EMERSON COPELAND CO2 Refrigeration Units Changeover Valve Service Kit User Manual

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 PRVs connected to the liquid receiver through the changeover valve. If the pressure relief valves (PRVs) cannot be disassembled from the changeover valve, it is necessary to replace the complete assembly (changeover valve + PRVs). 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.

(510-0902-01)
User manual – CV Kit| Instruction| 1| 3293976 (900-0010-00)

Table 1: BOM of changeover valve service kit

When replacing the changeover valve including PRVs, 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).

• Apply Teflon sealing tape (0.1×12 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 (0.1×12 mm) to both NPT PRVs by 5 to 6 turns clockwise (Figure 6).

• Mount both PRVs into the changeover valve; torque to 40 Nm (Figure 7).
• Turn the spindle into the 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 the liquid receiver, changeover valve, and PRVs (Figure 10).
• Pressurize the liquid receiver with nitrogen (5 bar) and perform a preliminary leak test.
• Perform the final leak test at 80 bar.

• 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).

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.

TI_Unit_CO2_Stream_04_EN_Rev00
Ident number 3293976 (P/N 900-0010-00/Rev00)

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