Emerson Copeland Scroll SZO44, Installation, Operation & Maintenance Manual

Page 1: ...Copeland Scroll Compressor Module Installation Operation Maintenance Manual Model Family SZV32 SZV44 SZO44 SZO56 ...

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Page 3: ...sures 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 Start...

Page 4: ...5 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 ...

Page 5: ...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...

Page 6: ... Oil Thermal Bypass Valve Setpoint F C Gas Bypass Valve Module Weight Lbs Dual Scroll Units SZO56C1A EDE 110 150 260 30 215 0 75 PSIG 52 mbarg 240 116 200 NO 625 SZO44C1A EDE 140 190 200 30 215 0 75 PSIG 52 mbarg 240 116 200 NO 625 SZO44C1A EDE 244 190 200 30 215 0 75 PSIG 52 mbarg 240 116 200 YES 625 SZV44C1A EDE 140 190 200 30 215 0 75 PSIG 52 mbarg 280 138 250 NO 625 SZV32C1A EDE 150 275 150 30...

Page 7: ...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...

Page 8: ...owing 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: ...g 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 1 The Compressor Module The Compressor Module consists of two Compressors and the other components shown in Figure 1 Figure 1 Compressor Module Components Oil coolers with fans 2 Oil circuit filt...

Page 10: ...e Compressor Package consists of the Compressor Module housed in an assembly ready for service in the field Equipment Packagers 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 Oil cooler Gas aftercooler if applicable Control and power panel Compressor Modu...

Page 11: ...ode 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 filter to remove debris from the gas stream The degree of filtration required depends on the specific application 2 2 Inlet and Discharge Pressures Refer to Table 1 for acceptable inlet and discharge pressure levels Table 1 Inlet and discharge pressure...

Page 12: ...s 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 modified 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 reli...

Page 13: ...ice access especially for gas and electrical connections at the rear of the Compressor Module Check applicable national and local electrical codes Cooling air flow 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 ...

Page 14: ... 02 C 01 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 filter PI002 Pressure gauge on first 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 stag...

Page 15: ... 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 fixed speed Each Compressor on a module must be protected by an individual manual reset overload between the VFD and the Compre...

Page 16: ...y 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 ...

Page 17: ...ure Sensor Compressor requirements 1 2 to 2 GPM 4 5 755 LPM flow 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 flow 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 V...

Page 18: ...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 Variabl...

Page 19: ...sor Module Electrical Requirements 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 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 in...

Page 20: ...ellow 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 Blac...

Page 21: ...erly SAFETY AND CONTROL DEVICES Make sure that all safety and control switches and devices are configured 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 M...

Page 22: ...ESE 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 Fir...

Page 23: ...uire more frequent service 4 5 2 Changing the Oil page 20 Check the condition of the lubricant periodically Normal color is clear or light gray Change the oil filter if equipped annually or as required Gas Inlet System Inspect and clean the inlet screen annually or more often as needed A restricted inlet screen will result in reduced flow 4 6 Cleaning the Inlet Screen page 22 Second Stage Separato...

Page 24: ...lied 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 fittings contain a core depressor that opens the Schrader valve when the fittings are attached A backseating c...

Page 25: ...e 4 5 1 Topping Off the Oil Level on page 20 Higher than 3 from the bottom Remove excess oil 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...

Page 26: ...ol valve 3 Connect one end of the oil transfer hose to the back seating 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 Caution W...

Page 27: ...nnect 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 flowing and gas comes out of the hose close the valves 6 Relocate the hose to the Schrader valv...

Page 28: ...e 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...

Page 29: ...E nut 8 Return the Compressor Package to service 9 Check for leaks at all fittings that have been disturbed 4 7 Servicing the Scavenge Line Orifice The scavenge line orifice in the oil separator block must remain clear of obstruction If this orifice is restricted the secondstage oil separator can become saturated increasing oil consumption Figure 17 Scavenge Line Orifice Orifice To inspect and cle...

Page 30: ... the Compressor Package to service 10 Check for leaks at all fittings that have been disturbed 4 9 Changing the Oil Filter Element To replace the oil filter 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 filter bowl by turning it counterclockwise Note The bowl ...

Page 31: ...l Temperature Fault Blocked air flow 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 first stage separator see 4 3 Checking the Oil Level on page 19 High Discharge Pressure Fault Restricted discharge and bypass valve fault VFD Fault The drive LED wil...

Page 32: ...r Saturated or dirty secondstage oil separator High oil level Restricted scavenge orifice Insufficient back pressure Oil dilution Compressors Won t Run Determine drive status Is inhibit circuit closed Is run signal present Does the VFD indicate a fault code Incorrect Compressor Speed Low inlet pressure High discharge pressure High temperature fan low oil oil cooler Problem with speed control senso...

Page 33: ... fluid 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 temperature3 4 14 F 10 C Power supply to inverter Voltage range Input frequency range 380 to 480VAC 50 60 Hz Overpressure detection outlet 215 psig open 290 psig for SZV32 Underpressure detection inlet 0 75 psig open low pres...

Page 34: ...Dual Compressor Module Technical Support and Service 28 2006SSD 75 R4 10 10 ...

Page 35: ...D 144 142 141 139 139 137 HP 21 23 25 27 29 31 50 241 238 236 233 232 23 25 27 30 32 65 304 297 295 291 291 24 26 28 31 33 Two Module Package 0 100 98 37 39 10 174 172 170 168 166 162 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 flow using varibable speed drive compressors operating at 80 Hz m...

Page 36: ...5 HP 25 27 28 30 31 32 20 MCFD 232 232 232 231 230 229 HP 27 28 30 31 31 32 25 MCFD 265 264 264 264 HP 31 31 32 33 Two Module Package 7 5 MCFD 86 84 HP 37 40 0 MCFD 194 193 191 190 188 188 188 187 185 HP 39 43 46 49 52 55 58 60 63 5 MCFD 262 261 259 258 257 256 255 253 252 HP 42 45 49 52 54 57 60 63 66 10 MCFD 329 329 328 327 325 323 321 320 HP 45 48 51 54 57 60 63 65 15 MCFD 396 396 395 394 392 3...

Page 37: ...0 21 22 24 24 24 26 28 29 30 31 32 25 MCFD 204 203 203 203 202 202 201 200 199 199 HP 23 24 24 25 27 28 30 31 32 33 Two Module Package 7 5 MCFD 66 64 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 10 MCFD 253 253 252 251 250 249 247 246...

Page 38: ...d MI 48642 Emergency Number 989 496 3780 A 2 Product Name and Information Product Trade name and synonyms CP 6006 Series Chemical Name Poly Alpha Olefin PAO Chemical Family Synthetic Hydrocarbon Formula C10n H20n 2 CAS Proprietary 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...

Page 39: ...Fire and Explosion Hazards A 8 Health Hazard Data Threshold Limit Value 5mg m3 ACGIH Situations to Avoid Avoid breathing oil mists First Aid Procedures Ingestion Consult physician at once DO NOT INDUCE VOMITING May cause nausea and diarrhea Inhalation Product is not toxic by inhalation If oil mist is inhaled remove to fresh air and consult physician To the best of our knowledge the toxicity of thi...

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Page 42: ...ectric Co or one of its affiliated companies 2011 Emerson Climate Technoligies Inc All rights reserved Printed in the USA 2006SSD 75 R4 EmersonClimate com Vilter Manufacturing LLC P O Box 8904 Cudahy WI 53110 8904 P 414 744 0111 F 414744 1769 www vilter com ...