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SZO56
User Manual
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User Manual
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Emerson SZO56, SZV32, SZV44, SZO44 User Manual

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Page 1
Copeland Scroll® Compressor Module
Installation, Operation & Maintenance Manual
Model Family SZV32 SZV44 SZO44 SZO56
Page 2
Page 3
Dual-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 ........................................................................................................................17
3.1 Initial Startup - Compressor Module ........................................................................................... 17
3.1.1 Pre-Startup Checklist .....................................................................................................................17
3.1.2 Post-Startup Checklist ................................................................................................................... 17
3.2 Initial Startup - Compressor Package ......................................................................................... 18
3.3 Normal Operation Checklist ........................................................................................................ 18
4.0 maiNteNaNCe ....................................................................................................................19
4.1 Routine Maintenance .................................................................................................................. 19
Page 4
Dual-Compressor Module TABLE OF CONTENTS
4.2 Maintenance Tools ...................................................................................................................... 20
4.3 Checking the Oil Level ................................................................................................................ 21
4.3.1 Oil Level Guidelines - Minimum Speed .........................................................................................21
4.3.2 Oil Level Guidelines - Maximum Speed ........................................................................................21
4.4 Oil Capacity and Type ................................................................................................................. 21
4.5 Adding and Removing Oil ........................................................................................................... 22
4.5.1 Topping Off the Oil Level ...............................................................................................................22
4.5.2 Changing the Oil ............................................................................................................................ 23
4.6 Cleaning the Inlet Screen ........................................................................................................... 25
4.7 Servicing the Scavenge Line Orice ........................................................................................... 25
4.8 Changing the Second-Stage Separator Element........................................................................ 26
4.9 Changing the Oil Filter Element .................................................................................................. 26
5.0 troubleshootiNg .............................................................................................................27
5.1 Troubleshooting Guide ............................................................................................................... 27
5.2 Motor Winding Resistance .......................................................................................................... 27
5.3 Platform Symptoms Diagnosis .................................................................................................... 28
6.0 speCifiCatioNs ..................................................................................................................29
appeNdix a material data safety sheet ....................................................................................32
A.1 Supplier ....................................................................................................................................... 32
A.2 Product Name and Information ................................................................................................... 32
A.3 Components and Hazard Statement .......................................................................................... 32
A.4 Safe Handling and Storage......................................................................................................... 32
A.5 Physical Data .............................................................................................................................. 32
A.6 Fire and Explosion Hazards ........................................................................................................ 33
A.7 Reactivity Data ............................................................................................................................ 33
A.8 Health Hazard Data .................................................................................................................... 33
A.9 Personal Protection Information ................................................................................................. 33
A.10 Spill or Leak Procedures ............................................................................................................. 33
A.11 Waste Disposal Methods ............................................................................................................ 33
Page 5
Dual-Compressor Module TABLE OF CONTENTS
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 Power Terminations .............................................................................................................................14
Figure 14 Maintenance Tools ...............................................................................................................................18
Figure 15 Adding or Draining Oil ......................................................................................................................... 21
Figure 16 Gas Inlet Block and Screen ................................................................................................................23
Figure 17 Scavenge Line Orice ......................................................................................................................... 23
Figure 18 Oil Filter Bowl and Element .................................................................................................................. 24
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 ...................................................................................................................................25
Table 5 Motor winding resistance .....................................................................................................................25
Table 6 Platform troubleshooting guidelines ..................................................................................................... 26
Table 7 Compressor Module specications ...................................................................................................... 27
Table 8 Compressor Module ow, pressure and horsepower data (see Notes 1 - 3*) .....................................29
iii 2006SSD-75 R4 (10/10)
Page 6
Dual-Compressor Module Compressor Module Nomenclature
Compressor module NomeNClature
Oil
High
Max Delivery Pressure
Model
SZO56C1A-EDE-110 150 260 30 215
SZO44C1A-EDE-140 190 200 30 215
SZO44C1A-EDE-244 190 200 30 215
SZV44C1A-EDE-140 190 200 30 215
SZV32C1A-EDE-150 275 150 30 290
(PSIG)
Max
Flow
(MCFD)
Drive
HP
Press
Switch
Setting
(PSIG)
Dual Scroll Units
Low
Press
Switch
Setting
0.75 PSIG
(52 mbarg)
0.75 PSIG
(52 mbarg)
0.75 PSIG
(52 mbarg)
0.75 PSIG
(52 mbarg)
0.75 PSIG
(52 mbarg)
High Temp
Setting
°F (°C)
240 (116) 200 NO 625
240 (116) 200 NO 625
240 (116) 200 YES 625
280 (138) 250 NO 625
280 (138) 250 NO 625
Thermal
Bypass
Valve
Setpoint
°F (°C)
Gas Bypass
Valve
Module Weight
(Lbs.)
Page 7
Dual-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
qualied 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 qualied 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.
1 2006SSD-75 R4 (10/10)
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Dual-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.
2 Form No. 2006SSD-75 (5/06) Rev. 0
Page 9
Dual-Compressor Module Introduction
1.0 iNtroduCtioN
The Copeland Scroll® SZO44 Compressor Module comes equipped with two Copeland Scroll® Compressors designed for Class I, Division II applications. The Compressor Module is designed for
assembly into a Compressor Package ready for service in the eld; 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 SZO44 Compressor Module shown in Section 1.1
• Compressor - a Copeland Scroll® Compressor (two per Compressor Module)
• Compressor Package - the entire assembly, including the Compressor Module, ready for service in
the eld
• Packagers - the company that prepares the Compressor Module for service
• VFD - Variable Frequency Drive used to power a variable speed Compressor Module
1.1 The Compressor Module
The Compressor Module consists of two Compressors and the other components shown in Figure 1.
Figure 1 Compressor Module Components
LEFT SIDE VIEW
Oil circuit
lter
RIGHT SIDE VIEW
Oil coolers with fans (2)
Oil circuit thermal bypass valve
Copeland Scroll compressors (2) for Class I, Divison II
Suction gas connection (1-1/2" NPT)
Inlet check valves (2)
®
Oil level
First-stage oil separator
sight tube
Inlet suction screen
High discharge gas pressure switch
High discharge gas temp switch
Fan speed thermistor
Oil cooler fans (2)
Control wiring terminations
Power wiring terminations
Second-stage separator
Discharge gas connection (1" NPT)
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Dual-Compressor Module Introduction
1.2 The Compressor
The Compressor refers to the Copeland Scroll® Compressor. Each Compressor Module has two Compressors. Figure 2 shows a cross-section of a Compressor and its key components.
Figure 2 Copeland Scroll® Compressor Cross Section
1.3 The Compressor Package
The Compressor Package consists of the Compressor Module housed in an assembly ready for service
in the eld. Equipment Packagers customize the assembly and complete the fabrication for Compressor Modules for each application. Figure 3 shows a simplied example of a Compressor Package.
Figure 3 Typical Compressor Package
Control and power panel
Oil cooler
Inlet gas scrubber for liquid removal
Gas aftercooler (if applicable)
Compressor Module
4 Form No. 2006SSD-75 (5/06) Rev. 0 4 Form No. 2006SSD-75 (5/06) Rev. 0
Page 11
Dual-Compressor Module Installation
2.0 iNstallatioN
2.1 Installation Guidelines
2.1.1 Required 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 ooding and
damaging the Compressor.
NOTE
Failing to use an appropriate inlet gas scrubber to remove liquids from the gas prior to
compression can cause ooding and damage the Compressor.
2.1.2 General 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 anges 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 10­micron inlet lter to remove debris from the gas stream. The degree of ltration required depends on the specic application.
2.2 Inlet 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 Pressure
Maximum Inlet Pressure
Discharge Pressure Range
0.75 psig Consult the factory for operations below 0.75 psig.
25 psig
70 psig
to
190 psig
(depends
on model)
Operation at pressures above 25 psig will result in:
• Excessive oil carryover
• 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 model (see Compressor Module Nomenclature on page iv):
• The Compressor Module goes into high discharge pressure recycle if
equipped.
• The Compressor Module’s bypass regulator diverts gas from the high-pressure
side to the low-pressure side of the module. All Compressor Modules must be equipped with pressure-limiting or relief devices. A minimum pressure differential of 70 psi between inlet and discharge pressure is required for proper operation.
5 2006SSD-75 R4 (10/10)
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Dual-Compressor Module Installation
NOTE: Required Component – High Pressure Discharge Gas Bypass Valve
In response to customer requests to eliminate redundancy, the high pressure discharge gas bypass (recycle)
valve was removed from some of the scroll modules (see table below).
Model
SZO56C1A-EDE-110
SZO44C1A-EDE-140
SZO44C1A-EDE-244
SZV44C1A-EDE-140
SZV32C1A-EDE-150
Max Delivery Pressure
PSIG
(barg)
150
(10.3)
190
(13.1)
190
(13.1)
190
(13.1)
275
(19.0)
Max
Flow
MCFD
(MCMD)
260
(7.36)
200
(5.7)
200
(5.7)
200
(5.7)
150
(4.2)
Drive
HP
30
30
30
30
30
High
Press
Switch
Setting
PSIG
(barg)
Dual Scroll Units
215
(14.8)
215
(14.8)
215
(14.8)
215
(14.8)
290
(20.0)
Low
Press
Switch
Setting
0.75 PSIG
(52 mbarg)
0.75 PSIG
(52 mbarg)
0.75 PSIG
(52 mbarg)
0.75 PSIG
(52 mbarg)
0.75 PSIG
(52 mbarg)
High Temp
Setting
°F (°C)
240
(116)
240
(116)
240
(116)
280
(138)
280
(138)
Oil
Thermal
Bypass
Valve
Setpoint
°F (°C)
200
(93)
200 (93)
200 (93)
250
(121)
250
(121)
Gas Bypass
Valve
NO
NO
YES
NO
NO
There are several reasons for making this change:
• Locating the valve at the module level becomes redundant when two or more of our modules are
packaged together.
Module Weight
Lbs. (kg)
600
(272)
600
(272)
625
(283)
625
(283)
600
(272)
• The original intent of the valve was to provide a means for the module to operate in cases where the discharge was 100% blocked due to a downstream event; however, packagers are ultimately responsible
for high pressure relief.
• When in use, the valve can act as an expansion valve when gas is passing through it, possibly
condensing water and or hydrocarbons which could be detrimental to our modules.
• The valve is a back pressure regulator which can maintain a steady discharge pressure, however the
majority of packages with our modules are controlled through suction gas recycle. Also, most packages have a back pressure regulator on the discharge of our modules to control the actual discharge pressure to a minimum of 70 PSIG.
• The presence of the valve was thought to protect the end user in case the discharge of our module is
isolated from the skid-level pressure relief valve and the other safeties on our module (high pressure
switch, drive current limit) are disabled or modied. However, inspectors do not consider our gas bypass valve to be a high pressure safety device. It is the packager’s responsibility to provide adequate high
pressure safety relief/shutdown.
Packagers will need to install downstream pressure relief of our module.
2.3 Ambient Temperature Range
The Compressor Module operating ambient temperature is 20°F to +122°F (-29° to +50°C). For details on ambient temperatures for VFD startup and Compressor Module operation, see Table 7 on page 27.
6 2006SSD-75 R4 (10/10)
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Dual-Compressor Module Installation
2.4 Installation Clearance and Dimensions
Allow sufcient clearance on all sides for service access, especially for gas and electrical connections at
the rear of the Compressor Module. Check applicable national and local electrical codes.
Cooling air ow is back to front—from the gas connection end to the oil cooler end. Do not block or restrict
the cooler fans or oil cooler.
Refer to Figure 4 for the dimensions of the Compressor Module.
Figure 4 Compressor Module Dimensions, in. (mm)
TOP VIEW
FRONT VIEW
SIDE VIEW
BOTTOM VIEW
7 2006SSD-75 R4 (10/10) 6 2006SSD-75 R4 (10/10)
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Dual-Compressor Module Installation
PI
002
TE
002
TS
002
TSHH
002
PI
003
EX-04
BPV-01
SEP-01
TCV-03
FL-05
PS
002
PSHH
002
PS 001
PSLL
001
480V
J.B.
SEP-02
Module Limits
Gas Suction 1-1/2" -NPT
Gas Discharge
1" -NPT
C-02
C-01
2.5 Process and Instrumentation Diagrams (P&IDs)
Figure 5 Compressor Module Gas and Oil Flow Diagram and Safety Shutdowns
Code Description
BPV-01 Gas bypass valve (optional) C-01 / C-02 Compressor and motor EX-04 Oil cooler, fan controlled by thermistor FL-05 Oil lter PI002 Pressure gauge on rst-stage oil separator PI003 Pressure gauge on second-stage oil separator PS002 / PSHH002 High discharge gas pressure switch PS001 / PSLL001 Inlet low pressure switch SEP-01 First-stage oil separator, 6” O.D. SEP-02 Second-stage oil separator/coalescing element TCV-03 Thermal bypass valve, 3-way, set @ 200°F (93°C) TE002 Fan speed thermistor TS002 / TSHH002 High discharge gas temp switch
8 2006SSD-75 R4 (10/10)
Page 15
Dual-Compressor Module Installation
2.6 Electrical Controls
2.6.1 General Considerations
All shutdown devices are dry contact switches rated Class I, Division II that are wired to a terminal box for connection to the packager supplied control circuit. The common wires on all switches are connected together. All switches are closed unless a fault condition is detected.
All safety and protective devices must be installed and used in accordance with applicable codes and regulations.
Switches
All switch connections are wired to terminal strips in a junction box on the Compressor Module.
Switch Status
• Low Inlet Gas Pressure Normally Open, closes on pressure rise
• High Discharge Gas Pressure Normally Closed, opens on pressure rise
• High Temperature Normally Closed, opens on temperature rise
Electrical Considerations - Variable Speed Compressor Module
• The Compressor power for a variable speed Compressor Module is the Variable Frequency Drive (VFD).
• Compressor speed control can be either a 4-20 mA or 0-10V signal (transducer supplied by customer)
applied to the VFD. Speed can also be manually controlled with a potentiometer or the VFD can be
set for a xed speed.
• Each Compressor on a module must be protected by an individual manual reset overload between
the VFD and the Compressor.
• The overloads should be able to be set at a maximum of 26A.
• If either overload opens, the VFD must be disabled.
• The overloads must be congured for manual reset.
• Normal full load run current for each Compressor on the module at 4800 rpm (80 Hz) is approximately
23A.
• The customer control circuit must supply an Enable signal to the VFD before the drive will accept a Run Fwd signal.
• The VFD will start when the Enable signal is on and a Run Fwd signal is applied.
• The VFD will stop if the Run Fwd signal is off or the Enable signal is removed.
NOTE
The drive provides 24V for the Enable and Run Fwd signals.
The installer must connect the Enable and Run Forward terminals to the drive’s 24V terminal.
9 2006SSD-75 R4 (10/10) 8 2006SSD-75 R4 (10/10)
Page 16
Dual-Compressor Module Installation
RED
Blue
White
Yellow
+24VDC
DC co mmon
No connection feedback
0-10VDC speed signal
Dropping Resistor One Fan 100 K Ohms Two Fans 60.4 K Ohms
PTC Thermistor In Thermowell
The PTC Thermistor is nonlinear and switches to high resistance in the 170-190°F (77-88°C) range.
Red Wire – 24VDC
Yellow Wire – 0-24VDC To fan speed control
Blue Wire – DC Common
2.6.2 Oil Cooler Fan Control
The Compressor Module temperature is controlled by managing module oil ow and temperature. The module’s precise temperature control is critical to system performance and equipment life. Maintaining
proper temperature control also reduces the possibility of gas condensing into liquids during operation.
• Cooling fans require 24VDC, 4.5A (105 Watts) x 2 (9A 210W total) for the Compressor Module. Fan
speed is controlled by a 0-10VDC control signal that is applied to the yellow lead on the fan terminal strip. Standard Compressor Modules use a nonlinear PTC thermistor to monitor oil temperature and provide a speed signal.
• High temperature Compressor Modules use a linear NTC thermistor to monitor oil temperature. This
signal is available to support a customer-provided fan speed control circuit.
• All power connections are wired to terminal strips in a junction box on the Compressor Module.
Figure 6 Brushless DC Fan
Figure 7 Basic Fan Control System
Page 17
Dual-Compressor Module Installation
Power Supply
24VDC
PLC
Or
Temperature
Control
SZO44 Compressor Module
0-10VDC Fan Speed Signal
0.9V = Off; 1.3V = 50%; 10V = 100%
Temperature Sensor
A B
C
Oil Cooler
Return
to Compressor
1st-Stage Separator
Figure 8 Optional Customer-Installed High Temperature Fan Control System
• Compressor requirements: 1.2 to 2 GPM (4.5-755 LPM) ow rate
• Operating temperature range, standard: 190° to 210°F (88°- 99°C)
• Thermal oil bypass valve, standard setting: 200°F (93°C)
• Thermal bypass valve operation (valve’s purpose is to provide discharge temperature control)
• Oil ow on valve is A to B when the unit is cold and A to C when the heat rises (see Figure 9).
Figure 9 Oil Cooling and Thermal Valve
11 2006SSD-75 R4 (10/10) 10 2006SSD-75 R4 (10/10)
Page 18
Dual-Compressor Module Installation
Variable
Frequency
Drive
MS2
OL2
480VAC
Variable Speed
480VAC
Fixed Speed
Drive Inhibit
MS 1 & 2 Inhibit
Compressor 2
Compressor 2Compressor 1
Compressor 1
OL1 OL2
MS1
OL1
2.6.3 Compressor Module Motor Protection
Variable Speed Compressor Module Protection
• The two Compressors in the variable speed Compressor Module should be treated as a single
Compressor. Both Compressors must be run at the same time to prevent oil from accumulating in one Compressor. Module capacity can be changed by varying the typical Compressor speed, ranging from 2400 to 4800 rpm.
• If two or more Compressor Modules are used together, each module can be considered as one
Compressor and individual modules can be turned off.
• Each Compressor on a variable speed Compressor Module requires independent overload protection
between the VFD and Compressor. See 2.6.1 on page 10.
Figure 10 Motor Control
Page 19
Dual-Compressor Module Installation
1
2
3
4
5 5
Optional if more than one
compressor module used
Power
to Compressors
(2)
24VDC
Cooling
Fan
24V Discrete Inputs
from Scroll Module
1 1
2.6.4 Electrical Requirements
Figure 11 Typical Compressor Module Electrical Requirements
Code Description
1 Control Techniques VFD,* 30 HP
2 24VDC power supply **
Optional if more than one Compressor Module used
3 PLC or other control for inputs from
Compressor Module
4 480V 3-phase input ***
5 Overload protection device, 2 required
Notes * VFD on Variable Speed Drive models. ** All other components supplied by Packagers. *** Contact factory for information about single-phase
applications.
Table 2 Typical Compressor Module power supply requirements
Compressor Power (data based on 480VAC) Variable Speed
Module horsepower 30 HP VFD voltage supply range 342-528VAC Phase 3-phase* Frequency 50/60 Hz Maximum VFD input current 37A
Low Voltage DC Specications - Oil Cooler Fan Voltage and Power
Fan motor voltage 24VDC Total fan motor current 9A
Additional power may be required to support customer logic and control circuits. * Contact factory for information about single-phase applications. ** Reduced capacity at 50 Hz.
13 2006SSD-75 R4 (10/10) 12 2006SSD-75 R4 (10/10)
Page 20
Dual-Compressor Module Installation
Terminal Strip
Red Lead (HDP)
Blue Lead (LIP)
Red Lead (HT)
Red Lead – To Fan +24VDC
Yellow Lead – To Fan Run
Blue Lead (Thermistor)
Blue Lead – To Fan DC Common
Brown Lead (LIP)
Brown Lead (HDP)
Brown Lead (HT)
Green/Yellow Lead (HT)
Green/Yellow Lead (HDP)
Green/Yellow Lead – Fan Ground
60K Resistor
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Green/Yellow Lead (LIP)
Black Lead (OFD)
Jumper
Jumper
Yellow Lead (Thermistor)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Terminal Strip
Black Lead Compressor 1 (L1)
1L1
2L2
3L3
4L1
5L2
6L3
7G1
8G1
1L1
2L2
3L3
4L1
5L2
6L3
7G1
8G1
Black Lead Compressor 1 (L2)
Black Lead Compressor 1 (L3)
Black Lead Compressor 2 (L1)
Black Lead Compressor 2 (L2)
Black Lead Compressor 2 (L3)
Green Lead Compressor 1 (G1)
Green Lead Compressor 2 (G1)
Cont rol w iring terminations
Po we r wir ing terminations
2.6.5 Wiring
Figure 12 Control Circuit Terminations
Figure 13 Power Terminations
From VFD
From VFD
From VFD
Page 21
Dual-Compressor Module Operation
3.0 operatioN
3.1 Initial Startup - Compressor Module
The following inspections should be made on initial startup—-typically, by the Packager—and after long periods of storage.
• Verify acceptable pre-startup conditions using the checklist in 3.1.1 - Pre-Startup Checklist.
• Start the Compressor Module, then perform the checks in 3.1.2 - Post-Startup Checklist.
3.1.1 Pre-Startup Checklist
Perform these checks BEFORE starting the Compressor Module:
MAIN POWER
Check for the following conditions: ___ 1. Motor type is correct for the application,
either Variable Speed (275V) or Fixed Speed motor (480V).
___ 2. Power phasing to the terminal strip and
Compressors is correct.
___ 3. Supply voltage to the Variable Frequency
Drive (VFD) or Fixed Speed Compressor motors is correct.
___ 4. Each Compressor motor is equipped with
current overload protection.
___ 5. Compressor motor overloads are congured
to inhibit the VFD or either xed speed
Compressor if either motor overload opens.
___ 6. Compressor motor overloads are congured
for manual reset.
___ 7. Compressor motor overloads are set for
proper current. ___ 8. All chassis, earth grounds are connected. ___ 9. A load reactor or other approved lter is
installed for systems with power lead lengths
in excess of 200 ft. (61m) between the VFD
and Compressor Module terminal box.
LOW VOLTAGE DEVICES
Verify these conditions for low voltage devices: ___ 1. DC polarity is correct. ___ 2. Temperature control device—if other than
standard thermistor control—is working
properly.
SAFETY AND CONTROL DEVICES
Make sure that all safety and control switches and devices are congured to inhibit Compressor operation if a fault condition is detected, including:
___ 1. Low inlet pressure switch ___ 2. High discharge pressure switch ___ 3. High temperature switch ___ 4. Variable Frequency Drive (VFD) fault ___ 5. Motor overload trip ___ 6. Other safety and control switches and
devices
MECHANICAL SYSTEMS
Inspect for these conditions: ___ 1. (Required) Compressor inlet is protected
from water slugging.
___ 2. (Recommended) Gas ltration and
treatment is appropriate for the application.
___ 3. Packager conguration applies back
pressure to the Compressors.
___ 4. Inlet and discharge valves allow the
module to be isolated.
___ 5. All guards and protective covers are
installed.
___ 6. Protection from freezing is provided if
needed for the application and location.
___ 7. A suitable enclosure providing protection
from the elements is appropriate for the application and location.
3.1.2 Post-Startup Checklist
Perform these checks AFTER starting the Compressor Module:
DURING INITIAL OPERATION, PERFORM THESE CHECKS:
___ 1. Compressor Module builds pressure on initial startup; no unusual mechanical noise.
___ 2. Oil level is correct at minimum and maximum speeds. ___ 3. No gas leaks are present. ___ 4. No oil leaks are present. ___ 5. Oil cooler fans turn on and run at the appropriate temperature. ___ 6. Oil cooler fan speed varies with temperature.
___ 7. Compressor motor speed varies appropriately for the Packager conguration.
___ 8. Compressor continues to operate in bypass when the Compressor Module discharge is blocked. ___ 9. Compressor Module is leak tight (maintains approximately 30 psig or more when the Compressors are initially
turned off).
15 2006SSD-75 R4 (10/10) 14 2006SSD-75 R4 (10/10)
Page 22
Dual-Compressor Module Operation
3.2 Initial Startup - Compressor Package
Refer to your Packager’s user manual for information on procedures to start up the Compressor Package,
which includes equipment added to the Compressor Module by the Packager.
3.3 Normal Operation Checklist
Observe the following conditions after startup—when power is applied to the VFD and the VFD receives the signal from the Compressor Package control system to run:
CHECK FOR THESE CONDITIONS UNDER NORMAL OPERATION:
___ 1. Compressor speed should range from 2400 to 4800 rpm during normal operation.
___ 2. Suction pressure should range from 0.75 psig to 25 psig.
___ 3. Discharge pressure should range from 70 psig to 190 psig, depending on the model
(see Compressor Module Nomenclature on page iv).
___ 4. Pressure differential between suction and discharge is at least 70 psi.
___ 5. First-stage separator temperature should be between 170°F and 220°F (77-104°C).
___ 6. Oil cooler fans should either run continuously or cycle periodically under normal conditions.
If any of these conditions are not met during normal operation, shut down the unit and refer to 5.0 - Troubleshooting on page 25.
Page 23
Dual-Compressor Module Maintenance
4.0 maiNteNaNCe
4.1 Routine Maintenance
Perform the maintenance procedures in Table 3 at least once per year or more often if needed.
Oil consumption varies by application and during initial operation. Monitor the oil level routinely to determine a consistent pattern of actual consumption.
Table 3 Maintenance summary
Components Maintenance Reason For details, see:
4.3 - Checking
Lubrication & Cooling System
Gas Inlet System
Second­Stage Separator System
Oil Heat Exchanger
• Monitor and check the oil level.
• Add oil as needed.
• Change oil annually.
Note: Some applications may require more
frequent service.
• Check the condition of the lubricant
periodically. Normal color is clear or light gray.
• Change the oil lter (if equipped) annually or as required.
• Inspect and clean the inlet screen annually or more often as needed.
• Inspect and clean the scavenge line orice
annually or more often as needed.
• Change the second-stage oil separator
element annually or more often if contaminated.
Note: Some applications may require more
frequent service.
• Ensure heat exchanger cooling ns are clear
of dust and debris.
• Verify that the fans run freely.
A low oil level or loss of oil in the system will result in overheating or mechanical failure.
A high oil level may result in excessive oil carryover and oil discharge from the Compressor Module when the Compressors are turned off.
A restricted inlet screen
will result in reduced ow.
A restricted scavenge
line orice will result in
excessive oil carryover.
A dirty or plugged separator element will result in excessive oil carryover.
— —
the Oil Level (page 18)
4.5.1 - Topping Off the Oil Level (page 19)
4.5.2 - Changing the Oil (page 20)
4.6 - Cleaning the Inlet Screen (page 22)
4.7 - Servicing the Scavenge
Line Orice
(page 22)
4.8 - Changing the Second­Stage Separator Element (page 23)
—
—
See 5.0 - Troubleshooting on page 25 for additional details.
17 2006SSD-75 R4 (10/10) 16 2006SSD-75 R4 (10/10)
Page 24
Dual-Compressor Module Maintenance
4.2 Maintenance Tools
Figure 14 shows the tools needed for maintenance of the Compressor Module. Contact the Packager to
obtain a maintenance tool kit. These are typical air conditioning and refrigeration service tools.
Figure 14 Maintenance Tools
Back-seating control valve
Oil pump, piston type,
high pressure
Designed to operate
up to 250 psig
Filter wrench
Alternate product:
Strap lter wrench
Charging hose
60" (1524mm)
Extension hose with valve
6" (152mm)
CAUTION
When pressure is applied to the oil pump, the handle may extend rapidly.
Verify the Compressor Module pressure is 0 psig before removing the second-stage oil separator.
NOTE
One full stroke oil pump of the handle dispenses 1.6 oz. (47ml) of oil. Move the pump handle slowly using long, slow, full strokes.
NOTE
The hose ttings contain a core depressor that opens the Schrader valve when the ttings are attached. A backseating control valve can be used to open the Schrader valves on the Compressor Module.
When the knob is turned fully counterclockwise, the core depressor is retracted and the
backseating control valve can be installed on a Schrader valve without loss of oil.
When the knob is turned clockwise, the core retractor is extended, opening the Schrader valve.
Page 25
Dual-Compressor Module Maintenance
Oil level sig ht t ube
4.3 Checking the Oil Level
The proper oil level varies according to the Compressor Module’s operating speed. To check the oil level on the rst-stage oil separator level gauge, use the following guidelines based on operating speed.
NOTE
The oil level indicated on the rst-stage oil separator sight tube varies with inlet and discharge pressures as well as operating speed. Check the oil level when the compressor is running.
4.3.1 Oil Level Guidelines - Minimum Speed
When operating the Compressor Module at minimum speed—2400 rpm, 40 Hz— check the oil level in the oil level sight tube, shown at right, then refer to the following suggested maintenance actions.
If the oil level is: Take this action:
• 1"– 3" from the bottom
of the oil level gauge
• Lower than 1” from the bottom Add factory-supplied PAO oil to this
• Higher than 3” from the bottom Remove excess oil
No action is required.
level (see 4.5.1 - Topping Off the Oil Level on page 20).
(see 4.5.2 - Changing the Oil on page 21).
4.3.2 Oil Level Guidelines - Maximum Speed
When operating the Compressor Module at maximum speed—4800 rpm, 80 Hz— check the oil level in the oil level sight tube, shown at right, then refer to the following suggested maintenance actions.
If the oil level is: Take this action:
• 1"– 3" from the top of the oil
level gauge
• Lower than 3” from the top Add factory-supplied PAO oil to this
• Higher than 1" from the top Remove excess oil
4.4 Oil Capacity and Type
The factory oil charge of the SZO Compressor Module is 380 uid ounces (11.25 liters).
Use the special Poly-Alpha-Olen (PAO) blend available from the Packager. Refer to Appendix A -
Material Data Safety Sheet on page 30 for details.
CAUTION
The Compressor Module REQUIRES a special PAO blend available from your Packager.
Do NOT substitute other types of oil. Using other types of oil will damage the equipment and void the warranty.
No action is required.
level (see 4.5.1 - Topping Off the Oil Level on page 20).
(see 4.5.2 - Changing the Oil on page 21).
19 2006SSD-75 R4 (10/10) 18 2006SSD-75 R4 (10/10)
Page 26
Dual-Compressor Module Maintenance
4.5 Adding and Removing Oil
Oil is drained from the system through the Schrader valves on the Compressor suction ttings, rst-stage
oil separator and oil cooler (see Figure 15 on page 21).
4.5.1 Topping Off the Oil Level
See 4.4 - Oil Capacity and Type on page 19 before adding oil. Also refer to 4.2 - Maintenance Tools on page 18 for information about the tools used in this procedure.
NOTE
Adding oil through the Schrader valve on either compressor suction tting permits adding the oil
with the compressor running.
Adding Oil
1. Turn the knob on the backseating control valve fully counterclockwise.
2. Remove the protective cap from the Schrader valve
on either compressor suction tting and connect the
backseating control valve.
3. Connect one end of the oil transfer hose to the back­seating control valve.
4. Connect the opposite end of the hose to the oil transfer pump.
5. Pour PAO oil into a clean container and attach the extension hose to the threaded neck of the container.
6. Turn the knob on the backseating control valve clockwise to open the Schrader valve and slowly open the oil transfer hose ball valve.
RIGHT SIDE VIEW
CAUTION
When pressure is applied to the oil pump, the handle may extend rapidly.
7. Move the pump handle slowly using long, slow, full strokes on the pump handle to transfer oil into the Compressor until the desired oil level is reached. One full pump stroke dispenses 1.6 oz. (47ml) of oil (see 4.3 - Checking the Oil Level on page 19).
8. Turn the knob on the backseating control valve counterclockwise to close the Schrader valve and remove the control valve.
9. Replace the protective cap on the Schrader valve.
10. Return the Compressor Package to service.
11. Check for leaks at all ttings that have been disturbed.
Page 27
Dual-Compressor Module Maintenance
4.5.2 Changing the Oil
These procedures describe how to drain oil from the system and to replace the oil after draining.
Figure 15 Adding or Draining Oil
LEFT SIDE VIEW RIGHT SIDE VIEWS
Compressor
Schrader Valves
First Stage Oil Separator
Schrader Valve
Compressor
Schrader Valve
Oil Cooler
Draining Oil
Under normal operation, the Compressor and oil circuit remain under pressure when the Compressor is turned off. This pressure can be used to drain most of the oil. It is also possible to use the gas supply pressure to force oil out of the Compressor Module. In some cases it may necessary to pressurize the module with an inert gas to remove the oil.
1. Turn the knob on the backseating control valve fully counterclockwise.
2. Connect the backseating control valve to the Schrader valve near the bottom of the rst-stage oil
separator, shown in Figure 15.
3. Connect one end of the oil transfer hose to the backseating control valve.
4. Place the free end of the hose into a suitable container and turn the knob on the backseating control valve clockwise to open the Schrader valve and open the oil transfer hose ball valve.
5. Leave the valves open until the oil stops owing and gas comes out of the hose; close the valves.
6. Relocate the hose to the Schrader valve on the inlet of one Compressor and repeat Steps 5 and 6. Repeat for the other Compressor on the Compressor Module.
7. Move the hose to the Schrader valve on the oil cooler and repeat Steps 5 and 6.
8. Close the valves, remove the service hose and replace the protective caps on all Schrader valves.
9. Note the volume of oil that has been drained from the Compressor Module; replace the oil as
described in the next section, Replacing Oil on page 22.
21 2006SSD-75 R4 (10/10) 20 2006SSD-75 R4 (10/10)
Page 28
Dual-Compressor Module Maintenance
Schrader valve
LEFT SIDE VIEW
Oil level sig ht tub e
First-stage oil separator
Replacing Oil
1. Turn the knob on the backseating control valve fully counterclockwise.
2. Remove the protective cap from the Schrader valve on
the rst-stage oil separator (shown at right) and connect
the backseating control valve.
3. Connect one end of the oil transfer hose to the back­seating control valve.
4. Connect the opposite end of the hose to the oil transfer pump.
5. Connect the 6” (152mm) extension hose to the oil transfer pump.
6. Pour PAO oil into a clean container and install the oil transfer pump.
7. Turn the knob on the backseating control valve clockwise to open the Schrader valve.
CAUTION
When pressure is applied to the oil pump, the handle may extend rapidly.
8. Move the pump handle slowly using long, slow, full strokes on the pump handle to transfer oil into the Compressor until the desired oil level is reached. One full pump stroke dispenses 1.6 oz. (47ml) of oil (see 4.3 - Checking the Oil Level on page 19).
9. After adding the same amount of oil that was drained from the Compressor Module, start the Compressors and verify that the operating oil level is correct (see 4.3 - Checking the Oil Level on page 2). If necessary, adjust the oil level (see 4.5.1 - Topping the Oil Level on page 20).
10. Turn the knob on the backseating control valve counterclockwise to close the Schrader valve.
11. Replace the protective cap on the Schrader valve.
12. Return the Compressor Package to service.
13. Check for leaks at all ttings that have been disturbed.
Page 29
Dual-Compressor Module Maintenance
Orifice
4.6 Cleaning the Inlet Screen
The 30-mesh screen in the inlet block must remain unobstructed for optimal ow rate. If the ow rate is
lower than expected even when the Compressor is running properly, this screen may be obstructed.
Figure 16 Gas Inlet Block and Screen
To inspect and clean the inlet screen:
1. Turn off and isolate the Compressor from all power sources.
2. Turn off the gas supply.
3. Vent the system to 0 psig.
4. Remove the SAE plug on the side of the inlet block.
5. Remove the screen.
6. Inspect the screen and inside of the block. Clean or replace if necessary.
7. Replace SAE nut.
8. Return the Compressor Package to service.
9. Check for leaks at all ttings that have been disturbed.
4.7 Servicing the Scavenge Line Orice
The scavenge line orice in the oil separator block must remain clear of obstruction. If this orice is
restricted, the secondstage oil separator can become saturated, increasing oil consumption.
Figure 17 Scavenge Line Orice
To inspect and clean the orice:
1. Turn off and isolate the Compressor from all power sources.
2. Turn off the gas supply.
3. Vent the system to 0 psig.
4. Disconnect the tube and remove the tting.
5. Inspect the screen. Clean or replace the tting assembly if necessary.
6. Replace the tting and reconnect the tube. Tighten the swage nut hand tight plus 1/4 turn.
7. Return the Compressor Package to service.
8. Check for leaks at all ttings that have been disturbed.
23 2006SSD-75 R4 (10/10) 22 2006SSD-75 R4 (10/10)
Page 30
Dual-Compressor Module Maintenance
Oi l fil te r elemen t
(inside oil filter bowl)
Oil filter bow l
4.8 Changing the Second-Stage Separator Element
To replace the second-stage separator element:
1. Turn off and isolate the Compressor from all power sources.
2. Turn off the gas supply.
3. Vent the system to 0 psig. Follow applicable safety procedures and codes.
4. Loosen the separator element by turning it counterclockwise with a strap wrench.
5. Remove the separator element. Verify the gasket is removed with the separator.
6. Inspect the separator block for contaminants and remove any debris.
7. Apply a small amount of oil to the gasket and internal "O" ring on the new separator element.
8. Install the element on the separator block; turn clockwise to tighten.
9. Return the Compressor Package to service.
10. Check for leaks at all ttings that have been disturbed.
4.9 Changing the Oil Filter Element
To replace the oil lter element:
1. Turn off and isolate the Compressor from all power sources.
2. Turn off the gas supply.
3. Vent the system to 0 psig. Follow applicable safety procedures and codes.
4. Remove the oil lter bowl by turning it counterclockwise. Note: The bowl will be lled with oil.
5. Remove the oil lter element from the lter block by pulling the element down.
6. Clean the oil lter bowl.
7. Install a new oil lter element in the lter block.
8. Apply a small amount of oil to the O-rings.
9. Replace the oil lter bowl by turning it clockwise.
10. Return the Compressor Package to service.
11. Check for leaks at the oil lter bowl and at all ttings that have been disturbed.
12. Check the oil level (see 4.3 - Checking the Oil Level on page 19). If necessary, adjust the oil level (see 4.5.1 - Topping the Oil Level on page 20).
Figure 18 Oil Filter Bowl and Element
Page 31
Dual-Compressor Module Troubleshooting
5.0 troubleshootiNg
This section offers tips for troubleshooting.
5.1 Troubleshooting Guide
Refer to Table 4 for recommended solutions to typical problems.
Table 4 Troubleshooting
Problem Recommended Actions
Low Inlet Gas Pressure Fault
High Oil Temperature Fault
High Discharge Pressure Fault
VFD Fault • The drive LED will display the specic fault
• Closed gas inlet valve.
• Restricted or insufcient gas supply.
• Blocked inlet lter/screen (located internally on the Compressor Module inlet block).
• Blocked air ow across oil cooler.
• Ensure cooling fans are operating when the unit is running and up to temperature; at
approximately 180°F (82°C), fans should start to run at minimum speed.
• Ensure adequate oil level in rst-stage separator (see 4.3 - Checking the Oil Level on page 19).
• Restricted discharge and bypass valve fault.
5.2 Motor Winding Resistance
Table 5 Motor winding resistance
Compressor
Model Motor Winding Resistance
C1A and C3A
C2A
All Compressor Modules
Phase-to-phase
Phase-to-phase
Phase-to-ground
= 1.2 to 1.4 ohms
= 0.7 ohms
= Innity
25 2006SSD-75 R4 (10/10) 24 2006SSD-75 R4 (10/10)
Page 32
Dual-Compressor Module Technical Support and Service
5.3 Platform Symptoms Diagnosis
Use the following guidelines to troubleshoot operating problems.
Table 6 Platform troubleshooting guidelines
Problem
Low Gas Flow
High Oil Carryover
Compressors Won’t Run
Incorrect Compressor Speed
High Temperature
Recommended Actions
• Low inlet pressure
• Insufcient gas supply
• High temperature
• Bypass valve open
• Low Compressor speed
• Restricted inlet screen
• Saturated or dirty secondstage oil separator
• High oil level
• Restricted scavenge orice
• Insufcient back pressure
• Oil dilution
• Determine drive status.
• Is inhibit circuit closed?
• Is run signal present?
• Does the VFD indicate a fault code?
• Low inlet pressure
• High discharge pressure
• High temperature, fan, low oil, oil cooler
• Problem with speed control sensor and related components
• Low oil level
• Restricted oil lter
• Blocked oil cooler air ow
• Oil cooler fan not operating
• Operation conditions outside of Compressor Module specications
Page 33
6.0 speCifiCatioNs
Table 7 Compressor Module Specications
General Information
Inlet pressure range Approximately -.75 to 25 psig
Outlet pressure range
Mechanical Description
Module weight Approximately 660 lb. (300kg)
Suction connection 1.5” NPT
Discharge connection 1.0” NPT
Sound level Approximately 75 dBA @ 1 m, 60 dBA @ 10 m
Vibration 3 mil at 60 Hz
Minimum cold start ambient temperature
Ambient operating temperature range
1,4
1,4
Module dimensions See Figure 4 on page 6
Materials of Construction
Compressor - general Cold rolled steel, aluminum, cast iron as required
Compressor bearings Self-lubricated, sleeve type, steel backed
Oil heat exchanger Aluminum
Oil/gas separator tank Cold rolled steel
Tubes/ttings/skid structure Stainless/carbon steel
Lubrication
Oil type Synthetic, 15 weight, PAO (special factory-supplied blend)
System oil capacity, oz. (ml) 380 uid ounces (11.25 liters)
Projected oil consumption
2
Approximately 40 oz. (0.9 l) / 8,000 hours at 0.25 psig suction (<5 ppm)
System Electrical (Standard)
Minimum VFD ambient startup temperature
3,4
70 to 275 psig (depends on model—see page
iv)
Compressor -20°F (-29°C) VFD power 14°F (-10°C)
0 to 122°F (-18 to 50°C)
+14°F (-10°C)
Power supply to inverter
380 to 480VAC (50/60 Hz)
• Voltage range
• Input frequency range
Overpressure detection (outlet) 215 psig open (290 psig for SZV32)
Underpressure detection (inlet) 0.75 psig open (low pressure system)
Oil overtemperature detection 240°F (110°C) open (280°F for SZV)
Fault output to customer Packager to establish
Run input from customer Dry contact
Gas Medium
Natural gas
H
S maximum content
2
Moisture content
Inlet temperature
1. If the Compressors are started at temperatures above the listed minimums and continue to run, the minimum operating temperature is 20°F (-29°C).
2. Based on sweet gas wellhead gas. Results may vary due to gas quality and site conditions.
3. Do not apply power to the VFD if ambient temperature is below this level.
4. If power is continuously supplied to the VFD when the Compressor is off, the minimum starting temperature is -4°F (-20°C).
5. Consult factory for more details and applications guidelines.
5
5
5
-20 to 115°F (-28 to 46°C); protection from freezing if water is present
100% saturated, no free liquids
450 ppm
Page 34
Dual-Compressor Module Technical Support and Service
Page 35
Compressor Module Horsepower Selection Chart
Module Model Number: SZV32C1A-EDE-150
Configuration Suction
Press
(PSIG)
One Module Package 0 MCFD 50 49
10 MCFD 87 86 85 84 83 81
25 MCFD 144 142 141 139 139 137
50 241 238 236 233 232
65 304 297 295 291 291
Two Module Package 0 100 98
10 174 172 170 168 166 162
MCFD
HP 18 19
HP 19 21 23 25 27 30
HP 21 23 25 27 29 31
Max Flow/HP as a function of discharge
pressure at maximum flow rate (Note 1)
150 175 200 225 250 275
23 25 27 30 32
24 26 28 31 33
37 39
38 42 46 50 54 60
25 288 284 282 278 278 274
42 46 50 54 58 62
50 482 476 472 466 464
46 50 54 60 64
65 608 594 590 582 582
48 52 56 62 66
NOTES:
1. Max ow using varibable speed drive, compressors operating at 80 Hz. max speed.
2. Standard test conditions: 60° F suction gas, 60° F ambient, 0.6 SG gas, 14.7 psia = 0 psig
3. Performance data to be used as an estimation guide only and is subject to change without notice
Page 36
Dual-Compressor Module Technical Support and Service
Compressor Module Horsepower Selection Chart
Module Model Number: SZO56C1A-EDE-240
Configuration Suction
Press
(PSIG)
One Module Package -7.5 MCFD 43 42
0 MCFD 97 96 96 95 94 94 94 93 93
5 MCFD 131 130 130 129 128 128 127 127 126
10 MCFD 165 164 164 163 163 162 161 160
15 MCFD 198 198 197 197 196 195
20 MCFD 232 232 232 231 230 229
25 MCFD 265 264 264 264
Two Module Package -7.5 MCFD 86 84
0 MCFD 194 193 191 190 188 188 188 187 185
5 MCFD 262 261 259 258 257 256 255 253 252
10 MCFD 329 329 328 327 325 323 321 320
15 MCFD 396 396 395 394 392 390
20 MCFD 464 465 463 463 460 458
25 MCFD 530 529 528 527
NOTES:
1. Max ow using varibable speed drive, compressors operating at 80 Hz. max speed.
2. Standard test conditions: 60° F suction gas, 60° F ambient, 0.6 SG gas, 14.7 psia = 0 psig
3. Performance data to be used as an estimation guide only and is subject to change without notice
Max Flow/HP as a function of discharge pressure at maximum flow
MCFD) 70 80 90 100 110 120 130 140 150
HP 19 20
HP 19 21 23 25 26 27 29 30 32
HP 21 23 24 26 27 29 30 31 33
HP 23 24 26 27 28 30 31 33
HP 25 27 28 30 31 32
HP 27 28 30 31 31 32
HP 31 31 32 33
HP 37 40
HP 39 43 46 49 52 55 58 60 63
HP 42 45 49 52 54 57 60 63 66
HP 45 48 51 54 57 60 63 65
HP 51 54 57 59 61 63
HP 54 56 59 62 63 64
HP 62 63 64 65
rate (Note 1)
Page 37
Dual-Compressor Module Technical Support and Service
Compressor Module Horsepower Selection Chart
Module Model Number: SZO44C1A-EDE-244
Configuration Suction
Press
(PSIG)
One Module Package -7.5 MCFD 33 32
10 MCFD 127 126 126 126 125 124 124 123 123 122 122 121 121
15 MCFD 152 152 152 152 151 150 150 149 148 148 147 147
20 MCFD 179 179 178 178 177 176 176 175 175 174 173 173
25 MCFD 204 203 203 203 202 202 201 200 199 199
Two Module Package -7.5 MCFD 66 64
10 MCFD 253 253 252 251 250 249 247 246 246 245 244 243 242
15 MCFD 305 305 304 303 301 300 299 298 297 296 295 294
20 MCFD 357 357 356 356 354 353 352 351 349 348 347 345
25 MCFD 407 407 406 405 404 403 402 400 399 397
NOTES:
1. Max ow using varibable speed drive, compressors operating at 80 Hz. max speed.
2. Standard test conditions: 60° F suction gas, 60° F ambient, 0.6 SG gas, 14.7 psia = 0 psig
3. Performance data to be used as an estimation guide only and is subject to change without notice
Max Flow/HP as a function of discharge pressure at maximum
flow rate (Note 1)
MCFD) 70 80 90 100 110 120 130 140 150 160 170 180 190
HP 14 15
0 MCFD 75 74 74 73 72 72 72 72 71 71 70 70 70
HP 15 16 18 19 20 21 22 23 24 25 26 27 28
5 MCFD 101 100 100 99 99 98 98 97 97 97 96 96 95
HP 16 17 19 20 21 22 23 24 25 26 27 28 29
HP 17 18 19 20 22 23 24 25 26 27 28 29 30
HP 19 20 21 23 23 24 25 27 28 29 30 31
HP 20 21 22 24 24 24 26 28 29 30 31 32
HP 23 24 24 25 27 28 30 31 32 33
HP 28 31
0 MCFD 150 148 147 146 145 145 144 144 143 142 141 140 139
HP 29 32 35 37 39 41 44 46 48 50 52 54 57
5 MCFD 201 201 200 199 197 197 196 195 194 193 192 191 191
HP 32 34 37 39 41 43 46 48 50 52 54 56 58
HP 34 37 39 41 43 45 47 49 51 53 55 58 60
HP 39 41 43 45 46 48 51 53 55 57 60 62
HP 41 43 45 47 47 49 52 55 57 59 61 64
HP 47 48 49 49 53 57 59 61 63 65
31 2006SSD-75 R4 (10/10) 30 2006SSD-75 R4 (10/10)
Page 38
Dual-Compressor Module Material Data Safety Sheet
appeNdix a - material data safety sheet
The information in this material safety data sheet should be provided to all who use, handle, store, transport or are otherwise exposed to this product. CPI believes the information in this document to be reliable and up to date as of the date of publication, but makes no guarantee that it is.
CAUTION
This oil is intended for use only in the Copeland Scroll® Compressor used in natural gas applications.
Use of any other oil may result in failure and is not covered by warranty.
DISPOSE WASTE OIL PROPERLY:
• If the oil has not been contaminated, it can be disposed the same as a synthetic motor oil.
• If the oil is contaminated, the end user must comply with all applicable regulations for disposal
of hazardous materials.
a.1 supplier
CPI Engineering Services Inc. 2300 James Savage Rd. Midland, MI 48642
Emergency Number: (989) 496-3780
a.2 produCt Name aNd iNformatioN
Product (Trade name and synonyms) Chemical Name Poly-Alpha-Olen (PAO) Chemical Family Synthetic Hydrocarbon Formula CAS# Proprietary
CP-6006 Series
C
10nH20n
a.3 CompoNeNts aNd hazard statemeNt
This product is non-hazardous. The product contains no known carcinogens. No special warning labels are required under OSHA 29 CFR 1910.1200.
FDA Statement. This product complies with FDA 21 CFR 178.3570 regarding lubricants for incidental food contact.
a.4 safe haNdliNg aNd storage
Handling. Do not take internally. Avoid contact with skin, eyes, and clothing. Upon contact with skin, wash with soap and water. Flush eyes with water for 15 minutes and consult physician. Wash contaminated clothing before reuse.
Storage. Keep container tightly sealed when not in use.
a.5 physiCal data
Appearance Clear, water-white liquid Boiling Point >300°F (149°C)
Vapor Pressure
Specic Gravity (water=1) 0.79-0.85
Volatiles, Percent by Volume 0% Odor None Solubility in Water Insoluble Evaporation Rate (butyl acetate=1) Nil
<0.01mm Hg @ 20°C (0.00039 in.Hg @ 68°F)
+2
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Dual-Compressor Module Material Data Safety Sheet
a.6 fire aNd explosioN hazards
Flash Point (by Cleveland Open Cup) Flammable Limits Not established Auto-Ignition Temperature No data
Health 0
HMIS Ratings
NFPA Ratings Not established Extinguishing Media Unusual Fire and Explosion Hazards None
Special Fire Fighting Techniques
Flammability 1 Reactivity 0
a.7 reaCtivity data
Stability Stable Hazardous Polymerization Will not occur Incompatible Materials Strong oxidizers Conditions to Avoid Excessive heat Hazardous Decomposition Products
a.8 health hazard data
Threshold Limit Value Situations to Avoid Avoid breathing oil mists.
First Aid Procedures
Ingestion
Inhalation
320-530°F (160-276°C)
Dry chemical; CO
Burning uid may evolve irritating/noxious fumes. Fireghters should
use NIOSH/MNSA-approved self-contained breathing apparatus.
Use water to cool re-exposed containers. Use water carefully near
exposed liquid to avoid frothing and splashing of hot liquid.
Analogous compounds evolve carbon monoxide, carbon dioxide,
and other unidentied fragments when burned. See A.6 - Fire and Explosion Hazards.
3
5mg/m
Consult physician at once. DO NOT INDUCE VOMITING. May cause nausea and diarrhea. Product is not toxic by inhalation. If oil mist is inhaled, remove to fresh air and consult physician.
ACGIH
foam; water spray (fog)
2
To the best of our knowledge the toxicity of this product has not been fully investigated. Analogous compounds are considered to be essentially non-toxic.
a.9 persoNal proteCtioN iNformatioN
Respiratory Protection Use in well ventilated area. Ventilation Local exhaust Protective Gloves Not required, but recommended, especially for prolonged exposure Eye/Face Protection Goggles
a.10 spill or leak proCedures
In case of spill:
• Wear suitable protective equipment, especially goggles.
• Stop source of spill.
• Dike spill area.
• Use absorbent materials to soak up uid (e.g., sand, sawdust, commercially available materials).
• Wash spill area with large amounts of water.
• Properly dispose of all materials.
a.11 Waste disposal methods
Incinerate this product and all associated wastes in a licensed facility in accordance with federal, state, and local regulations.
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EmersonClimate.com
Vilter Manufacturing LLC P.O. Box 8904 Cudahy, WI 53110-8904 P 414 744 0111 F 414744 1769 www.vilter.com
Copeland Scroll and Emerson are trademarks of Emerson Electric Co. or one of its affiliated companies.
©2011 Emerson Climate Technoligies, Inc. All rights reserved. Printed in the USA.
2006SSD-75 R4
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