Emerson SZV22, SZO22 User Manual
Copeland Scroll® Compressor Module
Installation, Operation & Maintenance Manual
Oil & Gas Compression
Model Family
SZO22
SZV22
400/480VAC,
50/60 Hz,
3-Phase
Single-Compressor Module TABLE OF CONTENTS
TABLE OF CONTENTS
COMPRESSOR MODULE NOMENCLATURE .............................................................................................IV
IMPORTANT SAFETY INFORMATION .......................................................................................................1
1.0 I
NTRODUCTION ......................................................................................................................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
i 2008SSD-34 (5/08)
Single-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 Orifi 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
7.0 T
A
PPENDIX A MATERIAL DATA SAFETY SHEET ...................................................................................35
A.1 Supplier ....................................................................................................................................... 35
A.2 Product Name and Information ................................................................................................... 35
A.3 Components and Hazard Statement ..........................................................................................35
A.4 Safe Handling and Storage......................................................................................................... 35
A.5 Physical Data ............................................................................................................ .................. 35
A.6 Fire and Explosion Hazards ........................................................................................................ 36
ECHNICAL SUPPORT AND SERVICE .......................................................................................34
A.7 Reactivity Data ............................................................................................................................ 36
A.8 Health Hazard Data .................................................................................................................... 36
A.9 Personal Protection Information ................................................................................................. 36
A.10 Spill or Leak Procedures ............................................................................................................. 36
A.11 Waste Disposal Methods ............................................................................................................ 36
ii 2008SSD-34 (5/08)
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 30 HP VFD Connections ......................................................................................................................15
Figure 15 Maintenance Tools ...............................................................................................................................20
Figure 16 Adding or Draining Oil .........................................................................................................................23
Figure 17 Gas Inlet Block and Screen ................................................................................................................25
Figure 18 Scavenge Line Orifi ce .........................................................................................................................25
Figure 19 Oil Filter Bowl and Element ..................................................................................................................26
TABLES
Table 1 Inlet and discharge pressure limits ........................................................................................................5
Table 2 Typical Compressor Module power supply requirements ....................................................................13
Table 3 Default and optional VFD confi gurations .............................................................................................16
Table 4 Typical 30 HP VFD parameters ............................................................................................................16
Table 5 Maintenance summary .........................................................................................................................19
Table 6 Troubleshooting ...................................................................................................................................27
Table 7 VFD fault codes and descriptions ........................................................................................................27
Table 8 Motor winding resistance .....................................................................................................................27
Table 9 Platform troubleshooting guidelines .....................................................................................................28
Table 10 Compressor Module specifi cations ......................................................................................................29
Table 11 Compressor Module fl ow, pressure and horsepower data (see Notes 1 - 4*) .....................................31
Table 12 Contact information ..............................................................................................................................34
iii 2008SSD-34 (5/08)
Single-Compressor Module Compressor Module Nomenclature
COMPRESSOR MODULE NOMENCLATURE
Oil
High
Max
Delivery
Pressure
Model
Single Scroll Units
SZO22C3A-EDE-234 125 100 10 215
SZV22C1A-EDE-140 190 100 15 215
(PSIG)
Max
Flow
(MCFD)
Drive
HP
Press
Switch
Setting
(PSIG)
Low
Press
Switch
Setting
2” W.C.
(5 mbarg)
2” W.C.
(5 mbarg)
High
Tem p
Setting
°F (°C)
240
(116)
280
(138)
Thermal
Bypass
Valve
Setpoint
°F (°C)
200 YES 350
250 NO 356
Gas
Bypass
Valve
Module
Weight
(Lbs.)
iv 2008SSD-34 (5/08)
Dual-Compressor Module Important Safety Information
IMPORTANT SAFETY INFORMATION
This manual contains important instructions for installation, operation and maintenance of your Copeland
®
Compressor Module.
Scroll
WARNING
The Compressor Module must be installed ONLY in systems that have been designed by
qualifi 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 qualifi 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 2008SSD-34 (5/08)
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.
2 Form No. 2006SSD-75 (5/06) Rev. 0
Dual-Compressor Module Introduction
1.0 INTRODUCTION
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 fi 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 SZO22 Compressor Module shown in Section 1.1
• Compressor - a Copeland Scroll
• Compressor Package - the entire assembly, including the Compressor Module, ready for service in
the fi 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 one Compressor and the other components shown in Figure 1.
Figure 1 Compressor Module Components
®
Compressor
3 2008SSD-34 (5/08)
Single-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 (not shown: Encapsulated Stator)
1.3 The Compressor Package
The Compressor Package consists of the Compressor Module housed in an assembly ready for service
in the fi eld. Equipment Packagers customize the assembly and complete the fabrication for Compressor
Modules for each application. Figure 3 shows a simplifi 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
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 fl 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 fl 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 fl 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 fi lter to remove debris from the gas stream. The degree of fi ltration required depends on
the specifi 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
Minimum
Differential
Pressure
0.75 psig / 2" water
column (model specifi c)
10 / 25 psig
(model specifi c)
70 psig
to
190 psig
(depends on model)
70 psi
Consult factory for operations below 0.0 psig.
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 2008SSD-34 (5/08)
Single-Compressor Module Installation
NOTE: Required Component – High Pressure Discharge Gas Bypass Valve
To eliminate redundancy, the high pressure discharge gas bypass (recycle) valve was removed from some of the
scroll modules (see table below). Packagers will need to install downstream pressure relief of our module.
Oil
High
Max
Delivery
Pressure
Model
Single Scroll Units
SZO22C3A-EDE-234 125 100 10 215
SZV22C1A-EDE-140 190 100 15 215
(PSIG)
Max
Flow
(MCFD)
Drive
HP
Press
Switch
Setting
(PSIG)
Low
Press
Switch
Setting
2” W.C.
(5 mbarg)
2” W.C.
(5 mbarg)
High
Tem p
Setting
°F (°C)
240
(116)
280
(138)
Thermal
Bypass
Valve
Setpoint
°F (°C)
200 YES 350
250 NO 356
Gas
Bypass
Valve
Module
Weight
(Lbs.)
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 10 on page 29.
6 2008SSD-34 (5/08)
Dual-Compressor Module Installation
2.4 Installation Clearance and Dimensions
Allow suffi 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 fl 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)
7 2008SSD-34 (5/08)
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