Emerson SZO22, SZV22 User Manual

Copeland Scroll® Compressor Module

Installation, Operation & Maintenance Manual

Model Family

SZO22

SZV22

Single-Compressor Module TABLE OF CONTENTS

TABLE OF CONTENTS

Compressor Module Nomenclature.............................................................................................			iv
Important Safety Information........................................................................................................			1
1.0	Introduction.......................................................................................................................		3
1.1	The Compressor Module...............................................................................................................		3
1.2	The Compressor............................................................................................................................		4
1.3	The Compressor Package.............................................................................................................		4
2.0	Installation........................................................................................................................		5
2.1	Installation Guidelines...................................................................................................................		5
	2.1.1 Required Component—Inlet Gas Scrubber.....................................................................................		5
	2.1.2	General Installation Guidelines........................................................................................................	5
2.2	Inlet and Discharge Pressures......................................................................................................		5
2.3	Ambient Temperature Range........................................................................................................		6
2.4	Installation Clearance and Dimensions.........................................................................................		7
2.5	Process and Instrumentation Diagrams (P&IDs)...........................................................................		8
2.6	Electrical Controls.........................................................................................................................		9
	2.6.1	General Considerations...................................................................................................................	9
	2.6.2 Oil Cooler Fan Control...................................................................................................................		10
	2.6.3 Compressor Module Motor Protection...........................................................................................		12
	2.6.4	Electrical Requirements.................................................................................................................	13
	2.6.5	Wiring.............................................................................................................................................	14
	2.6.6 Variable Frequency Drive (VFD) Terminations...............................................................................		15
3.0	Operation.........................................................................................................................		15
3.1	Initial Startup - Compressor Module............................................................................................		15
	3.1.1	Pre-Startup Checklist.....................................................................................................................	15
	3.1.2	Post-Startup Checklist....................................................................................................................	15
3.2	Initial Startup - Compressor Package..........................................................................................		16
3.3	Normal Operation Checklist........................................................................................................		16
4.0	Maintenance.....................................................................................................................		17
4.1	Routine Maintenance..................................................................................................................		17

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4.2	Maintenance Tools......................................................................................................................	18
4.3	Oil Service...................................................................................................................................	19
4.6	Cleaning the Inlet Screen............................................................................................................	21
4.7	Servicing the Scavenge Line Orifice...........................................................................................	21
4.8	Changing the Second-Stage Separator Element........................................................................	21
5.0	Troubleshooting..............................................................................................................	22
5.1	Troubleshooting Guide................................................................................................................	22
5.2	Motor Winding Resistance..........................................................................................................	22
5.3	Platform Symptoms Diagnosis....................................................................................................	23
6.0	Specifications...................................................................................................................	24
7.0 Technical Support and Service........................................................................................		25
Appendix A  Material Data Safety Sheet...................................................................................		26
A.1	Supplier.......................................................................................................................................	26
A.2	Product Name and Information...................................................................................................	26
A.3	Components and Hazard Statement...........................................................................................	26
A.4	Safe Handling and Storage.........................................................................................................	26
A.5	Physical Data..............................................................................................................................	26
A.6	Fire and Explosion Hazards........................................................................................................	27
A.7	Reactivity Data............................................................................................................................	27
A.8	Health Hazard Data.....................................................................................................................	27
A.9	Personal Protection Information..................................................................................................	27
A.10	Spill or Leak Procedures.............................................................................................................	27
A.11	Waste Disposal Methods.............................................................................................................	27

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	FIGURES
Figure 1	Compressor Module Components .........................................................................................................	3
Figure 2	Copeland Scroll® Compressor Cross Section.........................................................................................	4
Figure 3	Typical Compressor Package ................................................................................................................	4
Figure 4	Compressor Module Dimensions, in. (mm)............................................................................................	7
Figure 5	Compressor Module Gas and Oil Flow Diagram and Safety Shutdowns...............................................	8
Figure 6	Brushless DC Fan ................................................................................................................................	10
Figure 7	Basic Fan Control System ...................................................................................................................	10
Figure 8	Optional Customer-Installed High Temperature Fan Control System ..................................................	11
Figure 9	Oil Cooling and Thermal Valve.............................................................................................................	11
Figure 10	Motor Control .......................................................................................................................................	12
Figure 11	Typical Compressor Module Electrical Requirements..........................................................................	13
Figure 12	Control Circuit Terminations .................................................................................................................	14
Figure 13	Maintenance Tools................................................................................................................................	18
Figure 14	Gas Inlet Block and Screen .................................................................................................................	21
Figure 15	Scavenge Line Orifice ..........................................................................................................................	21
	TABLES
Table 1	Inlet and discharge pressure limits.........................................................................................................	5
Table 2	Typical Compressor Module power supply requirements.....................................................................	13
Table 3	Maintenance summary.........................................................................................................................	17
Table 4	Troubleshooting....................................................................................................................................	22
Table 5	VFD fault codes and descriptions.........................................................................................................	22
Table 6	Platform troubleshooting guidelines.....................................................................................................	23
Table 7	Compressor Module specifications.......................................................................................................	24

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Single-Compressor Module

Compressor Module Nomenclature

Compressor Module Nomenclature

Oil

High

Thermal

Max

Press

Low

High

Bypass

Delivery

Max

Switch

Press

Temp

Valve

Gas

Module

Pressure

Flow

Drive

Setting

Switch

Setting

Setpoint

Bypass

Weight

Model

(PSIG)

(MCFD)

HP

(PSIG)

Setting

°F (°C)

°F (°C)

Valve

(Lbs.)

Single Scroll Units

SZO22C3A-EDE-234

125

100

10

215

2” W.C.

240

200

YES

350

(5 mbarg)

(116)

SZV22C1A-EDE-140

190

100

15

215

2” W.C.

280

250

NO

356

(5 mbarg)

(138)

NOTE:

SZO modules are intended for use with clean, dry gas in applications with moderate ambient temperatures. Oil thermal bypass valve setpoint is 200°F. Most SZO module applications use PAO oil.

SZV modules keep discharge gas temperatures elevated to help with dewpoint control. SZV modules insulate the separators and use a 250°F oil thermal bypass valve. In cold ambient, and SZV module should be used with an enclosure. Most SZV module applications use PAG oil.

Refer to Copeland Scroll Gas Compression Module Performance Program for all details.

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Single-Compressor Module

Important Safety Information

Important Safety Information

This manual contains important instructions for installation, operation and maintenance of your Copeland Scroll® Compressor Module.

WARNING

The Compressor Module must be installed ONLY in systems that have been designed by qualified engineering personnel. The system must conform to all applicable local and national regulations and safety standards.

These instructions are intended to assist in the installation and operation of the Compressor Module and MUST be kept with the Compressor.

Service and maintenance of the Compressor Module must be performed by qualified technicians only. Service and maintenance must conform to all applicable local and national regulations and safety standards.

Thoroughly review this manual, all instructions and hazard warnings before performing any work on the Compressor Module.

Maintain all Compressor Module operation and hazard warning labels.

WARNING

Flammable gas can form explosive mixtures with air. Explosive gases can cause property damage, serious personal injury or death.

WARNING

Failure to disconnect and lockout electrical power from the Compressor Module before attempting maintenance can cause shock, burns, severe personal injury or death.

WARNING

Loosening or removing pressure-containing components from the Compressor Module when it is in operation can cause major property damage, serious personal injury or death.

Failure to relieve system pressure prior to performing service or maintenance on the Compressor Module can cause property damage or serious personal injury.

CAUTION

Extreme heat can cause personal injury or property damage.

CAUTION

Always use a lifting device capable of supporting the full weight of the Compressor Module or component being lifted.

Handling or lifting heavy assemblies can cause personal injury or property damage.

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Single-Compressor Module	Important Safety Information

Safety Symbols Used in This Manual

SAFETY ALERT SYMBOL

When you see this symbol on the Compressor Module or in this manual, look for one of the following words and be aware of the potential for personal injury or property damage.

WARNING

A Warning describes hazards that CAN or WILL cause serious personal injury, death or major property damage.

CAUTION

A Caution describes hazards that CAN cause personal injury or property damage.

NOTE

A Note indicates special instructions that are very important and must be followed.

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Single-Compressor Module

Introduction

1.0Introduction

The Copeland Scroll® SZO22 Compressor Module comes equipped with one Copeland Scroll® Compressor designed for Class I, Division II applications. The Compressor Module is designed for assembly into a Compressor Package ready for service in the field; the completed housing is done by equipment Packagers. This section provides an overview of these components.

These terms are used throughout this manual:

•Compressor Module - the SZO22 Compressor Module shown in Section 1.1

•Compressor - a Copeland Scroll® Compressor

•Compressor Package - the entire assembly, including the Compressor Module, ready for service in the field

•Packagers - the company that prepares the Compressor Module for service

•VFD - Variable Frequency Drive used to power a variable speed Compressor Module

1.1The Compressor Module

The Compressor Module consists of one Compressor and the other components shown in Figure 1.

Figure 1 Compressor Module Components

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Single-Compressor Module	Introduction

1.2The Compressor

The Compressor refers to the Copeland Scroll® Compressor. Figure 2 shows a cross-section of a Compressor and its key components.

Figure 2 Copeland Scroll® Compressor Cross Section (not shown: Encapsulated Stator)

1.3The Compressor Package

The Compressor Package consists of the Compressor Module housed in an assembly ready for service in the field. Equipment Packagers customize the assembly and complete the fabrication for Compressor Modules for each application. Figure 3 shows a simplified example of a Compressor Package.

Figure 3 Typical Compressor Package

Inlet gas scrubber for liquid removal

Control and power panel

Gas aftercooler (if applicable)

Oil cooler

Compressor

Module

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Single-Compressor Module

Installation

2.0Installation

2.1Installation Guidelines

2.1.1Required Component—Inlet Gas Scrubber

An appropriate inlet gas scrubber is REQUIRED to remove liquids from the gas prior to compression. If there is potential for liquid slugging, a suitable trap must be installed to prevent liquid from flooding and damaging the Compressor.

NOTE

Failing to use an appropriate inlet gas scrubber to remove liquids from the gas prior to compression can cause flooding and damage the Compressor.

2.1.2General Installation Guidelines

Follow these general guidelines for installation:

•The Compressor Module must be installed and operated in compliance with all applicable codes and regulations.

•The system must be installed on a level surface.

•Install pipe unions or flanges to connect the system to the inlet and discharge piping for ease of service.

•Install isolation valves on the inlet and discharge piping.

•A common ground must be connected between the Compressor Module and the

Compressor Package chassis. This ground must comply with the National Electric Code (NEC) and any other applicable codes.

•Solid debris also must be removed from the gas prior to compression. When required, use a 5 to 10-micron inlet filter to remove debris from the gas stream. The degree of filtration required depends on the specific application.

2.2Inlet and Discharge Pressures

Refer to Table 1 for acceptable inlet and discharge pressure levels.

	Table 1	Inlet and discharge pressure limits
	Type		Level	Operating Guidelines
	Minimum Inlet		0.75 psig / 2" water	Consult factory for operations below 0.0 psig.
	Pressure		column (model specific)
	Maximum Inlet		10 / 25 psig	Operation at pressures above 25 psig will result in:
				• Excessive oil carryover
	Pressure		(model specific)
				• Loss of oil from the Compressor Module
				When the discharge pressure of the Compressor Module reaches
				the maximum, which ranges from 70 to 190 psig, depending on the
	Discharge		70 psig	model (see Compressor Module Nomenclature on page iv):
				• The Compressor Module goes into high discharge pressure
			to
	Pressure			recycle if equipped.
			190 psig
	Range			• The Compressor Module’s bypass regulator diverts gas from the
			(depends on model)
				high-pressure side to the low-pressure side of the module.
				All Compressor Modules must be equipped with pressure-limiting
				or relief devices.
	Minimum			A minimum pressure differential of 70 psi between inlet and
	Differential		70 psi
				discharge pressure is required for proper operation.
	Pressure

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