Emerson Copeland Scroll SZO22 Instruction manual

Copeland Scroll®Compressor Module
Installation, Operation & Maintenance Manual
Model Family
SZO22
SZV22

Single-Compressor Module TABLE OF CONTENTS
i 2008SSD-34 (5/11)
TABLE OF CONTENTS
Compressor module NomeNClature............................................................................................. iv
importaNt safety iNformatioN .......................................................................................................1
1.0 iNtroduCtioN ......................................................................................................................3
1.1 The Compressor Module .............................................................................................................. 3
1.2 The Compressor........................................................................................................................... 4
1.3 The Compressor Package............................................................................................................ 4
2.0 iNstallatioN .......................................................................................................................5
2.1 Installation Guidelines................................................................................................................... 5
2.1.1 Required Component—Inlet Gas Scrubber.....................................................................................5
2.1.2 General Installation Guidelines........................................................................................................5
2.2 Inlet and Discharge Pressures...................................................................................................... 5
2.3 Ambient Temperature Range........................................................................................................ 6
2.4 Installation Clearance and Dimensions ........................................................................................ 7
2.5 Process and Instrumentation Diagrams (P&IDs).......................................................................... 8
2.6 Electrical Controls......................................................................................................................... 9
2.6.1 General Considerations...................................................................................................................9
2.6.2 Oil Cooler Fan Control...................................................................................................................10
2.6.3 Compressor Module Motor Protection...........................................................................................12
2.6.4 Electrical Requirements.................................................................................................................13
2.6.5 Wiring ............................................................................................................................................14
2.6.6 Variable Frequency Drive (VFD) Terminations ..............................................................................15
3.0 operatioN ........................................................................................................................15
3.1 Initial Startup - Compressor Module ........................................................................................... 15
3.1.1 Pre-Startup Checklist.....................................................................................................................15
3.1.2 Post-Startup Checklist ...................................................................................................................15
3.2 Initial Startup - Compressor Package......................................................................................... 16
3.3 Normal Operation Checklist........................................................................................................ 16
4.0 maiNteNaNCe ....................................................................................................................17
4.1 Routine Maintenance.................................................................................................................. 17

Single-Compressor Module TABLE OF CONTENTS
ii 2008SSD-34 (5/11)
4.2 Maintenance Tools...................................................................................................................... 18
4.3 Oil Service .................................................................................................................................. 19
4.6 Cleaning the Inlet Screen ........................................................................................................... 21
4.7 Servicing the Scavenge Line Orice........................................................................................... 21
4.8 Changing the Second-Stage Separator Element........................................................................ 21
5.0 troubleshootiNg .............................................................................................................22
5.1 Troubleshooting Guide ............................................................................................................... 22
5.2 Motor Winding Resistance.......................................................................................................... 22
5.3 Platform Symptoms Diagnosis.................................................................................................... 23
6.0 speCifiCatioNs ..................................................................................................................24
7.0 teChNiCal support aNd serviCe .......................................................................................25
appeNdix a material data safety sheet ...................................................................................26
A.1 Supplier....................................................................................................................................... 26
A.2 Product Name and Information................................................................................................... 26
A.3 Components and Hazard Statement .......................................................................................... 26
A.4 Safe Handling and Storage......................................................................................................... 26
A.5 Physical Data.............................................................................................................................. 26
A.6 Fire and Explosion Hazards........................................................................................................ 27
A.7 Reactivity Data............................................................................................................................ 27
A.8 Health Hazard Data .................................................................................................................... 27
A.9 Personal Protection Information ................................................................................................. 27
A.10 Spill or Leak Procedures............................................................................................................. 27
A.11 Waste Disposal Methods ............................................................................................................ 27

Single-Compressor Module TABLE OF CONTENTS
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Single-Compressor Module TABLE OF CONTENTS
iii 2008SSD-34 (5/11)
FIGURES
Figure 1 Compressor Module Components ........................................................................................................3
Figure 2 Copeland Scroll®Compressor Cross Section ........................................................................................4
Figure 3 Typical Compressor Package ...............................................................................................................4
Figure 4 Compressor Module Dimensions, in. (mm)............................................................................................7
Figure 5 Compressor Module Gas and Oil Flow Diagram and Safety Shutdowns ..............................................8
Figure 6 Brushless DC Fan ...............................................................................................................................10
Figure 7 Basic Fan Control System ..................................................................................................................10
Figure 8 Optional Customer-Installed High Temperature Fan Control System ................................................. 11
Figure 9 Oil Cooling and Thermal Valve............................................................................................................. 11
Figure 10 Motor Control ......................................................................................................................................12
Figure 11 Typical Compressor Module Electrical Requirements .........................................................................13
Figure 12 Control Circuit Terminations ................................................................................................................14
Figure 13 Maintenance Tools ...............................................................................................................................18
Figure 14 Gas Inlet Block and Screen ................................................................................................................21
Figure 15 Scavenge Line Orice .........................................................................................................................21
TABLES
Table 1 Inlet and discharge pressure limits ........................................................................................................5
Table 2 Typical Compressor Module power supply requirements ....................................................................13
Table 3 Maintenance summary.........................................................................................................................17
Table 4 Troubleshooting ...................................................................................................................................22
Table 5 VFD fault codes and descriptions ........................................................................................................22
Table 6 Platform troubleshooting guidelines.....................................................................................................23
Table 7 Compressor Module specications ......................................................................................................24

Single-Compressor Module Compressor Module Nomenclature
iv 2008SSD-34 (5/11)
Compressor module NomeNClature
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
Bypass
Valve
Module
Weight
(Lbs.)
Single Scroll Units
SZO22C3A-EDE-234 125 100 10 215 2” W.C.
(5 mbarg)
240
(116) 200 YES 350
SZV22C1A-EDE-140 190 100 15 215 2” W.C.
(5 mbarg)
280
(138) 250 NO 356
NOTE:
SZO modules are intended for use with clean, dry gas in applications with moderate ambient
temperatures. Oil thermal bypass valve setpoint is 200°F. Most SZO module applications use
PAO oil.
SZV modules keep discharge gas temperatures elevated to help with dewpoint control. SZV
modules insulate the separators and use a 250°F oil thermal bypass valve. In cold ambient,
and SZV module should be used with an enclosure. Most SZV module applications use PAG
oil.
Refer to Copeland Scroll Gas Compression Module Performance Program for all details.

Single-Compressor Module Important Safety Information
1 2008SSD-34 (5/11)
Single-Compressor Module Compressor Module Nomenclature
iv 2008SSD-34 (5/11)
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
qualied engineering personnel. The system must conform to all applicable local and national
regulations and safety standards.
These instructions are intended to assist in the installation and operation of the Compressor
Module and MUST be kept with the Compressor.
Service and maintenance of the Compressor Module must be performed by qualied technicians
only. Service and maintenance must conform to all applicable local and national regulations and
safety standards.
Thoroughly review this manual, all instructions and hazard warnings before performing any work
on the Compressor Module.
Maintain all Compressor Module operation and hazard warning labels.
WARNING
Flammable gas can form explosive mixtures with air. Explosive gases can cause property
damage, serious personal injury or death.
WARNING
Failure to disconnect and lockout electrical power from the Compressor Module before attempting
maintenance can cause shock, burns, severe personal injury or death.
WARNING
Loosening or removing pressure-containing components from the Compressor Module when it is
in operation can cause major property damage, serious personal injury or death.
Failure to relieve system pressure prior to performing service or maintenance on the Compressor
Module can cause property damage or serious personal injury.
CAUTION
Extreme heat can cause personal injury or property damage.
CAUTION
Always use a lifting device capable of supporting the full weight of the Compressor Module or
component being lifted.
Handling or lifting heavy assemblies can cause personal injury or property damage.

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.
NOTE
A Note indicates special instructions that are very important and must be followed.
2 Form No. 2008SSD-34 (5/11)

3 2008SSD-34 (5/11)
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 eld; 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 SZO22 Compressor Module shown in Section 1.1
• Compressor - a Copeland Scroll®Compressor
• Compressor Package - the entire assembly, including the Compressor Module, ready for service in
the eld
• Packagers - the company that prepares the Compressor Module for service
• VFD - Variable Frequency Drive used to power a variable speed Compressor Module
1.1 The Compressor Module
The Compressor Module consists of one Compressor and the other components shown in Figure 1.
Figure 1 Compressor Module Components

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 Compressor Module housed in an assembly ready for service
in the eld. Equipment Packagers customize the assembly and complete the fabrication for Compressor
Modules for each application. Figure 3 shows a simplied example of a Compressor Package.
Figure 3 Typical Compressor Package
Oil
cooler
Gas aftercooler
(if applicable)
Control and
power panel
Compressor
Module
Inlet gas scrubber
for liquid removal
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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 ooding and
damaging the Compressor.
NOTE
Failing to use an appropriate inlet gas scrubber to remove liquids from the gas prior to
compression can cause ooding and damage the Compressor.
2.1.2 General Installation Guidelines
Follow these general guidelines for installation:
• The Compressor Module must be installed and operated in compliance with all applicable codes and
regulations.
• The system must be installed on a level surface.
• Install pipe unions or anges to connect the system to the inlet and discharge piping for ease of
service.
• Install isolation valves on the inlet and discharge piping.
• A common ground must be connected between the Compressor Module and the
Compressor Package chassis. This ground must comply with the National Electric Code (NEC) and
any other applicable codes.
• Solid debris also must be removed from the gas prior to compression. When required, use a
5 to 10-micron inlet lter to remove debris from the gas stream. The degree of ltration required
depends on the specic application.
2.2 Inlet and Discharge Pressures
Refer to Table 1 for acceptable inlet and discharge pressure levels.
Table 1 Inlet and discharge pressure limits
Type Level Operating Guidelines
Minimum Inlet
Pressure
0.75 psig / 2" water
column (model specic) Consult factory for operations below 0.0 psig.
Maximum Inlet
Pressure
10 / 25 psig
(model specic)
Operation at pressures above 25 psig will result in:
• Excessive oil carryover
• Loss of oil from the Compressor Module
Discharge
Pressure
Range
70 psig
to
190 psig
(depends on model)
When the discharge pressure of the Compressor Module reaches
the maximum, which ranges from 70 to 190 psig, depending on the
model (see Compressor Module Nomenclature on page iv):
• The Compressor Module goes into high discharge pressure
recycle if equipped.
• The Compressor Module’s bypass regulator diverts gas from the
high-pressure side to the low-pressure side of the module.
All Compressor Modules must be equipped with pressure-limiting
or relief devices.
Minimum
Differential
Pressure
70 psi A minimum pressure differential of 70 psi between inlet and
discharge pressure is required for proper operation.

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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). For details on
ambient temperatures for VFD startup and Compressor Module operation, see Table 10 on page 24.

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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 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 Compressor Module Dimensions, in. (mm)

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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)

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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
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
All switch connections are wired to terminal strips in a junction box on the Compressor Module.
Switch Status
• Low Inlet Gas Pressure Normally Open, closes on pressure rise
• High Discharge Gas Pressure Normally Closed, opens on pressure rise
• High Temperature Normally Closed, opens on temperature rise
Electrical Considerations - Variable Speed Compressor Module
• Compressor power for a variable speed Compressor Module is the Variable Frequency Drive (VFD).
• Compressor speed control can be either a 4-20 mA or 0-10V signal (transducer supplied by customer)
applied to the VFD. Speed can also be manually controlled with a potentiometer or the VFD can be
set for a xed speed.
• The Compressor is protected by the VFD.
• The customer control circuit must supply an Enable signal to the VFD before the drive will accept a
Run Fwd signal.
• The VFD will start when the Enable signal is on and a Run Fwd signal is applied.
• The VFD will stop if the Run Fwd signal is off or the Enable signal is removed.
NOTE
The drive provides 24V for the Enable and Run Fwd signals.
The installer must connect the Enable and Run Forward terminals to the drive’s 24V terminal.

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Single-Compressor Module Installation
RED
Blue
White
Yell ow
+24VDC
DC co mmon
No connection feedback
0-10VDC speed signal
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 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. Fan speed is controlled
by a 0-10VDC control signal that is applied to the yellow lead on the fan terminal strip. Standard
Compressor Modules use a nonlinear PTC thermistor to monitor oil temperature and provide a speed
signal.
• High temperature Compressor Modules use a linear NTC thermistor to monitor oil temperature. This
signal is available to support a customer-provided fan speed control circuit.
• All power connections are wired to terminal strips in a junction box on the Compressor Module.
Figure 6 Brushless DC Fan
Figure 7 Basic Fan Control System
Dropping Resistor
One Fan 100 K Ohms
Two Fans 60.4 K Ohms
PTC Thermistor
In Thermowell
The PTC Thermistor is nonlinear and switches to high
resistance in the 170-190°F (77-88°C) range.
Red Wire – 24VDC Yellow Wire – 0-24VDC
To fan speed control Blue Wire – DC Common

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Single-Compressor Module Installation
Figure 8 Optional Customer-Installed High Temperature 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 (valve’s purpose is to provide discharge temperature control)
• Oil ow on valve is A to B when the unit is cold and A to C when the heat rises (see Figure 9).
Figure 9 Oil Cooling and Thermal Valve
A B
C
Oil Cooler
Return
to Compressor
1st-Stage Separator

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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 4800 rpm.
Figure 10 Motor Control

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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 Typical Compressor Module power supply requirements
Compressor Power (data based on 480VAC) Variable Speed
Module horsepower 10 or 15 HP
VFD voltage supply range 342-528VAC
Phase 3-phase*
Frequency 50/60 Hz
Low Voltage DC Specications - Oil Cooler Fan Voltage and Power
Fan motor voltage 24VDC
Total fan motor current 4.5A
Additional power may be required to support customer logic and control circuits.
* Contact factory for information about single-phase applications.
** Reduced capacity at 50 Hz.
Code Description
1 Control Techniques VFD,* 10 or 15 HP
model specic
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.
** All other components supplied by Packagers.
*** Contact factory for information about single-phase and
other voltage applications.
Optional if more than one
Compressor Module used

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Single-Compressor Module Installation
2.6.5 Wiring
Figure 12 Control Circuit Terminations
Control Wiring Terminations