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®
Copeland Scroll Compressor Module
Installation, Operation & Maintenance Manual
Model Family
SZV32
SZV44
SZO44
SZO56
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Dual-Compressor Module TABLE OF CONTENTS TABLE OF CONTENTS Compressor m odule NomeNCturela ............................................................................................. iv i aN mport t s afety i NN tioforma .......................................................................................................1 1.0 i NtroduCN tio ......................................................................................................................3 1.1 The Compressor Module ....
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Dual-Compressor Module TABLE OF CONTENTS 4.2 Maintenance Tools ...................................................................................................................... 20 4.3 Checking the Oil Level ................................................................................................................ 21 4.3.1 Oil Level Guidelines - Minimum Speed .........................................................................................21 4.3.2 Oil Level Guidelines - Max
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Dual-Compressor Module TABLE OF CONTENTS 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 .................................................................................
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Dual-Compressor Module Compressor Module Nomenclature Compressor m odule NomeNCturela Oil High Thermal Max Press Low Bypass Delivery Max Switch Press High Temp Valve Module Pressure Flow Drive Setting Switch Setting Setpoint Gas Bypass Weight Model (PSIG) (MCFD) HP (PSIG) Setting °F (°C) °F (°C) Valve (Lbs.) Dual Scroll Units 0.75 PSIG SZO56C1A-EDE-110 150 260 30 215 240 (116) 200 NO 625 (52 mbarg) 0.75 PSIG SZO44C1A-EDE-140 190 200 30 215 240 (116) 200 NO 625 (52 mbarg) 0.75 PSIG
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Dual-Compressor Module Compressor Module Nomenclature Dual-Compressor Module Important Safety Information i aN mport t s afety i NN tioforma 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. Th
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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 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
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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 ready for service in the field; the completed housing is done by equipment Packagers. This section provides an overview of these components. These terms are used throughout this manual: • Compressor Module - the SZO44 Com
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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 Package The 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 Co
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Dual-Compressor Module Installation 2.0 i NN tioallast 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. NOTE Failing to use an appropriate inlet gas scrubber to remove liquids from the gas prior to compression can cause flooding and dam
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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 Oil Max Press Thermal Delivery Max Switch Low Bypass Module Pressure Flow Setting Press High Temp Valve Weight PSIG MCFD Drive PSIG Switch Setting Setpoint Gas Bypass Lbs. Model (barg) (MCMD) HP (barg) S
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Dual-Compressor Module Installation 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 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 Compress
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Dual-Compressor Module Installation 2.5 Process and Instrumentation Diagrams (P&IDs) Figure 5 Compressor Module Gas and Oil Flow Diagram and Safety Shutdowns PSLL 001 Gas Discharge BPV-01 1" -NPT PS 001 Gas Suction PI PS PSHH PI 1-1/2" -NPT 002 002 003 002 C-01 TS TSHH 002 002 TE 002 SEP-02 480V J.B. SEP-01 C-02 TCV-03 FL-05 Module Limits 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 Pre
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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 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. Switches Al
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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. • Cooling fans require 24VDC, 4.5A (105 Watts) x 2 (9A 210W total) for the Compressor Module. Fan speed is controlled by a 0-1
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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 PLC 0.9V = Off; 1.3V = 50%; 10V = 100% Or Temperature Temperature Sensor Control • 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 purpo
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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. Module capacity can 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
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Dual-Compressor Module Installation 2.6.4 Electrical Requirements Figure 11 Typical Compressor Module Electrical Requirements 1 1 1 Code Description 1 Control Techniques VFD,* 30 HP 2 24VDC power supply ** 3 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 4 480V 3-phase input *** 5 Overload protection device, 2 required 4 2 Notes * VFD on Variable Speed Drive models. ** All other component
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Dual-Compressor Module Installation 2.6.5 Wiring Figure 12 Control Circuit Terminations Terminal Strip Blue Lead (LIP) 1 1 2 2 Red Lead (HDP) 3 3 60K Resistor Red Lead (HT) 4 4 Red Lead – To Fan +24VDC 5 5 Yellow Lead – To Fan Run 6 6 Yellow Lead (Thermistor) Blue Lead (Thermistor) 7 7 Jumper Blue Lead – To Fan DC Common 8 8 Brown Lead (LIP) 9 9 Control wiring Jumper terminations 10 10 Brown Lead (HDP) 11 11 Brown Lead (HT) 12 12 Black Lead (OFD) 13 13 Green/Yellow Lead (HT) 14 14 Green/Yellow
