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......................
Single-Compressor Module TABLE OF CONTENTS 4.2 Maintenance Tools....................................................................................................................... 18 4.3 Oil Service................................................................................................................................... 19 4.6 Cleaning the Inlet Screen............................................................................................................ 21 4.
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 ................................................................................................................
Single-Compressor Module Compressor Module Nomenclature Compressor Module Nomenclature Max Delivery Pressure (PSIG) Max Flow (MCFD) Drive HP High Press Switch Setting (PSIG) SZO22C3A-EDE-234 125 100 10 SZV22C1A-EDE-140 190 100 15 Model Oil Thermal Bypass Valve Setpoint °F (°C) Gas Bypass Valve Module Weight (Lbs.) Low Press Switch Setting High Temp Setting °F (°C) 215 2” W.C. (5 mbarg) 240 (116) 200 YES 350 215 2” W.C.
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 qualified engineering personnel. The system must conform to all applicable local and national regulations and safety standards.
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.
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 field; the completed housing is done by equipment Packagers. This section provides an overview of these components.
Single-Compressor Module 1.2 Introduction 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 1.3 Copeland Scroll® Compressor Cross Section (not shown: Encapsulated Stator) The Compressor Package The Compressor Package consists of the Compressor Module housed in an assembly ready for service in the field.
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 flooding and damaging the Compressor.
Single-Compressor Module Installation NOTE: Required Component – High Pressure Discharge Gas Bypass Valve To eliminate redundancy, the high pressure discharge gas bypass (recycle) valve was removed from some of the scroll modules. Packagers will need to install pressure relief downstream of our module. See table on page iv. 2.3 Ambient Temperature Range The Compressor Module operating ambient temperature is 20°F to +122°F (-29° to +50°C).
Single-Compressor Module 2.4 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. Refer to Figure 4 for the dimensions of the Compressor Module.
Single-Compressor Module 2.
Single-Compressor Module 2.6 Electrical Controls 2.6.1 General Considerations Installation 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. All switches are closed unless a fault condition is detected. All safety and protective devices must be installed and used in accordance with applicable codes and regulations.
Single-Compressor Module 2.6.2 Installation 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. • Cooling fans require 24VDC, 4.5A (105 Watts) for the Compressor Module.
Single-Compressor Module Figure 8 Optional Customer-Installed High Temperature Fan Control System • • • • Figure 9 Installation Compressor requirements: 0.8 to 2 GPM (3.0-755 LPM) flow rate Thermal oil bypass valve, standard setting: 200°F (93°C) / 250°F model specific 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).
Single-Compressor Module 2.6.3 Installation Compressor Module Motor Protection Variable Speed Compressor Module Protection • The VFD provides overload protection for the compressor. • Module capacity can be changed by varying the typical Compressor speed, ranging from 2400 to 4800 rpm.
Single-Compressor Module 2.6.4 Installation Electrical Requirements Figure 11 Typical Compressor Module Electrical Requirements 1 1 1 Code Optional Optional ifif more more than than one compressor Compressormodule Module used used 4 2 Description 1 Control Techniques VFD,* 10 or 15 HP model specific 2 24VDC power supply ** 3 PLC or other control for inputs from Compressor Module 4 480V 3-phase input *** Notes * VFD on Variable Speed Drive models.
Single-Compressor Module 2.6.
Single-Compressor Module 2.6.6 Installation Variable Frequency Drive (VFD) Terminations Refer to Product Bulletin on Variable Frequency Drive Applications for details on VFD terminations and typical VFD parameters. 3.0 Operation 3.1 Initial Startup - Compressor Module 3.1.1 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.
Single-Compressor Module 3.1.2 Operation Post-Startup Checklist Perform these checks AFTER starting the Compressor Module: DURING INITIAL OPERATION, PERFORM THESE CHECKS: ___ 1. Compressor Module builds pressure on initial startup; no unusual mechanical noise. ___ 2. Oil level is correct at minimum and maximum speeds. ___ 3. No gas leaks are present. ___ 4. No oil leaks are present. ___ 5. Oil cooler fan turn on and run at the appropriate temperature. ___ 6.
Single-Compressor Module Operation 4.0 Maintenance 4.1 Routine Maintenance Perform the maintenance procedures in Table 5 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 Maintenance Reason • Monitor and check the oil level.
Single-Compressor Module 4.2 Maintenance Maintenance Tools Figure 15 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.
Single-Compressor Module 4.3 Maintenance Oil Service The oil level indicated on the first-stage oil separator site glasses varies with inlet and discharge pressures and operating speed. • New oil is clear, it may be necessary to use a flashlight to verify the correct oil level. • The oil level should never reach the top of the upper site glass on the primary oil separator under any operating conditions. • If possible block the compressor discharge to force the system into full bypass. 1.
Single-Compressor Module Maintenance • Scavenge line orifice or screen is restricted. Clean or replace. • Insufficient back pressure. Confirm 50-60 psig or higher backpressure when the compressor is running. • No specific cause found. Replace oil separator block assembly, scavenge line and secondary oil separator element.
Single-Compressor Module 4.4 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 14 Gas Inlet Block and Screen To inspect and clean the inlet screen: 1. Turn off and isolate the Compressor from all power sources. 2. Turn off the gas supply. 3. Vent the system to 0 psig. 4.
Single-Compressor Module 4.6 Maintenance Changing the Second-Stage Separator Element To replace the second-stage separator element: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Turn off and isolate the Compressor from all power sources. Turn off the gas supply. Vent the system to 0 psig. Follow applicable safety procedures and codes. Loosen the separator element by turning it counterclockwise with a strap wrench. Remove the separator element. Verify the gasket is removed with the separator.
Single-Compressor Module 5.2 Maintenance Platform Symptoms Diagnosis Use the following guidelines to troubleshoot operating problems.
Single-Compressor Module Maintenance 6.0 Specifications Table 7 Compressor Module Specifications General Information Inlet pressure range Model specific - refer to application envelope Outlet pressure range 70 to 275 psig (depends on model—see page iv) Mechanical Description Module weight Approximately 350 lb. (160kg) Suction connection 1.0” NPT Discharge connection 0.
Single-Compressor Module Material Data Safety Sheet Appendix A - Material Data Safety Sheet 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. CAUTION This oil is intended for use only in the Copeland Scroll® Compressor used in natural gas applications.
Single-Compressor Module Material Data Safety Sheet A.6 Fire and Explosion Hazards Flash Point (by Cleveland Open Cup) Flammable Limits Auto-Ignition Temperature Health HMIS Ratings Flammability Reactivity NFPA Ratings Extinguishing Media Unusual Fire and Explosion Hazards Special Fire Fighting Techniques 320-530°F (160-276°C) Not established No data 0 1 0 Not established Dry chemical; CO2 foam; water spray (fog) None Burning fluid may evolve irritating/noxious fumes.
EmersonClimate.com Vilter Manufacturing LLC P.O. Box 8904 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.
