Emerson Copeland Scroll SZV22 Troubleshooting guide

Copeland Scroll® Compressor Module
Installation, Operation & Maintenance Manual
Model Family
SZO22
SZV22
Single-Compressor Module
TABLE OF CONTENTS
TABLE OF CONTENTS
Compressor Module Nomenclature. ............................................................................................ iv
Important Safety Information........................................................................................................1
1.0Introduction.......................................................................................................................3
1.1
The Compressor Module............................................................................................................... 3
1.2
The Compressor............................................................................................................................ 4
1.3
The Compressor Package............................................................................................................. 4
2.0Installation........................................................................................................................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
3.0Operation.........................................................................................................................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
4.0Maintenance.....................................................................................................................17
4.1
Routine Maintenance................................................................................................................... 17
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TABLE OF CONTENTS
4.2
Maintenance Tools....................................................................................................................... 18
4.3
Oil Service................................................................................................................................... 19
4.6
Cleaning the Inlet Screen............................................................................................................ 21
4.7
Servicing the Scavenge Line Orifice............................................................................................ 21
4.8
Changing the Second-Stage Separator Element........................................................................ 21
5.0Troubleshooting..............................................................................................................22
5.1
Troubleshooting Guide................................................................................................................ 22
5.2
Motor Winding Resistance........................................................................................................... 22
5.3
Platform Symptoms Diagnosis..................................................................................................... 23
6.0Specifications...................................................................................................................24
7.0Technical 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
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TABLE OF CONTENTS
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 Orifice ..........................................................................................................................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 specifications.......................................................................................................24
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Compressor Module Nomenclature
Compressor Module Nomenclature
Max
Delivery
Pressure
(PSIG)
Max
Flow
(MCFD)
Drive
HP
High
Press
Switch
Setting
(PSIG)
SZO22C3A-EDE-234
125
100
10
SZV22C1A-EDE-140
190
100
15
Model
Oil
Thermal
Bypass
Valve
Setpoint
°F (°C)
Gas
Bypass
Valve
Module
Weight
(Lbs.)
Low
Press
Switch
Setting
High
Temp
Setting
°F (°C)
215
2” W.C.
(5 mbarg)
240
(116)
200
YES
350
215
2” W.C.
(5 mbarg)
280
(138)
250
NO
356
Single Scroll Units
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.
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Important Safety Information
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
qualified 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 qualified 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.
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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.
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Introduction
1.0Introduction
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 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 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 field
• 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 1Compressor Module Components
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1.2
Introduction
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 field. Equipment Packagers customize the assembly and complete the fabrication for Compressor
Modules for each application. Figure 3 shows a simplified example of a Compressor Package.
Figure 3 Typical Compressor Package
Inlet gas scrubber
for liquid removal
Control and
power panel
Gas aftercooler
(if applicable)
Oil
cooler
Compressor
Module
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Installation
2.0Installation
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 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 flanges 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 filter to remove debris from the gas stream. The degree of filtration required
depends on the specific application.
2.2
Inlet and Discharge Pressures
Refer to Table 1 for acceptable inlet and discharge pressure levels.
Table 1
Type
Inlet and discharge pressure limits
Level
Minimum Inlet
Pressure
0.75 psig / 2" water
column (model specific)
Maximum Inlet
Pressure
10 / 25 psig
(model specific)
Discharge
Pressure
Range
70 psig
to
190 psig
(depends on model)
Minimum
Differential
Pressure
70 psi
Operating Guidelines
Consult factory for operations below 0.0 psig.
Operation at pressures above 25 psig will result in:
• Excessive oil carryover
• Loss of oil from the Compressor Module
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.
A minimum pressure differential of 70 psi between inlet and
discharge pressure is required for proper operation.
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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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2.4
Installation
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 Compressor Module Dimensions, in. (mm)
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2.5
Installation
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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2.6
Installation
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
• Low Inlet Gas Pressure
• High Discharge Gas Pressure
• High Temperature
Status
Normally Open, closes on pressure rise
Normally Closed, opens on pressure rise
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 fixed 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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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) 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
+24VDC
DC common
No connection feedback
0-10VDC speed signal
RED
Blue
White
Yellow
Figure 7 Basic Fan Control System
Dropping Resistor
One Fan 100 K Ohms
Two Fans 60.4 K Ohms
Red Wire – 24VDC
PTC Thermistor
In Thermowell
Yellow Wire – 0-24VDC
To fan speed control
Blue Wire – DC Common
The PTC Thermistor is nonlinear and switches to high
resistance in the 170-190°F (77-88°C) range.
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Figure 8 Optional Customer-Installed High Temperature Fan Control System
•
•
•
•
Compressor requirements: 0.8 to 2 GPM (3.0-755 LPM) flow rate
Thermal oil bypass valve, standard setting: 200°F (93°C) / 250°F model specific
Thermal bypass valve operation (valve’s purpose is to provide discharge temperature control)
Oil flow 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
1st-Stage Separator
A
B
Return
to Compressor
C
Oil Cooler
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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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Installation
2.6.4 Electrical Requirements
Figure 11 Typical Compressor Module Electrical Requirements
1
1
1
Code
Optional
Optional ifif more
more than
than one
compressor
Compressormodule
Module used
used
4
2
Description
1
Control Techniques VFD,* 10 or 15 HP
model specific
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.
3
Power
to Compressors
Table 2
24VDC
Cooling
Fan
24V Discrete Inputs
from Scroll Module
Typical Compressor Module power supply requirements
Compressor Power (data based on 480VAC)
Module horsepower
VFD voltage supply range
Phase
Frequency
Low Voltage DC Specifications - Oil Cooler Fan Voltage and Power
Fan motor voltage
Total fan motor current
Variable Speed
10 or 15 HP
342-528VAC
3-phase*
50/60 Hz
24VDC
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.
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Installation
2.6.5 Wiring
Figure 12 Control Circuit Terminations
Control Wiring Terminations
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Installation
2.6.6 Variable Frequency Drive (VFD) Terminations
Refer to Product Bulletin on Variable Frequency Drive Applications for details on VFD terminations
and typical VFD parameters.
3.0 Operation
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 acceptable pre-startup conditions using the checklist in 3.1.1 - Pre-Startup Checklist.
• Start the Compressor Module, then perform the checks in 3.1.2 - Post-Startup Checklist.
3.1.1 Pre-Startup Checklist
Perform these checks BEFORE starting the Compressor Module:
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 Frequency
Drive (VFD) or Fixed Speed Compressor
motors is correct.
___ 4.All chassis, earth grounds are connected.
___ 5.A load reactor or other approved filter is
installed for systems with power lead lengths
in excess of 200 ft. (61m) between the VFD
and Compressor Module terminal box.
LOW VOLTAGE DEVICES
Verify these conditions for low voltage devices:
___ 1.DC polarity is correct.
___ 2.Temperature control device—if other than
standard thermistor control—is working
properly.
SAFETY AND CONTROL DEVICES
Make sure that all safety and control switches
and devices are configured to inhibit Compressor
operation if a fault condition is detected, including:
___ 1.Low inlet pressure switch
___ 2.High discharge pressure switch
___ 3.High temperature switch
___ 4.Variable Frequency Drive (VFD) fault
___ 5.Motor overload trip
___ 6.Other safety and control switches and
devices
MECHANICAL SYSTEMS
Inspect for these conditions:
___ 1.(Required) Compressor inlet is protected
from water slugging.
___ 2.(Recommended) Gas filtration and
treatment is appropriate for the
application.
___ 3.Packager configuration applies back
pressure to the Compressors.
___ 4.Inlet and discharge valves allow the
module to be isolated.
___ 5.All guards and protective covers are
installed.
___ 6.Protection from freezing is provided if
needed for the application and location.
___ 7.A suitable enclosure providing protection
from the elements is appropriate for the
application and location.
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Operation
3.1.2 Post-Startup Checklist
Perform these checks AFTER starting the Compressor Module:
DURING INITIAL OPERATION, 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.No gas leaks are present.
___ 4.No oil leaks are present.
___ 5.Oil cooler fan turn on and run at the appropriate temperature.
___ 6.Oil cooler fan speed varies with temperature.
___ 7.Compressor motor speed varies appropriately for the Packager configuration.
___ 8.Compressor continues to operate in bypass when the Compressor Module discharge is blocked.
___ 9. Compressor Module is leak tight (maintains approximately 30 psig or more when the Compressors are initially
turned off).
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.
3.3
Normal Operation Checklist
Observe the following conditions after startup—when power is applied to the VFD and the VFD receives
the signal from the Compressor Package control system to run:
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 specific.
___ 3. Discharge pressure should range from 70 psig to 190 psig, depending on the model
(see Compressor Module Nomenclature on page iv).
___ 4. Pressure differential between suction and discharge is at least 70 psi.
___ 5. First-stage separator temperature should be between 170°F and 220°F (77-104°C) model specific.
___ 6. Oil cooler fans should either run continuously or cycle periodically under normal conditions.
If any of these conditions are not met during normal operation, shut down the unit and refer to 5.0 Troubleshooting on page 22.
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Operation
4.0Maintenance
4.1
Routine Maintenance
Perform the maintenance procedures in Table 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 of actual consumption.
Table 3
Maintenance summary
Components
Maintenance
Reason
• Monitor and check the oil level.
• Add oil as needed.
Lubrication
& Cooling
System
• Change oil annually.
Note: Some applications may require more
frequent service.
• Check the condition of the lubricant
periodically. Normal color is clear or light
gray.
A low oil level or loss
of oil in the system will
result in overheating or
mechanical failure.
A high oil level may result
in excessive oil carryover
and oil discharge from
the Compressor Module
when the Compressors
are turned off.
• Change the oil filter (if equipped) annually
or as required.
Gas Inlet
System
SecondStage
Separator
System
Oil Heat
Exchanger
For details, see:
4.3 - Oil Sevice
(page 19)
4.3 - Oil Service
(page 19)
4.3 - Oil Service
(page 19)
—
—
• Inspect and clean the inlet screen annually
or more often as needed.
A restricted inlet screen
will result in reduced flow.
4.6 - Cleaning
the Inlet Screen
(page 21)
• Inspect and clean the scavenge line orifice
annually or more often as needed.
A restricted scavenge
line orifice will result in
excessive oil carryover.
4.7 - Servicing
the Scavenge
Line Orifice
(page 21)
• Change the second-stage oil separator
element annually or more often if
contaminated.
Note: Some applications may require more
frequent service.
A dirty or plugged
separator element will
result in excessive oil
carryover.
4.8 - Changing
the SecondStage Separator
Element
(page 24)
• Ensure heat exchanger cooling fins are clear
of dust and debris.
• Verify that the fans run freely.
—
—
See 5.0 - Troubleshooting on page 22 for additional details.
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4.2
Maintenance
Maintenance Tools
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 Tools
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)
CAUTION
When pressure is applied to the oil pump, the handle may extend rapidly.
Verify the Compressor Module pressure is 0 psig before removing the second-stage oil separator.
Note
One full stroke oil pump of the handle dispenses 1.6 oz. (47ml) of oil. Move the pump handle
slowly using long, slow, full strokes.
Note
The hose fittings contain a core depressor that opens the Schrader valve when the fittings
are attached. A backseating control valve can be used to open the Schrader valves on the
Compressor Module.
When the knob is turned fully counterclockwise, the core depressor is retracted and the
backseating control valve can be installed on a Schrader valve without loss of oil.
When the knob is turned clockwise, the core retractor is extended, opening the Schrader valve.
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4.3
Maintenance
Oil Service
The oil level indicated on the first-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 flashlight to verify the correct oil level.
•
The oil level should never reach the top of the upper site glass on the primary oil separator under any
operating conditions.
•
If possible block the compressor discharge to force the system into full bypass.
1. Compressor operating at minimum speed 1,800 RPM,
•
Lower site glass 50%: No action required.
•
Lower site glass less than 50%: Add approved oil to this level.
•
Lower site glass more than 100%: Remove excess oil.
2. Compressor is operating at full speed 4,800 RPM the lower site glass will be 100% full and the upper
site glass will also show some level of oil
•
Upper site glass 50%: No action required.
•
Upper site glass 100% or more: Remove excess oil.
High Oil Carryover
1. System is overfilled with oil: The oil level should never reach the top of the primary oil separator top
site glass under any operating condition.
2. No back pressure on the discharge when the compressor is turned off resulting in oil foaming and
carrying over to the secondary oil separator: Check upper site glass when the compressor is first turned
off.
3. Contaminated or oil saturated secondary oil separator: Replace the secondary oil separator every
8,000 operating hours, more frequently if the gas is dirty.
4. Clogged or restricted scavenge line orifice: Remove inspect and clean.
5. Clogged or restricted oil scavenge tube: Remove inspect and clean.
6. Incorrect oil: Use only approved oil.
7. Inlet pressure too high: Verify that the inlet pressure is less than 10 PSIG.
Symptoms
•
Low oil level, High temperature fault, Oil in gas.
Possible Cause
•
Secondary oil separator is saturated with oil or at the end of its service life. Replace.
•
Oil level above top site glass under any operating condition. System overfilled with oil. Remove
excess oil, replace secondary oil separator.
•
Failed “O” ring in the oil separator block assembly. Repair or replace assembly.
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2008SSD-34 (5/11)
Single-Compressor Module
Maintenance
•
Scavenge line orifice or screen is restricted. Clean or replace.
•
Insufficient back pressure. Confirm 50-60 psig or higher backpressure when the compressor is
running.
•
No specific cause found. Replace oil separator block assembly, scavenge line and secondary oil
separator element.
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Single-Compressor Module
4.4
Maintenance
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 may be obstructed.
Figure 14Gas Inlet Block and Screen
To inspect and clean the inlet screen:
1. Turn off and isolate the Compressor from all power
sources.
2. Turn off the gas supply.
3. Vent the system to 0 psig.
4. Remove the SAE plug on the side of the inlet block.
5. Remove the screen.
6. Inspect the screen and inside of the block. Clean or
replace if necessary.
7. Replace SAE nut.
8. Return the Compressor Package to service.
9. Check for leaks at all fittings that have been disturbed.
4.5
Servicing the Scavenge Line Orifice
The scavenge line orifice in the oil separator block must remain clear of obstruction. If this orifice is
restricted, the secondstage oil separator can become saturated, increasing oil consumption.
Note: image shown is 90 degree orifice. Procedure is the same for straight orifice.
Figure 15 Scavenge Line Orifice
Orifice
To inspect and clean the orifice:
1.
2.
3.
4.
5.
6.
7.
8.
Turn off and isolate the Compressor from all power sources.
Turn off the gas supply.
Vent the system to 0 psig.
Disconnect the tube and remove the fitting.
Inspect the screen. Clean or replace the fitting assembly if necessary.
Replace the fitting and reconnect the tube. Tighten the swage nut hand tight plus 1/4 turn.
Return the Compressor Package to service.
Check for leaks at all fittings that have been disturbed.
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Single-Compressor Module
4.6
Maintenance
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 procedures and codes.
4. Loosen the separator element by turning it counterclockwise with a strap wrench.
5. Remove the separator element. Verify the gasket is removed with the separator.
6. Inspect the separator block for contaminants and remove any debris.
7. Apply a small amount of oil to the gasket and internal "O" ring on the new separator element.
8. Install the element on the separator block; turn clockwise to tighten.
9. Return the Compressor Package to service.
10. Check for leaks at all fittings that have been disturbed
5.0Troubleshooting
This section offers tips for troubleshooting.
5.1
Troubleshooting Guide
Refer to Table 6 for recommended solutions to typical problems.
Table 4
Troubleshooting
Problem
Low Inlet
Gas Pressure
Fault
High Oil
Temperature
Fault
Recommended Actions
• Closed gas inlet valve.
• Restricted or insufficient gas supply.
• Blocked inlet filter/screen (located internally on the Compressor Module inlet block).
• Blocked air flow across oil cooler.
• Ensure cooling fans are operating when the unit is running and up to temperature; at
approximately 180°F (82°C), fans should start to run at minimum speed.
• Ensure adequate oil level in first-stage separator (see 4.3 - Oil Service on page 19).
High Discharge
Pressure Fault
• Restricted discharge and bypass valve fault.
VFD Fault
• The drive LED will display the specific fault (see Table 7).
Table 5
VFD fault codes and descriptions
Code
Description
UU
Insufficient voltage
OU
Excessive voltage
OI.AC
Excessive motor current (instantaneous condition)
It.AC
Excessive motor current (overload condition)
Oh1, Oh2
Excessive heat sink temperature
Ph
Loss of AC supply phase
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Single-Compressor Module
5.2
Maintenance
Platform Symptoms Diagnosis
Use the following guidelines to troubleshoot operating problems.
Table 6
Platform troubleshooting guidelines
Problem
Recommended Actions
• Low inlet pressure
• Insufficient gas supply
Low Gas
Flow
• High temperature
• Bypass valve open
• Low Compressor speed
• Restricted inlet screen
• Saturated or dirty secondstage oil separator
High Oil
Carryover
• High oil level
• Restricted scavenge orifice
• Insufficient back pressure
• Oil dilution
• Determine drive status.
Compressors
Won’t Run
Incorrect
Compressor
Speed
High
Temperature
• Is inhibit circuit closed?
• Is run signal present?
• Does the VFD indicate a fault code?
• Low inlet pressure
• High discharge pressure
• High temperature, fan, low oil, oil cooler
• Problem with speed control sensor and related components
• Low oil level
• Restricted oil filter
• Blocked oil cooler air flow
• Oil cooler fan not operating
• Operation conditions outside of Compressor Module specifications
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Single-Compressor Module
Maintenance
6.0Specifications
Table 7
Compressor Module Specifications
General Information
Inlet pressure range
Model specific - refer to application envelope
70 to 275 psig (depends on model—see page iv)
Outlet pressure range
Mechanical Description
Module weight
Approximately 350 lb. (160kg)
Suction connection
1.0” NPT
Discharge connection
0.75” NPT
Sound level
Approximately 72 dBA @ 1 m, 58 dBA @ 10 m
Vibration
3 mil at 60 Hz
Minimum cold start ambient temperature
Ambient operating temperature range
1,4
Compressor -20°F (-29°C) VFD power 14°F (-10°C)
0 to 122°F (-18 to 50°C)
1,4
See Figure 4 on page 7
Module dimensions
Materials of Construction
Compressor - general
Cold rolled steel, aluminum, cast iron as required
Compressor bearings
Self-lubricated, sleeve type, steel backed
Oil heat exchanger
Aluminum
Oil/gas separator tank
Cold rolled steel
Tubes/fittings/skid structure
Stainless/carbon steel
Lubrication
Oil type
Synthetic, 15 or 32 weight, PAO (special factory-supplied blend)
System oil capacity, oz. (ml)
Projected oil consumption
2
170 fluid ounces (5.0 liters)
Approximately 40 oz. (0.9 l) / 8,000 hours at 0.25 psig suction (<5 ppm)
System Electrical (Standard)
+14°F (-10°C)
Minimum VFD ambient startup temperature3,4
Power supply to inverter
• Voltage range
• Input frequency range
380 to 480VAC (50/60 Hz)
Overpressure detection (outlet)
215 psig open
Underpressure detection (inlet)
0.75 psig open (low pressure system) / 2" water column
Oil overtemperature detection
240°F (110°C) open (280°F for SZV) model specific
Fault output to customer
Packager to establish
Run input from customer
Dry contact
Gas Medium
Natural gas
25 ppm
H2S maximum content 5
Moisture content
100% saturated, no free liquids
5
Inlet temperature 5
-20 to 115°F (-28 to 46°C); protection from freezing if water is present
1.If the Compressors are started at temperatures above the listed minimums and continue to run, the minimum operating temperature
is 20°F (-29°C).
2.Based on sweet gas wellhead gas. Results may vary due to gas quality and site conditions.
3.Do not apply power to the VFD if ambient temperature is below this level.
4.If power is continuously supplied to the VFD when the Compressor is off, the minimum starting temperature is -4°F (-20°C).
5.Consult factory for more details and applications guidelines.
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2008SSD-34 (5/11)
Single-Compressor Module
Material Data Safety Sheet
Appendix A - Material Data Safety Sheet
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
reliable and up to date as of the date of publication, but makes no guarantee that it is.
CAUTION
This oil is intended for use only in the Copeland Scroll® Compressor used in natural gas
applications.
Use of any other oil may result in failure and is not covered by warranty.
Dispose OF Waste Oil Properly:
• If the oil has not been contaminated, it can be disposed the same as a synthetic motor oil.
• If the oil is contaminated, the end user must comply with all applicable regulations for disposal
of hazardous materials.
A.1Supplier
CPI Engineering Services Inc.
2300 James Savage Rd.
Midland, MI 48642
Emergency Number: (989) 496-3780
A.2Product Name and Information
Product (Trade name and synonyms)
Chemical Name
Chemical Family
CP-6006 Series
Poly-Alpha-Olefin (PAO)
Synthetic Hydrocarbon
Formula
C10nH20n+2
CAS#
Proprietary
A.3 Components and Hazard Statement
This product is non-hazardous. The product contains no known carcinogens. No special warning labels
are required under OSHA 29 CFR 1910.1200.
FDA Statement. This product complies with FDA 21 CFR 178.3570 regarding lubricants for incidental
food contact.
A.4Safe Handling and Storage
Handling. Do not take internally. Avoid contact with skin, eyes, and clothing. Upon contact with skin, wash
with soap and water. Flush eyes with water for 15 minutes and consult physician. Wash contaminated
clothing before reuse.
Storage. Keep container tightly sealed when not in use.
A.5Physical Data
Appearance
Boiling Point
Vapor Pressure
Specific Gravity (water=1)
Volatiles, Percent by Volume
Odor
Solubility in Water
Evaporation Rate (butyl acetate=1)
Clear, water-white liquid
>300°F (149°C)
<0.01mm Hg @ 20°C
(0.00039 in.Hg @ 68°F)
0.79-0.85
0%
None
Insoluble
Nil
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2008SSD-34 (5/11)
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Material Data Safety Sheet
A.6Fire and Explosion Hazards
Flash Point (by Cleveland Open
Cup)
Flammable Limits
Auto-Ignition Temperature
Health
HMIS Ratings
Flammability
Reactivity
NFPA Ratings
Extinguishing Media
Unusual Fire and Explosion Hazards
Special Fire Fighting Techniques
320-530°F (160-276°C)
Not established
No data
0
1
0
Not established
Dry chemical; CO2 foam; water spray (fog)
None
Burning fluid may evolve irritating/noxious fumes. Firefighters should
use NIOSH/MNSA-approved self-contained breathing apparatus.
Use water to cool fire-exposed containers. Use water carefully near
exposed liquid to avoid frothing and splashing of hot liquid.
A.7Reactivity Data
Stability
Hazardous Polymerization
Incompatible Materials
Conditions to Avoid
Hazardous
Decomposition
Products
Stable
Will not occur
Strong oxidizers
Excessive heat
Analogous compounds evolve carbon monoxide, carbon dioxide,
and other unidentified fragments when burned. See A.6 - Fire and
Explosion Hazards.
A.8Health Hazard Data
Threshold Limit Value
Situations to Avoid
First Aid
Procedures
Ingestion
Inhalation
5mg/m3 ACGIH
Avoid breathing oil mists.
Consult physician at once. DO NOT INDUCE VOMITING. May cause
nausea and diarrhea.
Product is not toxic by inhalation. If oil mist is inhaled, remove to fresh
air and consult physician.
To the best of our knowledge the toxicity of this product has not been fully investigated.
Analogous compounds are considered to be essentially non-toxic.
A.9Personal Protection Information
Respiratory Protection
Ventilation
Protective Gloves
Eye/Face Protection
Use in well ventilated area.
Local exhaust
Not required, but recommended, especially for prolonged exposure
Goggles
A.10Spill or Leak Procedures
In case of spill:
•
•
•
•
•
•
Wear suitable protective equipment, especially goggles.
Stop source of spill.
Dike spill area.
Use absorbent materials to soak up fluid (e.g., sand, sawdust, commercially available materials).
Wash spill area with large amounts of water.
Properly dispose of all materials.
A.11 Waste Disposal Methods
Incinerate this product and all associated wastes in a licensed facility in accordance with federal, state,
and local regulations.
26
2008SSD-34 (5/11)
EmersonClimate.com
Vilter Manufacturing LLC
P.O. Box 8904
Cudahy, WI 53110-8904
P 414 744 0111
F 414744 1769
www.vilter.com
Copeland Scroll and Emerson are trademarks of Emerson Electric Co. or one of its affiliated companies.
©2011 Emerson Climate Technoligies, Inc. All rights reserved. Printed in the USA.
2008SSD-34-R2