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Emerson SZO22 manual

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Table of contents for the manual

  • Page 1

    Cope l and Scroll ® C ompre ss or Module Installation, O pera tion & Mainten ance Manual Model F amily SZ O22 SZV22[...]

  • Page 2

    [...]

  • Page 3

    Single-Compressor Module T ABLE OF CONTENTS i 2008SSD-34 (5/1 1) T ABLE OF CONTENTS C ompressor m odule N omeNCla ture ............................................................................................. iv i mport aNt s afety i Nforma tioN ....................................................................................................[...]

  • Page 4

    Single-Compressor Module T ABLE OF CONTENTS ii 2008SSD-34 (5/1 1) 4.2 Maintenance T ools ...................................................................................................................... 18 4.3 Oil Service ...........................................................................................................................[...]

  • Page 5

    Single-Compressor Module T ABLE OF CONTENTS ii 2008SSD-34 (5/1 1) Single-Compressor Module T ABLE OF CONTENTS iii 2008SSD-34 (5/1 1) FIGURES Figure 1 Compressor Module Components ........................................................................................................ 3 Figure 2 Copeland Scroll ® Compressor Cross Section ...........[...]

  • Page 6

    Single-Compressor Module Compressor Module Nomenclature iv 2008SSD-34 (5/1 1) C ompressor m odule N omeNCla ture Model Max Delivery Pressure (PSIG) Max Flow (MCFD) Drive HP High Press Switc h Setting (PSIG) Low Press Switc h Setting High Te m p Setting °F (°C) Oil Thermal Bypass V alve Setpoint °F (°C) Gas Bypass Va l ve Module W eight (Lbs.) S[...]

  • Page 7

    Single-Compressor Module Important Safety Information 1 2008SSD-34 (5/1 1) Single-Compressor Module Compressor Module Nomenclature iv 2008SSD-34 (5/1 1) i mport aNt s afety i Nforma tioN This manual contains important instructions for installation, operation and maintenance of your Copeland Scroll ® Compressor Module. W ARNING The Compressor Modul[...]

  • Page 8

    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. W ARNING A W arning describes hazards that CAN or WILL cause [...]

  • Page 9

    3 2008SSD-34 (5/1 1) Single-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 for service in the eld; the completed hous[...]

  • Page 10

    Single-Compressor Module Introduction 1.2 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 Copeland Scroll ® Compressor Cross Section (not shown: Encapsulated Stator) 1.3 The Compressor Package The Compressor Package consists of the Compresso[...]

  • Page 11

    5 2008SSD-34 (5/1 1) Single-Compressor Module Installation 2.0 i Nst alla tioN 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 fro[...]

  • Page 12

    6 2008SSD-34 (5/1 1) Single-Compressor Module Installation NOTE: Required Component – High Pressure Discharge Gas Bypass V alve T o 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[...]

  • Page 13

    7 2008SSD-34 (5/1 1) 6 2008SSD-34 (5/1 1) Single-Compressor Module Installation 2.4 Installation Clearance and Dimensions Allow suf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. Cooling air ow is back to [...]

  • Page 14

    8 2008SSD-34 (5/1 1) Single-Compressor Module Installation 2.5 Process and Instrumentation Diagrams (P&IDs) Figure 5 Compressor Module Gas and Oil Flow Diagram and Safety Shutdowns Single Compressor Module Gas & Oil Flow Diagram & Safety Shutdowns (Gas bypass valve shown is optional)[...]

  • Page 15

    9 2008SSD-34 (5/1 1) 8 2008SSD-34 (5/1 1) Single-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 togethe[...]

  • Page 16

    10 2008SSD-34 (5/1 1) Single-Compressor Module Installation R ED Bl ue Wh it e Y e ll ow +24VD C DC c o m m on N o co n n ecti o n feed b ack 0-10VD C sp eed si g n al 2.6.2 Oil Cooler Fan Control The Compressor Module temperature is controlled by managing module oil ow and temperature. The module’s precise temperature control is critical to s[...]

  • Page 17

    11 2008SSD-34 (5/1 1) 10 2008SSD-34 (5/1 1) Single-Compressor Module Installation Figure 8 Optional Customer-Installed High T emperature Fan Control System • Compressor requirements: 0.8 to 2 GPM (3.0-755 LPM) ow rate • Thermal oil bypass valve, standard setting: 200°F (93°C) / 250°F model specic • Thermal bypass valve operation (val[...]

  • Page 18

    12 2008SSD-34 (5/1 1) Single-Compressor Module Installation 2.6.3 Compressor Module Motor Protection V ariable 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. Figure 10 Motor Control[...]

  • Page 19

    13 2008SSD-34 (5/1 1) 12 2008SSD-34 (5/1 1) Single-Compressor Module Installation 2.6.4 Electrical Requirements Figure 1 1 T ypical Compressor Module Electrical Requirements 1 2 3 4 Op ti on al if mo re th an on e co mp re ss or mo du le us ed Po we r to Co mp resso rs 24 VD C C ooling Fa n 24 V Di screte Input s fr om S cr oll Mod ule 1 1 T able 2[...]

  • Page 20

    14 2008SSD-34 (5/1 1) Single-Compressor Module Installation 2.6.5 Wiring Figure 12 Control Circuit T erminations Control Wiring T erminations[...]

  • Page 21

    15 2008SSD-34 (5/1 1) 14 2008SSD-34 (5/1 1) Single-Compressor Module Installation 2.6.6 V ariable Frequency Drive (VFD) T erminations Refer to Product Bulletin on V ariable Frequency Drive Applications for details on VFD terminations and typical VFD parameters. 3.0 o pera tioN 3.1 Initial Startup - Compressor Module The following inspections should[...]

  • Page 22

    16 2008SSD-34 (5/1 1) Single-Compressor Module Operation 3.1.2 Post-Startup Checklist Perform these checks AFTER starting the Compressor Module: DURING INITIAL OPERA TION, 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. [...]

  • Page 23

    17 2008SSD-34 (5/1 1) 16 2008SSD-34 (5/1 1) Single-Compressor Module Operation 4.0 m aiNteNaNCe 4.1 Routine Maintenance Perform the maintenance procedures in T able 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 o[...]

  • Page 24

    18 2008SSD-34 (5/1 1) Single-Compressor Module Maintenance 4.2 Maintenance T ools 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. Figure 13 Maintenance T ools CAUTION When pressure is applied to the o[...]

  • Page 25

    19 2008SSD-34 (5/1 1) 18 2008SSD-34 (5/1 1) Single-Compressor Module Maintenance 4.3 Oil Service The oil level indicated on the rst-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 ashlight to verify the correct oil level. • The oil level shou[...]

  • Page 26

    20 2008SSD-34 (5/1 1) Single-Compressor Module Maintenance • Scavenge line orice or screen is restricted. Clean or replace. • Insufcient back pressure. Conrm 50-60 psig or higher backpressure when the compressor is running. • No specic cause found. Replace oil separator block assembly , scavenge line and secondary oil separator el[...]

  • Page 27

    21 2008SSD-34 (5/1 1) 20 2008SSD-34 (5/1 1) Single-Compressor Module Maintenance 4.4 Cleaning the Inlet Screen The 30-mesh screen in the inlet block must remain unobstructed for optimal ow rate. If the ow rate is lower than expected even when the Compressor is running properly , this screen may be obstructed. Figure 14 Gas Inlet Block and Scr[...]

  • Page 28

    22 2008SSD-34 (5/1 1) Single-Compressor Module Maintenance 4.6 Changing the Second-Stage Separator Element T o replace the second-stage separator element: 1. T urn of f and isolate the Compressor from all power sources. 2. T urn of f the gas supply . 3. V ent the system to 0 psig. Follow applicable safety procedures and codes. 4. Loosen the separat[...]

  • Page 29

    23 2008SSD-34 (5/1 1) 22 2008SSD-34 (5/1 1) Single-Compressor Module Maintenance 5.2 Platform Symptoms Diagnosis Use the following guidelines to troubleshoot operating problems. T able 6 Platform troubleshooting guidelines Problem Recommended Actions Low Gas Flow • Low inlet pressure • Insufcient gas supply • High temperature • Bypass va[...]

  • Page 30

    24 2008SSD-34 (5/1 1) Single-Compressor Module Maintenance 6.0 s peCifiCa tioNs T able 7 Compressor Module Specications General Information Inlet pressure range Model specic - 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) [...]

  • Page 31

    Single-Compressor Module Material Data Safety Sheet 25 2008SSD-34 (5/1 1) 24 2008SSD-34 (5/1 1) a ppeNdix a - m a terial d a t a 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 in this document to be r[...]

  • Page 32

    Single-Compressor Module Material Data Safety Sheet 26 2008SSD-34 (5/1 1) 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 T emperature No data HMIS Ratings Health 0 Flammability 1 Reactivity 0 NFP A Ratings Not established Extinguishing Media Dry chemical; [...]

  • Page 33

    Single-Compressor Module Material Data Safety Sheet 26 2008SSD-34 (5/1 1)[...]

  • Page 34

    EmersonClim ate .com Vilter M anufacturing LLC P .O. Bo x 8904 Cud ahy , WI 53110-8904 P 414 744 0111 F 414744 1769 www .vilte r .com Copeland Scroll and Eme rson are trademarks of Eme rson Electric Co. or one of its affiliated c ompanies. ©2011 Emerson Climate T echnoligies, Inc. All rights rese rved. Printed in the USA. 2008SSD-34-R2[...]