Emerson SZV22 - Manuals - manualsarea.com

Page 2 - TABLE OF CONTENTS

Single-Compressor Module TABLE OF CONTENTS i 2008SSD-34 (5/08) TABLE OF CONTENTS C OMPRESSOR M ODULE N OMENCLATURE ............................................................................................. IV I MPORTANT S AFETY I NFORMATION ...........................................................

Page 3 - A M

Single-Compressor Module TABLE OF CONTENTS ii 2008SSD-34 (5/08) 4.2 Maintenance Tools ...................................................................................................................... 20 4.3 Checking the Oil Level ....................................................................

Page 4 - FIGURES

Dual-Compressor Module TABLE OF CONTENTS iii 2008SSD-34 (5/08) FIGURES Figure 1 Compressor Module Components ........................................................................................................ 3 Figure 2 Copeland Scroll ® Compressor Cross Section ...................................

Page 5 - OMPRESSOR

Single-Compressor Module Compressor Module Nomenclature iv 2008SSD-34 (5/08) C OMPRESSOR M ODULE N OMENCLATURE Model Max Delivery Pressure (PSIG) Max Flow (MCFD) Drive HP High Press Switch Setting (PSIG) Low Press Switch Setting High Temp Setting °F (°C) Oil Thermal Bypass Valve Setpoint °F (°C) Gas...

Page 6 - MPORTANT

Dual-Compressor Module Important Safety Information 1 2008SSD-34 (5/08) I MPORTANT S AFETY I 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...

Page 7 - SAFETY ALERT SYMBOL

Single-Compressor Module Important Safety Information S AFETY S YMBOLS U SED IN T HIS M 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 W...

Page 8 - NTRODUCTION; The Compressor Module

3 2008SSD-34 (5/08) Dual-Compressor Module Introduction 1.0 I NTRODUCTION 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 ...

Page 9 - Compressor

Single-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 (not shown: Encap...

Page 10 - NSTALLATION; Guidelines; Required Component—Inlet Gas Scrubber; REQUIRED; Inlet and Discharge Pressures; Table 1; Type

5 2008SSD-34 (5/08) Dual-Compressor Module Installation 2.0 I NSTALLATION 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 t...

Page 11 - Ambient Temperature Range; on page

6 2008SSD-34 (5/08) 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 (see table below). Packagers will need to install ...

Page 12 - Installation Clearance and Dimensions; Refer to; Figure 4; for the dimensions of the Compressor Module.

7 2008SSD-34 (5/08) Dual-Compressor Module Installation 2.4 Installation Clearance and Dimensions Allow suffi cient 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. Coo...

Page 13 - Code

8 2008SSD-34 (5/08) Single-Compressor Module Installation 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 controlle...

Page 14 - Controls; Considerations; The drive provides 24V for the Enable and Run Fwd signals.

9 2008SSD-34 (5/08) Dual-Compressor Module Installation 2.6 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 swit...

Page 15 - Figure 6 Brushless DC Fan

10 2008SSD-34 (5/08) Single-Compressor Module Installation R ED B lu e W hi te Yell ow +24VDC DC co mmon No co nn ectio n feedb ack 0-10VDC sp eed sig nal 2.6.2 Oil Cooler Fan Control The Compressor Module temperature is controlled by managing module oil fl ow and temperature. The module’s precise t...

Page 16 - • Oil; Figure 9

11 2008SSD-34 (5/08) Dual-Compressor Module Installation Figure 8 Optional Customer-Installed High Temperature Fan Control System • Compressor requirements: 0.8 to 2 GPM (3.0-755 LPM) fl ow rate • Thermal oil bypass valve, standard setting: 200°F (93°C) / 250F model specifi c • Thermal bypass valve ...

Page 17 - Compressor Module Motor Protection; • The VFD provides overload protection for the compressor.; Figure 10 Motor Control

12 2008SSD-34 (5/08) Single-Compressor Module Installation 2.6.3 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 48...

Page 18 - Requirements; Figure 11 Typical Compressor Module Electrical Requirements; Variable Speed

13 2008SSD-34 (5/08) Dual-Compressor Module Installation 2.6.4 Electrical Requirements Figure 11 Typical Compressor Module Electrical Requirements 1 2 3 4 Optional if more than one compressor module used Power to Compressors 24VDC Cooling Fan 24V Discrete Inputs from Scroll Module 1 1 Table 2 Typica...

Page 19 - Figure 12 Control Circuit Terminations

14 2008SSD-34 (5/08) Single-Compressor Module Installation 2.6.5 Wiring Figure 12 Control Circuit Terminations Figure 13 Power Terminations C on tro l wir in g ter min atio ns Po wer wir in g ter min atio ns From VFD From VFD From VFD

Page 20 - Table 3

15 2008SSD-34 (5/08) Dual-Compressor Module Installation 2.6.6 Variable Frequency Drive (VFD) Terminations Figure 14 shows VFD terminations. See Table 3 on page 15 for default and optional VFD terminal confi gurations. The VFD is shipped confi gured for a 0-10V speed control input on Terminal 2. If ...

Page 22 - Table 4 Typical VFD parameters; PERATION; Initial Startup - Compressor Module; • Verify acceptable pre-startup conditions using the checklist in; Checklist; Perform these checks BEFORE starting the Compressor Module:

17 2008SSD-34 (5/08) Dual-Compressor Module Operation Table 4 Typical VFD parameters Parameter Description Typical Value 01 Minimum speed (Hz) 40.0 02 Maximum speed (Hz) 80.0 03 Acceleration rate (s/100 Hz) 1.0 04 Deceleration rate (s/100 Hz) 10.0 05 Speed reference select A1.A2 06 Motor rated curre...

Page 23 - MAIN POWER; DURING INITIAL OPERATION, PERFORM THESE CHECKS:; Initial Startup - Compressor Package

18 2008SSD-34 (5/08) Single-Compressor Module Operation MAIN POWER Check for the following conditions:___ 1. Motor type is correct for the application, either Variable Speed C3A or C2A motor. ___ 2. Power phasing to the terminal strip and Compressors is correct. ___ 3. Supply voltage to the Variable...

Page 24 - AINTENANCE; Maintenance; Components

19 2008SSD-34 (5/08) Dual-Compressor Module Maintenance CHECK FOR THESE CONDITIONS UNDER NORMAL OPERATION: ___ 1. Compressor speed should range from 2400 to 4800 rpm during normal operation. ___ 2. Suction pressure range is model specifi c. ___ 3. Discharge pressure should range from 70 psig to 190 ...

Page 25 - Tools; Figure 15 Maintenance Tools; CAUTION

20 2008SSD-34 (5/08) Single-Compressor Module Maintenance Back-seatingcontrol valve Oil pump, piston type, high pressure Designed to operate up to 250 psig Filter wrench Alternate product: Strap fi lter wrench Charging hose 60" (1524mm) Extension hose with valve 6" (152mm) 4.2 Maintenance To...

Page 26 - Checking the Oil Level

21 2008SSD-34 (5/08) Dual-Compressor Module Maintenance 4.3 Checking the Oil Level The proper oil level varies according to the Compressor Module’s operating speed. To check the oil level on the fi rst-stage oil separator level gauge, use the following guidelines based on operating speed. NOTE - THI...

Page 27 - Adding and Removing Oil; Adding Oil

22 2008SSD-34 (5/08) Single-Compressor Module Maintenance RIGHT SIDE VIEW 4.5 Adding and Removing Oil Oil is drained from the system through the Schrader valves on the Compressor suction fi ttings, fi rst-stage oil separator and oil cooler (see Figure 16 on page 23 ). 4.5.1 Topping Off the Oil Level...

Page 28 - Figure 16 Adding or Draining Oil; Draining Oil; Steps 5

23 2008SSD-34 (5/08) Dual-Compressor Module Maintenance L EFT SI DE VIEW RI GHT SI DE VIEW S Co mpr essor C omp resso r Oi l coo ler Fi rst-stage oi l separato r Sch rad er val ves 4.5.2 Changing the Oil These procedures describe how to drain oil from the system and to replace the oil after draining...

Page 29 - Replacing Oil

24 2008SSD-34 (5/08) Single-Compressor Module Maintenance Schr ader valve LEF T SID E VIEW Oil l evel sig ht tub e Fi rst-stage oi l separ ato r Replacing Oil 1. Turn the knob on the backseating control valve fully counterclockwise. 2. Remove the protective cap from the Schrader valve on the fi rst-...

Page 30 - Cleaning the Inlet Screen; Figure 17 Gas Inlet Block and Screen; To inspect and clean the inlet screen:; Servicing the Scavenge Line Orifi ce; Figure 18 Scavenge Line Orifi ce; To inspect and clean the orifi ce:

25 2008SSD-34 (5/08) Dual-Compressor Module Maintenance 4.6 Cleaning the Inlet Screen The 30-mesh screen in the inlet block must remain unobstructed for optimal fl ow rate. If the fl ow rate is lower than expected even when the Compressor is running properly, this screen may be obstructed. Figure 17...

Page 31 - Changing the Second-Stage Separator Element; To replace the second-stage separator element:; Guide; for recommended solutions to typical problems.; Table 6

26 2008SSD-34 (5/08) Single-Compressor Module Maintenance 4.8 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 pro...

Page 32 - Platform Symptoms Diagnosis; Table 9; Problem

27 2008SSD-34 (5/08) Dual-Compressor Module Troubleshooting 5.2 Platform Symptoms Diagnosis Use the following guidelines to troubleshoot operating problems. Table 9 Platform troubleshooting guidelines Problem Recommended Actions Low GasFlow • Low inlet pressure • Insuffi cient gas supply • High temp...

Page 33 - PECIFICATIONS; Compressor Module Specifi cations

Single-Compressor Module Technical Support and Service 28 2008SSD-34 (5/08) 6.0 S PECIFICATIONS Table 10 Compressor Module Specifi cations General Information Inlet pressure range Model specifi c - refer to application envelope Outlet pressure range 70 to 275 psig (depends on model—see page iv ) Mec...

Page 36 - ECHNICAL

Single-Compressor Module Technical Support and Service 31 2008SSD-34 (5/08) T ECHNICAL S UPPORT AND S ERVICE For product and support information on Copeland® Brand Gas Compressors, visit the Web site listed in Table 12 or contact the factory by mail, phone or fax. Table 12 Contact information Web Si...

Page 37 - This oil is intended for use only in the Copeland Scroll; DISPOSE WASTE OIL PROPERLY:; of hazardous materials.; Keep container tightly sealed when not in use.

Single-Compressor Module Material Data Safety Sheet 32 2008SSD-34 (5/08) A PPENDIX A - M ATERIAL D ATA S AFETY S 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 ...

Page 40 - Oil & Gas Compression; Copeland Scroll; Installation, Operation & Maintenance Manual; The Company Behind the Products; Web Site

Oil & Gas Compression Copeland Scroll ® Compressor Module Installation, Operation & Maintenance Manual The Company Behind the Products Emerson Process Management™ and the Emerson Process Management logo are service marks and trademarks of Emerson Electric Co. Copeland Scroll ® is a trademark...