Emerson SZV32, SZV44, SZO56, SZO44 User Manual

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Copeland Scroll® Compressor Module

Installation, Operation & Maintenance Manual

Model Family

SZV32

SZV44

SZO44

SZO56

Dual-CompressorModule 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—InletGas 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-StartupChecklist.....................................................................................................................

17

 

3.1.2

Post-StartupChecklist....................................................................................................................

17

3.2

Initial Startup - Compressor Package..........................................................................................

18

3.3

Normal Operation Checklist........................................................................................................

18

4.0

Maintenance.....................................................................................................................

19

4.1

Routine Maintenance..................................................................................................................

19

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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 Orifice...........................................................................................

25

4.8

Changing the Second-StageSeparator 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

AppendixA  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

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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-InstalledHigh 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 Orifice ..........................................................................................................................

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 specifications.......................................................................................................

27

Table 8

Compressor Module flow, pressure and horsepower data (see Notes 1 - 3*)......................................

29

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Compressor Module Nomenclature

CompressorModuleNomenclature

 

 

 

 

 

 

 

Oil

 

 

 

 

 

 

High

 

 

Thermal

 

 

 

Max

 

 

Press

Low

 

Bypass

 

 

 

Delivery

Max

 

Switch

Press

High Temp

Valve

 

Module

 

Pressure

Flow

Drive

Setting

Switch

Setting

Setpoint

Gas Bypass

Weight

Model

(PSIG)

(MCFD)

HP

(PSIG)

Setting

°F (°C)

°F (°C)

Valve

(Lbs.)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Dual Scroll Units

 

 

 

 

SZO56C1A-EDE-110

150

260

30

215

0.75 PSIG

240 (116)

200

NO

625

(52 mbarg)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SZO44C1A-EDE-140

190

200

30

215

0.75 PSIG

240 (116)

200

NO

625

(52 mbarg)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SZO44C1A-EDE-244

190

200

30

215

0.75 PSIG

240 (116)

200

YES

625

(52 mbarg)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SZV44C1A-EDE-140

190

200

30

215

0.75 PSIG

280 (138)

250

NO

625

(52 mbarg)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SZV32C1A-EDE-150

275

150

30

290

0.75 PSIG

280 (138)

250

NO

625

(52 mbarg)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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2006SSD-75R4 (10/10)

Dual-CompressorModule

Important Safety Information

ImportantSafetyInformation

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

WARNING

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

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

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

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

Maintain all Compressor Module operation and hazard warning labels.

WARNING

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

WARNING

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

WARNING

Loosening or removing pressure-containingcomponents 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

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Dual-CompressorModule

Important Safety Information

 

 

SafetySymbolsUsed inThisManual

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-CompressorModule

Introduction

1.0Introduction

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 field; the completed housing is done by equipment Packagers. This section provides an overview of these components.

These terms are used throughout this manual:

Compressor Module - the SZO44 Compressor Module shown inSection 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 field

Packagers - the company that prepares the Compressor Module for service

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

1.1The Compressor Module

The Compressor Module consists of two Compressors and the other components shown inFigure 1.

Figure 1 Compressor Module Components

Oil coolers with fans (2)

LEFT

SIDE

VIEW

Oil circuit filter

Oil circuit thermal bypass valve

Copeland Scroll® compressors (2) for Class I, Divison II

RIGHT

SIDE

VIEW

Suction gas connection (1-1/2"NPT)

Control wiring terminations

Power wiring terminations

Second-stageseparator

Discharge gas connection (1" NPT)

Inlet check valves (2)

Oil level First-stagesight tube oil separator

Inlet suction screen

High discharge

gas pressure switch

High discharge gas temp switch

Fan speed thermistor

Oil cooler fans (2)

3

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Introduction

 

 

1.2The Compressor

The Compressor refers to the Copeland Scroll® Compressor. Each Compressor Module has two Compressors.Figure 2 shows across-sectionof a Compressor and its key components.

Figure 2 Copeland Scroll® Compressor Cross Section

1.3The Compressor Package

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

Figure 3 Typical Compressor Package

Inlet gas scrubber for liquid removal

Control and power panel

Gas aftercooler (if applicable)

Oil cooler

Compressor

Module

4

Form No. 2006SSD-75(5/06) Rev. 0