be ramped up
considerations. to 3,000 RPM within 3 seconds. The compressor
should operate at 3,000-3,600 RPM f or a minimum of
VARIABLE SPEED OPERATION 10 seconds before ramping the speed up or down to the
desired operating speed. A normal ramp speed is 200
Introduction revolutions per second.
Variable speed drives may be used with the 20-to-40-
ton Copeland scroll compressors. The acceptable Stopping
speed ranges and operating envelope are model Ramping down the f requency to the minimum speed
dependent. Contact Application Engineering for speed bef ore stopping the drive-compressor is considered a
ranges f or a specif ic compressor model. good shutdown routine. However, given the operating
f requency and speed range of the compressor it is not
Operating Envelope necessary to decelerate the compressor prior to
The system controller must have the ability to keep the shutdown. Depending on the drive interf ace and
operating condition and speed inside of the prescribed control, the drive should be given a "stop" command to
operating envelope. stop the compressor. In rare cases when a system
protection device trips (i.e. high pressure cut-out
Drive Selection switch) power to the drive input should be immediately
interrupted.
Copeland offers an EVM and EVH drive lineup for use
with a wide range of compressor models. Contact Vibration
Application Engineering f or details on the EVM and
EVH drive offering and technical documents. If a third A compressor driven at a variable speed will impose
party drive is used, it must be selected and sourced dif ferent f requencies at each speed, so the f ramework
separately for the compressor. The drive and controller and piping design to accommodate vibration
must control the compressor to the specifications throughout the speed range can be more complex. As
required in this section of the bulletin. a rule of thumb, the system should be designed, or the
drive control should be configured such that there is no
Electrical Requirements operation at resonant f requencies between the
minimum and maximum speeds.
The drive must be sized to accommodate the maximum
expected running amps of the compressor. For Oil Recovery Cycle
operation throughout the operating envelope at +/-10%
voltage variation the drive should be selected based on Particular attention must be given to the system
the compressor maximum continuous current (MCC). ref rigerant pipe size with the variable speed scrolls.
The electrical data f or the specific compressor can be ASHRAE guidelines for pipe sizing should be followed
ref erenced at Copeland Mobile. to ensure that ref rigerant velocities are high enough at
low speeds to ensure oil return to the compressor. At
The recommended switching frequency of the drive is 2 the same time, high refrigerant velocities at high speed
operation can result in excessive pressure drop and
to 3 kHz. Higher switching f requencies can result in
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loss of system ef ficiency. A caref ul evaluation and testing conditions shall be at minimum mass f low and
compromise in pipe sizing will likely have to be settled minimum density of suction gas in continuous and
upon. A compressor sample with a sight-tube for f requent start-stop-cycling.
monitoring the oil level should be used during system ▪ In multiple compressor systems: to check oil return
development to ensure an adequate oil level is and oil balancing in the tandem or trio, testing
maintained during all operating conditions and speeds. conditions shall be at the corner points of the system
If testing shows a gradual, continuous loss of oil in the application envelope in continuous and f requent start-
compressor sight-tube over long run cycles at low stop-cycling.
speed, an oil recovery cycle should be incorporated into ▪ In all systems: to test liquid f loodback, all possible
the system logic. A recovery cycle is accomplished by transient operation conditions in the system should be
ramping the compressor up to a higher speed to checked, compressor f requent start/stop, compressor
increase the ref rigerant f low rate to f lush or sweep oil start af ter long off time with migration, defrost, switching
back to the compressor. How often a recovery cycle is between the operation modes in reversible systems,
initiated depends on many variables and would have to load changes, f ans or pumps cycling at low load and
be determined through testing for each system type and more. To evaluate the risk of liquid f loodback, please
conf iguration. ref er to the oil dilution chart in Figure 8. Liquid level and
superheat at compressor suction should be checked.
CORESENSE COMMUNICATIONS
For variable speed applications, the above oil balancing
Description and system oil return tests must be perf ormed. The
The 20 to 40 ton Copeland scroll compressors are used concern is that a very low oil level will develop after
with a CoreSense protection module. The CoreSense extended hours of operation at low speed. In addition
Communications module, installed in the compressor to oil balancing and system oil return tests, the suction
electrical box, provides advanced diagnostics, and discharge tubing must be evaluated to determine
protection, and communications that enhance the resonant f requencies. Once the resonant
compressor perf ormance and reliability. Ref er to the f requencies are known, they can be shifted to a safe
AE8-1384 CoreSense bulletin f or more inf ormation. range by changing the mass of the line f or constant
speed applications or they can be avoided f or variable
speed applications.
APPLICATION TESTS
Application Engineering is available to recommend
The system designer is responsible f or testing the
additional tests and to evaluate test results.
system to ensure it operates as designed. These tests
should be perf ormed during system development and
ASSEMBLY LINE PROCEDURES
are dependent on the system type and amount of
ref rigerant charge. These application tests are to help
Installing the Compressor
identify errors in system design that may produce
conditions that could lead to compressor f ailure. WARNING
Use care and the appropriate material handling
The evaporating temperature and the bottom shell
equipment when lifting and moving compressors.
temperature shall be taken with a high sampling rate Personal protective equipment must be used.
during the entire oil return or oil balance testing and
under all tested conditions. The liquid level in the sight
tube should be observed and recorded also. Testing Copeland scroll compressors leave the f actory
conditions shall include defrost and varying loads. If the dehydrated and with a positive dry air charge. Plugs
system is reversible, the tests should be conducted in should not be removed f rom the compressor until the
both operation modes. compressor has had sufficient time to warm up if stored
outside, is ready for assembly in the unit and has been
System engineers should review the system design and
set into the unit. The suggested warm up time is one
operation to identify the critical conditions and to check
hour per 4°F (2 Kelvin) difference between outdoor and
oil return, oil balancing and liquid f loodback. Typically, indoor temperature. The larger suction plug should be
the f ollowing situations should be considered:
removed f irst to relieve the internal dry air pressure.
Removing the smaller discharge plug could result in a
▪ In single compressor systems: to check oil return, spray of oil out of this fitting since some oil accumulates
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in the head of the compressor after Copeland’s run test Unbrazing System Components
and may also result in oil mist coating the suction tube
making brazing difficult. The inside of both f ittings WARNING
should be wiped with a lint free cloth to remove residual
Before attempting to braze, it is important to
oil prior to brazing. A compressor containing POE oil
recover all refrigerant from both the high and low
should never be lef t open longer than 5 minutes. side of the system.
The copper coated steel suction tube should be If the ref rigerant charge is removed f rom a scroll-
cleaned before brazing (see Figure 1). No object (e.g., equipped unit by evacuating the high side only, it is
a swaging tool) should be inserted deeper than two
possible f or the scrolls to seal, preventing pressure
inches (51 mm) into the suction tube, or it might equalization through the compressor. This may leave
damage the suction screen and motor.
the low side shell and suction line tubing pressurized.
Mounting
Many OEM customers buy the mounting parts directly Removing Compressors
f rom the supplier, but Copeland 's grommet design and
durometer recommendations should be f ollowed for WARNING
best vibration reduction through the mounting f eet. Before attempting to cut copper tubing, it is
important to recover all refrigerant from both the
Suction and Discharge Fittings high and low side of the system.
These compressors are available with stub tube or
rotalock connections. The stub tube version has Instructions should be provided in appropriate product
copper-plated steel suction and discharge fittings. Due literature and assembly (line repair) areas. If a
to the dif ferent thermal properties of steel and copper, compressor removal is required, the compressor
brazing procedures may have to be changed from should be cut out of system rather than unbrazed. See
those commonly used. See Figure 1 f or assembly line Figure 1 f or the proper compressor removal procedure.
and f ield brazing procedures and Table 1 f or Rotalock
torque values. Pressure Testing
Assembly Line Brazing Procedure
Never pressurize the compressor to more than 475
WARNING psig (33 bar) for leak checking purposes. Never
Personal protective equipment must be used pressurize the compressor from a nitrogen
during brazing operation. Heat shields should be cylinder or other pressure source without an
used to prevent overheating or burning nearby appropriately sized pressure regulating and relief
temperature sensitive parts. A fire extinguisher valve.
should be accessible.
The pressure used on the line to meet the U.L. burst
pressure requirement must not be higher than 475 psig
Figure 1 discusses the proper procedures f or brazing
(33 bar). Higher pressure may result in permanent
the suction and discharge lines to a scroll compressor. def ormation of the compressor shell and possible
misalignment, bottom cover distortion and/or shell
It is important to flow nitrogen through the system while
rupture.
brazing all joints during the system assembly process.

Nitrogen displaces the air and prevents the f ormation of Assembly Line System Charging Procedure
copper oxides in the system. If allowed to f orm, the Systems should be charged with liquid on the high side
copper oxide f lakes can later be swept through the to the extent possible. Most of the charge should be
system and block screens such as those protecting pumped in the high side of the system to prevent low
capillary tubes, thermal expansion valves, and voltage starting difficulties, hipot motor test failures, and
accumulator oil return holes. The blockage - whether it bearing washout during the f irst-time start on the
is of oil or ref rigerant - is capable of doing damage assembly line. If additional charge is needed, it should
resulting in compressor f ailure. be added as liquid to the low side of the system with the
compressor operating. Pre-charging on the high side
and adding liquid on the low side of the system are both
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meant to protect the compressor f rom operating with Final Run Test
abnormally low suction pressures during charging. Do Customers that use a nitrogen f inal run test must be
not operate the compressor without enough system caref ul to not overheat the compressor. Nitrogen is not
charge to maintain at least 55 psig (3.8 bar) suction a good medium for removing heat from the compressor,
pressure. Do not operate the compressor with the low and the scroll tips can be easily damaged with high
pressure cut-out disabled. Do no operate with a compression ratios and/or long test times. Copeland
restricted suction or liquid line. scroll compressors are designed for use with refrigerant
and testing with nitrogen may result in a situation where
Depending on the discharge pressure, allowing
the compressor does not develop a pressure differential
pressure to drop below 55 psig (3.8 bar) for more than
(no pump condition). When testing with nitrogen, the
a f ew seconds may overheat the scrolls and cause compressor must be allowed to cool for several minutes
early drive bearing damage. between tests.

SERVICE PROCEDURES
CAUTION
Field Replacement
Do not use the compressor to test the opening set
point of a high pressure cutout.
Bearings are susceptible to damage before they have Use care and the appropriate material handling
had several hours of normal running f or proper break equipment when lifting and moving compressors.
in. Personal protective equipment must be used.

'Hipot' (AC High Potential) Motor Testing Removing Oil

If the oil level is higher than the oil Schrader f itting on
CAUTION the sump of the compressor oil can be drained f rom this
Use caution with high voltage and never hipot test f itting until the oil level reaches the level of the Schrader
when compressor is in a vacuum. f itting. To remove oil from the compressor when the oil
level is below the oil Schrader f itting one of two different
Copeland scroll compressors are configured with the procedures can be used. The f irst procedure is to
motor down and the pumping components at the top of remove the compressor from the system and drain the
the shell. As a result, the motor can be immersed in oil f rom the compressor suction connection. This
ref rigerant to a greater extent than hermetic method ensures complete removal of the oil f rom the
reciprocating compressors when liquid ref rigerant is compressor. The second procedure is to remove the
present in the shell. In this respect, the scroll is more compressor sight-glass and insert a hose into the sump
like semi-hermetic compressors that have horizontal of the compressor and draw the oil out with a hand -held
motors partially submerged in oil and refrigerant. When pump.
Copeland scroll compressors are hipot tested with
liquid ref rigerant in the shell, they can show higher Electrical
levels of leakage current than compressors with the
motor on top. This phenomenon can occur with any When replacing a compressor, especially one that has
compressor when the motor is immersed in refrigerant. been in the f ield f or several years, it is always a good
idea to replace the contactor.
The level of current leakage does not present any
saf ety issue. To lower the current leakage reading, the Note: See the locked rotor on the nameplate of the new
system should be operated f or a brief period to compressor and make sure the contactor exceeds this
redistribute the ref rigerant to a more normal locked rotor rating.
conf iguration and the system hipot tested again. See
AE4-1294 f or megohm testing recommendations. Compressor Replacement After a Motor Burn
Under no circumstances should the hipot test be In the case of a motor burn, most of the contaminated
perf ormed while the compressor is under a vacuum. oil will be removed with the compressor. The rest of the
oil is cleaned with the use of suction and liquid line filter
U.L. sets the requirement f or dielectric strength testing
driers. A 100% activated alumina suction f ilter drier is
and they should be consulted f or the appropriate
recommended but must be removed af ter 72 hours.
voltage and leakage values. See AE24-1105 f or clean up procedures and AE11-
1297 f or liquid line f ilter-drier recommendations.
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It is highly recommended that the suction accumulator Follow the unit manufacturer’s guidelines for
be replaced if the system contains one. properly evacuating and charging of the system. Do
not start the compressor while the system is in a
This is because the accumulator oil return orif ice or vacuum. Internal arcing may occur when any type
screen may be plugged with debris or may become of compressor is started in a vacuum which may
plugged shortly af ter a compressor f ailure. This will result in terminal venting.
result in starvation of oil to the replacement compressor
and a second f ailure. Do not operate the compressor without enough
system charge to maintain at least 55 psig (3.8 bar)
Manifolded Compressor Replacement suction pressure. Do not operate with a restricted
suction or liquid line. Do not operate with the low
pressure cut-out disabled.
Use care and the appropriate material handling
equipment when lifting and moving compressors. Allowing suction pressure to drop below 55 psig (3.8
Personal protective equipment must be used. bar) f or more than a f ew seconds may overheat the
scrolls and cause early drive bearing damage. Never
Should a compressor f ail in a manif olded set, only the install a system in the f ield and leave it unattended
f ailed compressor should be replaced and not both with no charge, a holding charge, or with the service
compressors. The oil f rom the f ailed compressor will valves closed without securely locking out the system.
stay mostly in the failed compressor. Any contaminated This will prevent unauthorized personnel f rom
oil that does enter the tandem circuit will be cleaned by accidentally ruining the compressor by operating with
the liquid line f ilter drier, and when used, the suction line no ref rigerant f low.
f ilter drier.
The suction and discharge manifolds can be reused if Refrigerant Retrofits
the f ailed compressor is caref ully removed, and the
manif olds are cut in such a way that a coupling and
short piece of copper can reconnect the new
Only use approved refrigerants, lubricants, and
compressor. Ref erence the AE4-1430 Compressor
parts in accordance with the system and
Multiples Bulletin for more information on installing a
compressor specifications. Recover all the
new oil equalization line.
refrigerant from the system including the high and
low side. Use a tubing cutter to remove the
Start-Up of a New or Replacement Compressor
compressor.
It is good service practice, when charging a system with
a scroll compressor, to charge liquid refrigerant into the These compressors are UL recognized and
high side only. It is not good practice to dump liquid use with any other refrigerant than originally
ref rigerant from a ref rigerant cylinder into the crankcase intended for use will void the compressor UL
of a stationary compressor. If additional charge is recognition.
required, charge liquid into the low side of the system For a list of Copeland approved refrigerants
with the compressor operating. please refer to Form 93-11, Refrigerants and
Lubricants Approved for Use in Copeland
Compressors.

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Figure 1 - Scroll Tube Fitting Brazing

New Installations
• The copper-coated steel tube f itting 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 suction tube fitting I.D. and suction tube O.D. are clean prior to assembly. If oil film is present wipe
with denatured alcohol, Dichloro -Trif luoroethane or other suitable solvent.
• Using a double-tipped torch apply heat in Area 1. As tube approaches brazing temperature, move torch
f lame to Area 2.
• Heat Area 2 until braze temperature is attained, moving torch up and down and rotating around tube as
necessary to heat tube evenly. Add braze material to the joint while moving torch around joint to flow braze
material around circumf erence.
• Af ter braze material flows around joint, move 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 b e detrimental to the result.

Field Service

Remove refrigerant charge from both the low and high side of the compressor before cutting the
suction and discharge lines to remove the compressor. Verify the charge has been completely
removed with manifold gauges.

• To disconnect: Reclaim ref rigerant f rom both the high and low side of the system. Cut tubing near
compressor. The compressor should be disconnected using a tubing cutter.
• To reconnect:
✓ Recommended brazing materials: Silf os with minimum 5% silver or silver braze material with f lux.
✓ Insert tubing stubs into f itting and connect to the system with tubing connectors.
✓ Follow New Installation brazing instructions above.

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Figure 2 - YA YP Scroll Nomenclature

Figure 3 - Crankcase Heater Location

YA219, YA275, YP233 & YP293

YA360, YA460, YP385 & YP485

Connect the heater so the connection point straddles the compressor weld seam
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Figure 4 - Operating Envelope YA219K1, YA275K1

Figure 5 - Operating Envelope YA360K1, YA460K1

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Figure 6 - Operating Envelope YP233K1, YP293K1

Figure 7 - Operating Envelope YP385K1 – YP485K1

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Figure 8 – Oil Dilution Chart

Figure 9 – Variable Speed Output Frequency

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Table 1 – Torque Values

Torque
Part
ft-lb in-lb N-m
1-3/4" Sight Glass 53-65 635-780 71-88
2-1/4" Suction Rotalock Valve 140-148 1680-1770 190-200
125-
1-3/4" Suction/Discharge Rotalock Valve 1500-1590 169-180
133
1-1/4" Discharge Rotalock Valve 74-81 885-975 100-110
TPTL Rotalock Fitting 125-133 1500-1590 170-180
Schrader Valve 20-21 240-250 27-28
Terminal Block Screws 1.0-1.3 12-15 1.4-1.7
Oil Access Fitting (Threads Into Oil
3.3-5.0 40-60 4.5-6.8
Rotalock)
Crankcase Heater 1.7-2.1 20-25 2.3-2.8
Tandem Mounting Bolts 7.5-10.4 90-125 10-14
M6 Terminal Box Mounting Stud Nuts 2.7-3.2 32-39 3.6-4.4

The contents of this publication are presented for informational purposes only and are not to be construed as warranties or guarantees, express or implied, regarding
the products or services described herein or their use or applicability. Copeland LP and/or its affiliates (collectively "Copeland"), as applicable, reserve the right to
modify the design or specifications of such products at any time without notice. Copeland does not assume responsibility for the selection, use or maintenance of any
product. Responsibility for proper selection, use and maintenance of any Copeland product remains solely with the purchaser or end user .

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