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Summary of Contents for Emerson Copeland Scroll SZV32
- Page 1 Copeland Scroll Compressor Module ® Installation, Operation & Maintenance Manual Model Family SZV32 SZV44 SZO44 SZO56...
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Page 3: Table Of Contents
Dual-Compressor Module TABLE OF CONTENTS TABLE OF CONTENTS ..................... ompressor odule omeNClature .......................1 mportaNt afety NformatioN ........................3 NtroduCtioN The Compressor Module ......................3 The Compressor ........................... 4 The Compressor Package ......................4 ........................5 NstallatioN Installation Guidelines ........................5 2.1.1 Required Component—Inlet Gas Scrubber ..................5 2.1.2 General Installation Guidelines ......................5 Inlet and Discharge Pressures ...................... - Page 4 Dual-Compressor Module TABLE OF CONTENTS Maintenance Tools ........................20 Checking the Oil Level ........................ 21 4.3.1 Oil Level Guidelines - Minimum Speed ..................21 4.3.2 Oil Level Guidelines - Maximum Speed ..................21 Oil Capacity and Type ......................... 21 Adding and Removing Oil ......................22 4.5.1 Topping Off the Oil Level .......................22 4.5.2...
- Page 5 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...
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Page 6: Compressor Module Nomenclature
Dual-Compressor Module Compressor Module Nomenclature ompressor odule omeNClature High Thermal Press Bypass Delivery Switch Press High Temp Valve Module Pressure Flow Drive Setting Switch Setting Setpoint Gas Bypass Weight Model (PSIG) (MCFD) (PSIG) Setting °F (°C) °F (°C) Valve (Lbs.) Dual Scroll Units 0.75 PSIG SZO56C1A-EDE-110... -
Page 7: I Mportant S Afety I Nformation
Dual-Compressor Module Important Safety Information mportaNt afety NformatioN 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. - Page 8 Dual-Compressor Module Important Safety Information afety ymbols sed iN aNual 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.
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Page 9: Ntroduction
Dual-Compressor Module Introduction NtroduCtioN 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. -
Page 10: The Compressor
Dual-Compressor Module Introduction 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 ® The Compressor Package The Compressor Package consists of the Compressor Module housed in an assembly ready for service in the field. -
Page 11: Nstallation
Dual-Compressor Module Installation NstallatioN 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 flooding and damaging the Compressor. -
Page 12: Ambient Temperature Range
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). High Press Thermal... -
Page 13: Installation Clearance And Dimensions
Dual-Compressor Module Installation Installation Clearance and Dimensions Allow sufficient 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 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. -
Page 14: Process And Instrumentation Diagrams (P&Ids)
Dual-Compressor Module Installation Process and Instrumentation Diagrams (P&IDs) Figure 5 Compressor Module Gas and Oil Flow Diagram and Safety Shutdowns PSLL Gas Discharge BPV-01 1" -NPT PSHH Gas Suction 1-1/2" -NPT C-01 TSHH SEP-02 480V J.B. SEP-01 C-02 TCV-03 FL-05 Module Limits Code Description... -
Page 15: Electrical Controls
Dual-Compressor Module Installation Electrical Controls 2.6.1 General Considerations All shutdown devices are dry contact switches rated Class I, Division II that are wired to a terminal box for connection to the packager supplied control circuit. The common wires on all switches are connected together. -
Page 16: Oil Cooler Fan Control
Dual-Compressor Module Installation 2.6.2 Oil Cooler Fan Control The Compressor Module temperature is controlled by managing module oil flow and temperature. The module’s precise temperature control is critical to system performance and equipment life. Maintaining proper temperature control also reduces the possibility of gas condensing into liquids during operation. •... -
Page 17: Figure 8 Optional Customer-Installed High Temperature Fan Control System
Dual-Compressor Module Installation Figure 8 Optional Customer-Installed High Temperature Fan Control System SZO44 Compressor Module Power Supply 24VDC 0-10VDC Fan Speed Signal 0.9V = Off; 1.3V = 50%; 10V = 100% Temperature Temperature Sensor Control • Compressor requirements: 1.2 to 2 GPM (4.5-755 LPM) flow rate •... -
Page 18: Compressor Module Motor Protection
Dual-Compressor Module Installation 2.6.3 Compressor Module Motor Protection Variable Speed Compressor Module Protection • The two Compressors in the variable speed Compressor Module should be treated as a single Compressor. Both Compressors must be run at the same time to prevent oil from accumulating in one Compressor. -
Page 19: Electrical Requirements
Dual-Compressor Module Installation 2.6.4 Electrical Requirements Figure 11 Typical Compressor Module Electrical Requirements Code Description Control Techniques VFD,* 30 HP 24VDC power supply ** PLC or other control for inputs from Optional if more than one Optional if more than one Compressor Module compressor module used Compressor Module used... -
Page 20: Wiring
Dual-Compressor Module Installation 2.6.5 Wiring Figure 12 Control Circuit Terminations Terminal Strip Blue Lead (LIP) Red Lead (HDP) 60K Resistor Red Lead (HT) Red Lead – To Fan +24VDC Yellow Lead – To Fan Run Yellow Lead (Thermistor) Blue Lead (Thermistor) Jumper Blue Lead –... -
Page 21: O Peration
Dual-Compressor Module Operation peratioN Initial Startup - Compressor Module The following inspections should be made on initial startup—-typically, by the Packager—and after long periods of storage. • Verify acceptable pre-startup conditions using the checklist in 3.1.1 - Pre-Startup Checklist. • Start the Compressor Module, then perform the checks in 3.1.2 - Post-Startup Checklist. 3.1.1 Pre-Startup Checklist Perform these checks BEFORE starting the Compressor Module: MAIN POWER... -
Page 22: Initial Startup - Compressor Package
Dual-Compressor Module Operation Initial Startup - Compressor Package Refer to your Packager’s user manual for information on procedures to start up the Compressor Package, which includes equipment added to the Compressor Module by the Packager. Normal Operation Checklist Observe the following conditions after startup—when power is applied to the VFD and the VFD receives the signal from the Compressor Package control system to run: CHECK FOR THESE CONDITIONS UNDER NORMAL OPERATION: ___ 1. -
Page 23: M Aintenance
Dual-Compressor Module Maintenance aiNteNaNCe Routine Maintenance Perform the maintenance procedures in Table 3 at least once per year or more often if needed. Oil consumption varies by application and during initial operation. Monitor the oil level routinely to determine a consistent pattern of actual consumption. Table 3 Maintenance summary Components... -
Page 24: Maintenance Tools
Dual-Compressor Module Maintenance Maintenance Tools Figure 14 shows the tools needed for maintenance of the Compressor Module. Contact the Packager to obtain a maintenance tool kit. These are typical air conditioning and refrigeration service tools. Figure 14 Maintenance Tools Back-seating Oil pump, piston type, Filter wrench Charging hose... -
Page 25: Checking The Oil Level
Dual-Compressor Module Maintenance Checking the Oil Level The proper oil level varies according to the Compressor Module’s operating speed. To check the oil level on the first-stage oil separator level gauge, use the following guidelines based on operating speed. NOTE The oil level indicated on the first-stage oil separator sight tube varies with inlet and discharge pressures as well as operating speed. -
Page 26: Adding And Removing Oil
Dual-Compressor Module Maintenance Adding and Removing Oil Oil is drained from the system through the Schrader valves on the Compressor suction fittings, first-stage oil separator and oil cooler (see Figure 15 on page 21). 4.5.1 Topping Off the Oil Level See 4.4 - Oil Capacity and Type on page 19 before adding oil. -
Page 27: Changing The Oil
Dual-Compressor Module Maintenance 4.5.2 Changing the Oil These procedures describe how to drain oil from the system and to replace the oil after draining. Figure 15 Adding or Draining Oil LEFT SIDE VIEW RIGHT SIDE VIEWS Compressor First Stage Oil Separator Compressor Schrader Valve Schrader Valves... - Page 28 Dual-Compressor Module Maintenance Replacing Oil 1. Turn the knob on the backseating control valve fully LEFT SIDE VIEW counterclockwise. 2. Remove the protective cap from the Schrader valve on the first-stage oil separator (shown at right) and connect Oil level sight tube the backseating control valve.
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Page 29: Cleaning The Inlet Screen
Dual-Compressor Module Maintenance Cleaning the Inlet Screen The 30-mesh screen in the inlet block must remain unobstructed for optimal flow rate. If the flow rate is lower than expected even when the Compressor is running properly, this screen may be obstructed. Figure 16 Gas Inlet Block and Screen To inspect and clean the inlet screen: 1. -
Page 30: Changing The Second-Stage Separator Element
Dual-Compressor Module Maintenance Changing the Second-Stage Separator Element To replace the second-stage separator 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. -
Page 31: T Roubleshooting
Dual-Compressor Module Troubleshooting roubleshootiNg This section offers tips for troubleshooting. Troubleshooting Guide Refer to Table 4 for recommended solutions to typical problems. Table 4 Troubleshooting Problem Recommended Actions • Closed gas inlet valve. Low Inlet Gas Pressure • Restricted or insufficient gas supply. Fault •... -
Page 32: Platform Symptoms Diagnosis
Dual-Compressor Module Technical Support and Service Platform Symptoms Diagnosis Use the following guidelines to troubleshoot operating problems. Table 6 Platform troubleshooting guidelines Problem Recommended Actions • Low inlet pressure • Insufficient gas supply • High temperature Low Gas Flow • Bypass valve open •... -
Page 33: S Pecifications
Dual-Compressor Module Technical Support and Service peCifiCatioNs Table 7 Compressor Module Specifications General Information Inlet pressure range Approximately -.75 to 25 psig Outlet pressure range 70 to 275 psig (depends on model—see page iv) Mechanical Description Module weight Approximately 660 lb. (300kg) Suction connection 1.5”... - Page 34 Dual-Compressor Module Technical Support and Service 2006SSD-75 R4 (10/10)
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Page 35: Table 8 Compressor Module Flow, Pressure And Horsepower Data (See Notes 1 - 3*)
Dual-Compressor Module Technical Support and Service Compressor Module Horsepower Selection Chart Module Model Number: SZV32C1A-EDE-150 Configuration Suction MCFD Max Flow/HP as a function of discharge Press pressure at maximum flow rate (Note 1) (PSIG) One Module Package MCFD MCFD MCFD Two Module Package NOTES: 1. - Page 36 Dual-Compressor Module Technical Support and Service Compressor Module Horsepower Selection Chart Module Model Number: SZO56C1A-EDE-240 Configuration Suction Max Flow/HP as a function of discharge pressure at maximum flow Press rate (Note 1) (PSIG) MCFD) One Module Package -7.5 MCFD MCFD MCFD MCFD MCFD...
- Page 37 Dual-Compressor Module Technical Support and Service Compressor Module Horsepower Selection Chart Module Model Number: SZO44C1A-EDE-244 Configuration Suction Max Flow/HP as a function of discharge pressure at maximum Press flow rate (Note 1) (PSIG) MCFD) 100 110 120 130 140 150 160 170 180 190 One Module Package -7.5 MCFD...
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Page 38: Supplier
Dual-Compressor Module Material Data Safety Sheet a - m ppeNdix aterial afety heet The information in this material safety data sheet should be provided to all who use, handle, store, transport or are otherwise exposed to this product. CPI believes the information in this document to be reliable and up to date as of the date of publication, but makes no guarantee that it is. -
Page 39: Fire And Explosion Hazards
Dual-Compressor Module Material Data Safety Sheet a.6 f ire aNd xplosioN azards Flash Point (by Cleveland Open 320-530°F (160-276°C) Cup) Flammable Limits Not established Auto-Ignition Temperature No data Health HMIS Ratings Flammability Reactivity NFPA Ratings Not established Extinguishing Media Dry chemical; CO foam;... -
Page 42: 2006Ssd-75 R4
Cudahy, WI 53110-8904 P 414 744 0111 F 414744 1769 www.vilter.com Copeland Scroll and Emerson are trademarks of Emerson Electric Co. or one of its affiliated companies. ©2011 Emerson Climate Technoligies, Inc. All rights reserved. Printed in the USA. 2006SSD-75 R4...
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