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SZV22
User Manual
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User Manual
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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
Single-Compressor Module TABLE OF CONTENTS
4.2 Maintenance Tools ...................................................................................................................... 18
4.3 Oil Service .................................................................................................................................. 19
4.6 Cleaning the Inlet Screen ........................................................................................................... 21
4.7 Servicing the Scavenge Line Orice ........................................................................................... 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
Single-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 Maintenance Tools ...............................................................................................................................18
Figure 14 Gas Inlet Block and Screen ................................................................................................................21
Figure 15 Scavenge Line Orice ......................................................................................................................... 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 specications ...................................................................................................... 24
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.)
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.
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
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.
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. 2008SSD-34 (5/11)
Single-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 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
• 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 one Compressor and the other components shown in Figure 1.
Figure 1 Compressor Module Components
Single-Compressor Module Introduction
1.2 The 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)
1.3 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. 2008SSD-34 (5/11)
Single-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 10-micron 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
Minimum Differential Pressure
0.75 psig / 2" water
column (model specic)
10 / 25 psig
(model speci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.
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