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4-1309
Table of Contents
With the Contour semi – hermetic screw Part Load Operation/Start Unloading Full Load Operation
compressors a newly developed system for fully au-
tomatic Vi-control has been incorporated. The Control Piston
CR CR2 CR1
Figure 4a Figure 4b
Location of Capacity Control Solenoids Location of Capacity Control Solenoids
SHM1 3000, 3500, 4000 SHM1 5000, 6000, 7000, 8000, 9000
SHL1 2000, 2500, 3000 SHL1 4000, 5000, 6000, 7000, 7500
2.5 Oil Circulation The standard accessory kit of the Contour Screw
compressor includes the necessary items for the oil
The compressor oil is obtained from the external oil injection line (oil filter, oil flow switch, oil solenoid
separator that also serves as the oil reservoir. Due valve, sight glass and misc. fittings). In addition a
to the pressure difference between the separator/ line of oil separators is also available. Oil cooling by
reservoir and the injection point, an exactly thermosyphon or Jet Kool principal is also
measured quantity of oil is injected into the available but require individual design and
compression chamber and the bearings of the component selection.
12 13 1/4" ∅
1. Compressor
2. Oil filter
3. Oil flow switch
11 4. Oil solenoid valve
1 5. Oil sight glass
6. Oil separator/receiver
7. Oil level control
8. Oil thermostat
4 5 6 9. Oil heater
10. Oil cooler
(if required)
3 11. Check valve
FZ
12. Solenoid valve
(Off cycle by-pass)
2 7 13. Isolation valve
10 9 8
Figure 6
Oil Circuit
In systems with higher thermal loading, oil cooling is required. The following operating conditions must be
considered:
Figure 7a Figure 7b
Water-cooled oil cooling Air-cooled oil cooling
ECO
Figure 7c Figure 7d
Thermosyphon oil cooling Direct refrigerant Injection oil cooling
• The oil cooler should be installed in close • The oil flow solenoid valve should be installed
proximity to the compressor. as close as possible to the compressor to limit
• The piping should be designed so that no vapor the amount of oil draining to the compressor
accumulations can occur and to eliminate the during shut down periods (eliminate the
possibility of the oil charge draining back to the possibility of flooding the compressor with oil).
oil separator during shut down periods. • A full port ball valve should be installed in the oil
Preferably the oil cooler should be located be- line after the oil cooler to facilitate servicing.
low the compressor/oil separator. • The oil cooler must be thermostatically
• Pressure drop on the oil side of the oil cooler controlled (see table)
should be less than 7 psig during normal
operation.
©2000 Copeland Corporation 6
Printed in U.S.A.
Copeland 4-1309
• To facilitate the heating of the oil circuit and to to 10% of the compressors refrigerating
reduce the pressure drop with cold oil an oil by- capacity due to the dilution of the oil at higher
pass (or possibly heating of the oil cooler during injection ratios.
off cycle) is required under the following condi- • Only specially designed expansion valves that
tions: regulate by discharge gas temperature are
- When the oil temperature in the oil cooler suitable (Danfoss TEAT20, Sporlan Y1037, Alco
can drop below 68°F during a long off cycle. series 935) with a temperature setting of 195°F.
- When the volume of oil in the oil cooler and • The sensing bulb must be installed on the
associated piping is greater than 7 gal. discharge line approximately 8 inches from the
compressor. The pipe should be cleaned to a
“bright metal” and coated with heat transfer paste
Note: The oil bypass valve should have a
and held in place with pipe clamps.
modulating control function. The use of solenoid
• To ensure bubble free liquid to the expansion
valves (intermittent control) requires a control
valve, the connection to the main liquid line
thermostat with high sensitivity and minimum switch-
should be in a horizontal run and slope down
ing differential (temperature fluctuation) of 20°.
away from the main liquid line.
• Additional items required to be installed in the
Water Cooled Oil Cooler injection line include; solenoid valve (wired in
parallel to the compressor motor), fine mesh
Temperature control by the use of a thermostatic filter and liquid sight glass.
water regulator (temperature range up to 212°F) is
recommended. Thermosyphon Cooling
The above information is intended as a guide for Further Recommendations for Unit Construction
general possible applications only. This information and Pipe Layouts
does not have the purpose of confirming certain oil
characteristics or their suitability for a particular use. Due to the low level of vibration and discharge gas
pulsation, the suction and discharge lines can
3.2 Mixing Of Lubricants Oil Changes usually be installed without flexible connections or
mufflers. The piping must however be sufficiently
flexible and must not exert any strain on the
Different lubricants may not be mixed without compressor. Pipe runs parallel to the compressor
agreement from Copeland Corp. Especially in the are preferred. The distance from the compressor
case of an oil change, this is however only axis should be kept as small as possible and the
necessary in exceptional cases for systems with parallel section of piping should be at least as long
screw compressors using HCFC and HFC as the compressor.
refrigerants (acid formation, contaminated oil).
An oil heater is installed in the sump section of the
4. Incorporation into the Refrigeration Circuit oil separator to prevent high concentrations of re-
frigerant diluting the oil during shutdown periods.
Semi hermetic screw compressors, SHM/SHL An adjustable thermostat that should be set at
series, can be used for all refrigeration systems from approximately 160°F. controls the heater. In
air conditioning to low temperature addition, an off cycle by-pass that reduces the
applications. The capacity range can be easily pressure in the oil separator to suction pressure
expanded due to the simple and economic Cope- and reduces the refrigerant saturation of the oil,
land compound technology. can also be installed. An added benefit to this is to
additional reduce the start loading of the
4.1 General Design Recommendation / Pipe Lay- compressor. A check valve after the oil separator,
out and a ¼” Ø equalizing line, with a solenoid valve,
between the oil separator and the suction of the
The screw compressors can be incorporated into compressor must be installed. The solenoid can only
the system in a similar way to reciprocating be opened when all the compressors in the system
are off.
©2000 Copeland Corporation 8
Printed in U.S.A.
Copeland 4-1309
A generously sized good quality liquid line filter drier is recommended. A suction accumulator should be
is required to provide the system with a high degree installed to protect against liquid slugging. To avoid
of dehydration and help maintain the chemical increased oil carry-over, due to a rapid reduction of
stability of the system. pressure in the oil separator, it is necessary to
maintain the oil temperature is at least 54 to 72°F
The installation of a suction filter (25 µ) is above the condensing temperature, during the
recommended to protect the compressor from change over. In addition the installation of a
damage due to dirt or debris especially during the pressure regulator directly after the oil separator is
initial start of the system. recommended to limit the reduction in pressure. Un-
der certain circumstances it is also possible to stop
the compressor shortly before the change over pro-
6 mm (1/4")
5 cedure and then to start it again after a pressure
1 7
PRV
equalization has taken place. The compressor must
6
be operating with the necessary minimum pressure
differential within 30 seconds (see application limits,
FZ
TC
LZ TC
section 6.3).
3 2
8
4 4.3 Condenser Pressure Regulation
PC
9
In order to guarantee consistent good quality oil
supply to the compressor and to maintain oil
separator efficiency a closely stepped or stepless
condenser pressure regulation is required. Rapid
Figure 8 depressurization of the oil separator can lead to
Typical Application excessive foaming, oil migration and possible shut
down by the oil level sensor. Insufficient oil supply
4.2 Guide Lines for Special System Consider- and corresponding shutdown can also occur with
ations insufficient of delayed build up of condenser
pressure. An additional pressure regulator in the
In installations where the system is exposed to low discharge line, after the oil separator, may be
ambient temperatures or the high pressure side is necessary with the following operating conditions:
exposed to high temperatures (heat pumps),
additional insulation of the oil separator is required. • Extreme part load conditions and/or long shut
down periods with outdoor installation of the
In systems where the where the compressor or the condenser in low ambient areas.
suction line/accumulator can reach a lower • High suction pressure during start up in
temperature than the evaporator a pump down cycle conjunction with low temperatures of the heat
must be employed. transfer fluid on the high-pressure side, critical
start conditions.
For systems with multi-circuit condensers and/or • Hot gas defrost, reverse cycle operation.
evaporators additional safeguards are necessary. • Booster applications, low pressure differention
When individual circuits are turned off, liquid from suction to discharge.
refrigerant will migrate to the evaporator/ condenser
(temperature and pressure equalization is not 4.4 Start Unloading
possible), the installation of an additional check valve
in the discharge line and an automatic sequential
switching arrangement for the compressor are Due to the compression characteristics of screw
required. The same also applies for plants with compressors, high suction pressure during start up
individual circuits where temperature and pressure can lead to high mechanical loading and insufficient
equalization cannot occur during long shutdown oil supply. Effective unloading is therefore
periods. In some cases it may be necessary to necessary. In addition, compressors of this size and
install a suction accumulator or utilize a pump down capacity usually require a means to reduce the
circuit. starting current, such as part winding starting.
Systems with reverse cycling or hot gas defrost Start unloading can be achieved by the following
require individually designed safeguards to protect methods:
the compressor against liquid slugging and increased
oil carry-over. In addition a complete system review • Integrated start unloading, see section 2.3.
Standard on all SHM & SHL compressors.
©2000 Copeland Corporation 9
Printed in U.S.A.
Copeland 4-1309
• Limited start unloading is possible by the use 4.6 Parallel operation
of an off cycle by-pass, see General
Recommendations section 4.1, with low The Copeland Contour SHM & SHL series
temperature operation in conjunction with a compressors are particularly suitable for parallel op-
pressure limiting TX-valve or a crankcase eration due to the use of the external oil
pressure regulator. This method is however separator/receiver.
limited to single compressor systems of
specifically designed parallel compressor Important advantages of the Copeland Contour
systems. compound technology:
NOTE: An external start unloading bypass as is • Extension to the limited capacity provided by a
typically used with reciprocating compressors single compressor, up to six (6) compressors
cannot be utilized with screw compressors due to can be compounded.
possible damage of the compressor. • Compounding compressors of similar or
differing capacities.
4.5 Capacity Regulation • Possible to compound systems with differing
suction temperatures.
• Extended capacity regulation.
The requirement for capacity regulation is
• Simple oil distribution with single oil separator/
dependent on the system design and requirements.
receiver.
The following methods are available:
• Higher degree of operational safety, not
dependent on a single compressor.
• Integrated capacity regulation, see section 2.3. • Simple and economical installation.
Standard on all SHM & SHL compressors
• Frequency Inverter
• Parallel operation, see section 4.6, possibly Oil separators and other accessories are available
combined with any of the above methods. that allow up to six (6) compressors in a single cir-
cuit.
2 1
FZ FZ FZ 3 FZ
PRV
4
6 7
LZ TC
TC
8
Figure 9
Parallel compounding with a common oil separator and a water-cooled oil
1
2
FZ FZ FZ 3 FZ
PRV
4 7
6
LZ TC
ϑ
10
12
Figure 10
Parallel compounding with a common oil separator and a air-cooled oil cooler
t0 < t0 >
5
2 1
FZ FZ FZ 3 FZ
PRV
4 7
6
LZ TC
TC TC
8
Figure 11
Parallel compounding for varying suction temperatures
2 1
FZ FZ FZ 3 FZ
4
6
LZ TC
11
TC TC
8 12
Figure 12
Parallel compounding with common oil separator, water-cooled oil cooler and oil pump
Legend
1 – Compressor 7 – Condensing Pressure Regulator (if required)
2 – Oil Solenoid Valve 8 – Water Cooled Oil Cooler
3 – Oil Flow Switch 9 – Condenser
4 – Oil Filter 10 – Air Cooled Oil Cooler
5 – Off Cycle By-pass 11 – Oil Pump
6 – Oil Separator with Heater & level control 12 – Mixing Valve
Compressor Design
4.8 Two-Stage Systems
• High pressure stage: SHM series
• Low pressure stage: SHL series
Although screw compressors can be efficiently used • Special booster design
with high compression ratios, there are a number of • Operation without an oil pump requires a
applications where two-stage compression can be minimum differential pressure of 36 psi with a
beneficial. This type of system is particularly maximum pressure drop in the oil line from the
beneficial for systems with different suction separator to the compressor of 5 psi
©2000 Copeland Corporation 12
Printed in U.S.A.
Copeland 4-1309
PRV 2 1
LP HP
3
FZ FZ FZ
PRV
4 7
6
LZ TC LZ TC
PC
9
TC
8
11
Figure 13
Two stage system with independent low and high pressure compressors
• Part winding start to reduce the starting cur- Part - Winding Start Direct – On – Line Start
rent
• Direct on-line start (DOL) PW2 PW2
T1 T1
5.2 Selection of Electrical Components 7
L1
When selecting cables, contactors and fuses the 1 1
maximum operating current / maximum motor power 8 L1 L1
must be used (see section 6.2). L2
2 2
Note: Nominal power is not the same as maximum 9 L2 L2
motor power. L3
3 3
L3 L3
T2 T2
Figure 14
Motor Connections
©2000 Copeland Corporation 13
Printed in U.S.A.
Copeland 4-1309
5.3 Protection Devices Semi-Hermetic Screw Compressors
80 80
60 60
SH=40°F SH=40°F
40 40
-60 -40 -20 0 20 SST40 [°F] 60 -60 -40 -20 0 20 SST 40 [°F] 60
Kit includes: oil filter housing, oil filter element, flow switch, solenoid valve & coil, sight glass, rotation switch
with vibration damper, fittings and O-rings.