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COPELAND CO2

Emerson COPELAND CO2 User manual

  • Hello! I have analyzed the provided technical information for the Emerson Changeover Valve and Pressure Relief Valve. This document outlines the correct procedure for replacing the changeover valve on Copeland CO2 refrigeration units, including details for the PRV’s and performing leak tests after the replacement. I am ready to answer any specific questions you may have about this process or the product.
  • What is included in the service kit N°3290262?
    What thread size is relevant for the changeover valve?
    What should be done if the PRVs cannot be disassembled?
    What is the torque for mounting the changeover valve?
    What is the torque for the PRV?
TI_Unit_CO2_Stream_04_EN_Rev00 Ident number 3293976 (P/N 900-0010-00/Rev00) 1/3
Date of last update: Aug-22
Ref: TI_Unit_CO2_Stream_04_EN_Rev00
Application Engineering Europe
COPELAND™ CO2 REFRIGERATION UNITS
CHANGEOVER VALVE SERVICE KIT
This technical information provides instructions for the replacement of the changeover valve on Copeland CO2
refrigeration units. These instructions are valid only for Copeland CO2 refrigeration units with M24x1.5 thread on the
PRV’s connected to the liquid receiver through the changeover valve. If the pressure relief valves (PRV’s) cannot be
disassembled from the changeover valve, it is necessary to replace the complete assembly (changeover valve +
PRV’s). The PRV version with metric thread M24x1.5 cannot be used anymore. The PRV on the high-pressure side
is not affected by this change.
The service kit N°3290262 includes the components shown in the table below.
Components
Description
Quantity
Valve-Change-Over 1/2"NPT
Changeover valve
1
Valve-Safety assm 90 bar
Pressure relief valve (PRV)
2
User manual - CV Kit
Instruction
1
Table 1: BOM of changeover valve service kit
When replacing the changeover valve including PRV’s, the instructions in this technical information must be carefully
followed. Use the recommended torque at each step.
Only qualified and authorized HVAC or refrigeration personnel are permitted to conduct the changes described in
this technical information. All appropriate safety measures must be considered.
Replacement of changeover valve:
▪ Release all the pressure/refrigerant from the unit (Figure 1).
▪ Disassemble the changeover valve from the liquid receiver (Figure 2).
▪ Connect a nitrogen hose to the liquid receiver so that no thread debris can fall into it (Figure 3).
▪ Clean the liquid receiver thread (Figure 3).
Figure 1 Figure 2 Figure 3
TI_Unit_CO2_Stream_04_EN_Rev00 Ident number 3293976 (P/N 900-0010-00/Rev00) 2/3
▪ Apply teflon sealing tape (0.1x12 mm) to the changeover valve by 5 to 6 turns clockwise (Figure 4).
▪ Mount the changeover valve onto the liquid receiver; torque to 50 Nm (Figure 5).
▪ Apply teflon sealing tape (0.1x12 mm) to both NPT PRV‘s by 5 to 6 turns clockwise (Figure 6).
Figure 4 Figure 5 Figure 6
▪ Mount both PRV‘s into the changeover valve; torque to 40 Nm (Figure 7).
▪ Turn the spindle into middle position so that both PRV ports are open (Figure 8).
▪ Close the shut-off valves on the compressor (discharge port) and on the liquid receiver (Figure 9).
▪ Open the high-pressure valve and perform a bubble leak test on all connections between liquid receiver,
changeover valve and PRV’s (Figure 10).
▪ Pressurize the liquid receiver with nitrogen (5 bar) and perform a preliminary leak test.
▪ Perform the final leak test at 80 bar.
Figure 7 Figure 8 Figure 9
Figure 10
TI_Unit_CO2_Stream_04_EN_Rev00 Ident number 3293976 (P/N 900-0010-00/Rev00) 3/3
▪ Mount the deflector and tighten it manually to 1-5 Nm (Figures 11 & 12).
▪ The changeover valve must be fully open during unit operation (spindle out Figures 13 & 15).
▪ Mount the spindle cap and check the presence of the copper gasket (Figure 14).
Figure 11 Figure 12 Figure 13 Figure 14
Figure 15
Spindle protective cap
Spindle "open" / "closed"
Seal gland
40 Nm
25 Nm
15 Nm
Table 2: Torques on the changeover valve in Nm
NOTE: For information on the maintenance and lifetime of the PRV, please refer to the unit application
guidelines.
- 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.
- Emerson Climate Technologies GmbH and/or its affiliates (collectively "Emerson"), as applicable, reserve the right to modify the design or specifications of such
products at any time without notice.
- Emerson does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any
Emerson product remains solely with the purchaser or end user.
- Emerson does not assume responsibility for possible typographic errors contained in this publication.
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