Page 3 - TABLE OF CONTENTS
Dual-Compressor Module TABLE OF CONTENTS i 2006SSD-75 R4 (10/10) TABLE OF CONTENTS C ompressor m odule N omeNClature ............................................................................................. iv i mportaNt s afety i NformatioN .........................................................
Page 4 - Servicing the Scavenge Line Orifice; a m
Dual-Compressor Module TABLE OF CONTENTS ii 2006SSD-75 R4 (10/10) 4.2 Maintenance Tools ...................................................................................................................... 20 4.3 Checking the Oil Level ..................................................................
Page 5 - FIGURES; Figure 17 Scavenge Line Orifice; TABLES; Table 7
Dual-Compressor Module TABLE OF CONTENTS ii 2006SSD-75 R4 (10/10) Dual-Compressor Module TABLE OF CONTENTS iii 2006SSD-75 R4 (10/10) FIGURES Figure 1 Compressor Module Components ........................................................................................................ 3 Figure 2 Copel...
Page 6 - ompressor; Dual Scroll Units
Dual-Compressor Module Compressor Module Nomenclature iv 2006SSD-75 R4 (10/10) 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) G...
Page 7 - mportaNt
Dual-Compressor Module Important Safety Information 1 2006SSD-75 R4 (10/10) Dual-Compressor Module Compressor Module Nomenclature iv 2006SSD-75 R4 (10/10) i mportaNt s afety i NformatioN This manual contains important instructions for installation, operation and maintenance of your Copeland Scroll ®...
Page 8 - SAFETY ALERT SYMBOL; NOTE
Dual-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 War...
Page 9 - NtroduCtioN; The Compressor Module
3 2006SSD-75 R4 (10/10) Dual-Compressor Module Introduction 1.0 i 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 r...
Page 10 - The Compressor Package; in the field. Equipment; Inlet gas scrubber
Dual-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 1.3 The Compressor ...
Page 11 - NstallatioN; Installation Guidelines; Required Component—Inlet Gas Scrubber; REQUIRED; compression can cause flooding and damage the Compressor.; Inlet and Discharge Pressures; Table 1; • Excessive oil carryover
5 2006SSD-75 R4 (10/10) 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 suitab...
Page 12 - valve was removed from some of the scroll modules (see table below).; Ambient Temperature Range; on page
6 2006SSD-75 R4 (10/10) 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 belo...
Page 13 - Installation Clearance and Dimensions; Figure 4; for the dimensions of the Compressor Module.
7 2006SSD-75 R4 (10/10) 6 2006SSD-75 R4 (10/10) Dual-Compressor Module Installation TOP VIEW FRONT VIEW SIDE VIEW BOTTOM VIEW 2.4 Installation Clearance and Dimensions Allow sufficient clearance on all sides for service access, especially for gas and electrical connections at the rear of the Compres...
Page 14 - Code; Oil filter
8 2006SSD-75 R4 (10/10) Dual-Compressor Module Installation 2.5 Process and Instrumentation Diagrams (P&IDs) Figure 5 Compressor Module Gas and Oil Flow Diagram and Safety Shutdowns PI 002 TE 002 TS 002 TSHH 002 PI 003 EX -04 BPV-01 SEP-01 TCV-03 FL-05 PS 002 PSHH 002 PS 001 PSLL 001 480V J.B. S...
Page 15 - Electrical Controls; Switches; The drive provides 24V for the
9 2006SSD-75 R4 (10/10) 8 2006SSD-75 R4 (10/10) 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. ...
Page 16 - provide a speed signal.; Figure 6 Brushless DC Fan
10 2006SSD-75 R4 (10/10) Dual-Compressor Module Installation RED BlueWhite Yellow +24VDC DC common No connection feedback 0-10VDC speed signal 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 co...
Page 17 - Figure 9
11 2006SSD-75 R4 (10/10) 10 2006SSD-75 R4 (10/10) Dual-Compressor Module Installation Figure 8 Optional Customer-Installed High Temperature Fan Control System Power Supply 24VDC PLC Or Temperature Control SZO44 Compressor Module 0-10VDC Fan Speed Signal0.9V = Off; 1.3V = 50%; 10V = 100% Temperature ...
Page 18 - Compressor Module Motor Protection; Compressor and individual modules can be turned off.; Figure 10 Motor Control; Variable; Variable Speed
12 2006SSD-75 R4 (10/10) 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 p...
Page 19 - Figure 11 Typical Compressor Module Electrical Requirements; Table 2
13 2006SSD-75 R4 (10/10) 12 2006SSD-75 R4 (10/10) Dual-Compressor Module Installation Code Description 1 Control Techniques VFD,* 30 HP 2 24VDC power supply ** 3 PLC or other control for inputs from Compressor Module 4 480V 3-phase input *** 5 Overload protection device, 2 required Notes* VFD on Var...
Page 20 - Figure 12 Control Circuit Terminations; From VFD
14 2006SSD-75 R4 (10/10) 14 2006SSD-75 R4 (10/10) Dual-Compressor Module Installation 2.6.5 Wiring Figure 12 Control Circuit Terminations Figure 13 Power Terminations Terminal Strip Red Lead (HDP) Blue Lead (LIP) Red Lead (HT) Red Lead – To Fan +24VDC Yellow Lead – To Fan Run Blue Lead (Thermistor) ...
Page 21 - peratioN; MAIN POWER; to inhibit the VFD or either fixed speed; LOW VOLTAGE DEVICES; and devices are configured to inhibit Compressor; MECHANICAL SYSTEMS; Gas filtration and; DURING INITIAL OPERATION, PERFORM THESE CHECKS:
15 2006SSD-75 R4 (10/10) 14 2006SSD-75 R4 (10/10) Dual-Compressor Module Operation 14 2006SSD-75 R4 (10/10) 3.0 o peratioN 3.1 Initial Startup - Compressor Module The following inspections should be made on initial startup—-typically, by the Packager—and after long periods of storage. • Verify accep...
Page 22 - Initial Startup - Compressor Package; the signal from the Compressor Package control system to run:; CHECK FOR THESE CONDITIONS UNDER NORMAL OPERATION:; iv
16 2006SSD-75 R4 (10/10) 16 2006SSD-75 R4 (10/10) Dual-Compressor Module Operation 3.2 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. ...
Page 23 - aiNteNaNCe; Routine Maintenance; Table 3
17 2006SSD-75 R4 (10/10) 16 2006SSD-75 R4 (10/10) Dual-Compressor Module Maintenance 16 2006SSD-75 R4 (10/10) 4.0 m aiNteNaNCe 4.1 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 initia...
Page 24 - Maintenance Tools; Figure 14 Maintenance Tools; CAUTION
18 2006SSD-75 R4 (10/10) Dual-Compressor Module Maintenance Back-seating control valve Oil pump, piston type, high pressure Designed to operate up to 250 psig Filter wrench Alternate product: Strap filter wrench Charging hose 60" (1524mm) Extension hose with valve 6" (152mm) 4.2 Maintenance ...
Page 25 - Checking the Oil Level; • Lower than 1” from the bottom; Oil Capacity and Type
19 2006SSD-75 R4 (10/10) 18 2006SSD-75 R4 (10/10) Dual-Compressor Module Maintenance Oil level sight tube 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 first-stage oil separator level gauge, use the followin...
Page 26 - Adding and Removing Oil; with the compressor running.; Adding Oil; on either compressor suction fitting and connect the; Check for leaks at all fittings that have been disturbed.
20 2006SSD-75 R4 (10/10) Dual-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 fittings, first-stage oil separator and oil cooler (see Figure 15 on page 21 ). 4.5.1 Topping Off the Oil Level...
Page 27 - Figure 15 Adding or Draining Oil; Draining Oil; Steps 5; LEFT SIDE VIEW
21 2006SSD-75 R4 (10/10) 20 2006SSD-75 R4 (10/10) 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 Draining Oil Under normal operation, the Compressor and oil c...
Page 28 - Replacing Oil; Check for leaks at all fittings that have been disturbed.
22 2006SSD-75 R4 (10/10) Dual-Compressor Module Maintenance Replacing Oil 1. Turn the knob on the backseating control valve fully counterclockwise. 2. Remove the protective cap from the Schrader valve on the first-stage oil separator (shown at right) and connect the backseating control valve. 3. Con...
Page 29 - Cleaning the Inlet Screen; Figure 16 Gas Inlet Block and Screen; Remove the SAE plug on the side of the inlet block.; To inspect and clean the orifice:
23 2006SSD-75 R4 (10/10) 22 2006SSD-75 R4 (10/10) Dual-Compressor Module Maintenance 4.6 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 m...
Page 30 - Changing the Second-Stage Separator Element; Return the Compressor Package to service.; Changing the Oil Filter Element; Turn off and isolate the Compressor from all power sources.; Figure 18 Oil Filter Bowl and Element
24 2006SSD-75 R4 (10/10) 24 2006SSD-75 R4 (10/10) Dual-Compressor Module Maintenance Oil filter element (inside oil filter bowl) Oil filter bowl 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...
Page 31 - roubleshootiNg; Troubleshooting Guide; Refer to; for recommended solutions to typical problems.; Table 4; • Ensure adequate oil level in first-stage separator (see; Motor Winding Resistance; Table 5; Infinity
25 2006SSD-75 R4 (10/10) 24 2006SSD-75 R4 (10/10) Dual-Compressor Module Troubleshooting 24 2006SSD-75 R4 (10/10) 5.0 t roubleshootiNg This section offers tips for troubleshooting. 5.1 Troubleshooting Guide Refer to Table 4 for recommended solutions to typical problems. Table 4 Troubleshooting Probl...
Page 32 - Platform Symptoms Diagnosis; Table 6
Dual-Compressor Module Technical Support and Service 26 2006SSD-75 R4 (10/10) 5.3 Platform Symptoms Diagnosis Use the following guidelines to troubleshoot operating problems. Table 6 Platform troubleshooting guidelines Problem Recommended Actions Low Gas Flow • Low inlet pressure• Insufficient gas s...
Page 33 - peCifiCatioNs; • Voltage range
Dual-Compressor Module Technical Support and Service Dual-Compressor Module Technical Support and Service 26 2006SSD-75 R4 (10/10) 27 2006SSD-75 R4 (10/10) 6.0 s peCifiCatioNs Table 7 Compressor Module Specifications General Information Inlet pressure range Approximately -.75 to 25 psig Outlet press...
Page 35 - Configuration
Dual-Compressor Module Technical Support and Service Dual-Compressor Module Technical Support and Service 28 2006SSD-75 R4 (10/10) 29 2006SSD-75 R4 (10/10) Compressor Module Horsepower Selection Chart Module Model Number: SZV32C1A-EDE-150 Configuration Suction Press (PSIG) MCFD Max Flow/HP as a func...
Page 38 - DISPOSE WASTE OIL PROPERLY:; Synthetic Hydrocarbon
Dual-Compressor Module Material Data Safety Sheet 32 2006SSD-75 R4 (10/10) 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 informatio...
Page 39 - Analogous compounds are considered to be essentially non-toxic.; • Wear suitable protective equipment, especially goggles.
Dual-Compressor Module Material Data Safety Sheet 32 2006SSD-75 R4 (10/10) Dual-Compressor Module Material Data Safety Sheet 33 2006SSD-75 R4 (10/10) a.6 f ire aNd e xplosioN h azards Flash Point (by Cleveland Open Cup) 320-530°F (160-276°C) Flammable Limits Not established Auto-Ignition Temperature...