Emerson SZV32, SZV44, SZO56, SZO44 User Manual
Copeland Scroll® Compressor Module
Installation, Operation & Maintenance Manual
Model Family
SZV32
SZV44
SZO44
SZO56
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
i 2006SSD-75 R4 (10/10)
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 Orice ........................................................................................... 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
ii 2006SSD-75 R4 (10/10)
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 Orice ......................................................................................................................... 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 specications ...................................................................................................... 27
Table 8 Compressor Module ow, pressure and horsepower data (see Notes 1 - 3*) .....................................29
iii 2006SSD-75 R4 (10/10)
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
iv 2006SSD-75 R4 (10/10)
(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.)
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
qualied 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 qualied 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)
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
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)
3 2006SSD-75 R4 (10/10)
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 simplied 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 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 specic 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)
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 modied. 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)
Dual-Compressor Module Installation
2.4 Installation Clearance and Dimensions
Allow sufcient 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)
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)
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