copeland tae1309

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Copeland 4-1309Copeland 4-1309Copeland 4-1309Copeland 4-1309Copeland 4-1309

©2000 Copeland CorporationPrinted in U.S.A.

Issued February, 2000

4-1309

Application Engineering Bulletin

AE-1309

1. General ....................................................... 2

2. Design and Functions ............................... 22.1 Construction Features ............................ 22.2 Compression Procedure -

Automatic Vi � Control ............................ 22.3 Capacity Control / Start Unloading ......... 32.4 Mounting the Compressor ...................... 42.5 Oil Circulation ........................................ 52.6 Oil Cooling ............................................. 6

3. Lubricants .................................................. 73.1 Table of Lubricants ................................. 73.2 Mixing Of Lubricants, Oil Changes ......... 8

4. Incorporation into theRefrigeration Circuit ..................................84.1 General Design Recommendations/

Pipe Layout ............................................ 84.2 Guide Lines for Special System

Considerations ....................................... 9

APPLICATION GUIDELINES FORSHL1/SHM1 & SHL2/SHM2

SEMI-HERMETIC SCREW COMPRESSORS

Table of Contents

4.3 Additional Cooling by DirectRefrigerant Injection ............................... 9

4.4 Start Unloading ...................................... 94.5 Capacity Regulation ............................. 104.6 Parallel Operation ................................ 104.7 Economizer Operation ......................... 124.8 Two-Stage Systems ............................. 12

5. Electrical ................................................... 135.1 Motor Design ....................................... 135.2 Selection of Electrical Components ..... 135.3 Protection Devices ............................... 14

6. Selection of Compressor ........................ 146.1 Compressor Summary ......................... 146.2 Technical Data ..................................... 146.3 Application Ranges .............................. 156.4 Screw Compressor Accessories .......... 166.5 Dimensional Drawings ....................17-25

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The compressor is driven by a three-phaseasynchronous motor that is build into the extendedcompressor housing. The motor rotor is located onthe shaft of the male screw rotor. Cooling is achievedby cold refrigerant vapor that mainly flows acrossthe motor rotor, in addition to providingcooling, this design also functions simultaneouslyas a centrifugal liquid separator.

2.2 Compression Procedure - Automatic VIControl

The compression in a screw compressor takes placein one direction (linear compression). The meshingrotors enclose a working space whose volume iscontinuously reduced as it moves in the axial direc-tion. Refrigerant vapor is drawn in on the suctionside and subsequently compressed by the mesh-ing action of the rotors in the enclosed working vol-ume. As soon as this working volume is opened tothe discharge port, the vapor is discharged to thehigh-pressure side and flows to the oil separator.

Figure 1Semi Hermetic Screw Compressor

1. Male Rotor2. Female Rotor3. Rolling Contact Bearing4. Check Valve5. Capacity Control / Start Unloading Pistons6. Automatic V1 Control7. Internal Pressure Relief Valve8. Oil Injection

9. Discharge Gas Temperature Sensor ( PTC )10. Motor11. Terminal Box12. Motor Protective Device

1. General

The SHL & SHM series of screw compressors fromCopeland once again set the standards intechnology and performance. This advanced seriesis the result of intensive research based on manyyears experience manufacturing small and mediumcapacity screw compressors.

Features:

� High capacity and efficiency due to- Unique rotor design- High motor efficiency- Ease of economized operation- Automatic Vi Control- Precise machining process

� Simple and robust design and construction� Oversized bearings� Efficient capacity control (unloaded start)� Integrated discharge check valve� Internal pressure relief valve� ESC 200 electronic control module� Motor protection device� Discharge gas temperature protection� Electronic oil flow switch� Fine mesh oil filter (10 µ )� Compatible with R22, R134a, R404A and R507

- Other refrigerants upon request� Low noise and vibration levels� Small installed space requirement� Complete line of accessories (E.I. oil separa-

tors, oil filters etc.)

2. Design and Function

2.1 Construction Features

The Contour screw compressors are oftwo-shaft rotary displacement design withspecifically developed profile geometry (lobe ratio5:6 or 5:7). The main parts of thesecompressors are the two rotors (male andfemale) which are fitted into a closed housing. Therotors are precisely located at both ends by rollerbearings (radial and axial) which, in conjunction withthe generously sized oil supply chambers, providesoptimum operating characteristics.

Owing to the specific design this type ofcompressor does not require any working valves.To protect against reverse running when thecompressor is switched off (expansionoperation) a check valve is incorporated in thedischarge chamber (this valve does nothowever replace any check valves required by thesystem design). Internal differential pressure reliefvalves are fitted as over pressure protection.

Side View

Top View

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2.3 Capacity Control / Start Unloading

For the Contour Screw Compressors a new formof regulating system has been developed. Thebasic principle corresponds to that of a control slideof large industrial compressors, a part of thetransported vapor flows back to the suction side ofthe rotor chamber. In contrast to larger capacitycompressors the control unit is designed so that itdoes not reduce the stability of the compressor hous-ing. The gap between the rotors and thehousing thus remains within tight tolerances, evenwith high operating temperatures and pressures.This is an important stage of development andensures good overall efficiency of smaller screw com-pressors, due to the higher precision andtolerance demands.

The control system consists of hydraulicallyactivated pistons for the male and female rotor, whichare flush with the end wall/housing during full loadoperation. The same efficiencies/characteristics aretherefore guaranteed as with a compressor withoutcapacity control. Typical losses as with slider sys-tems are avoided. During part load operation thepistons move to the rear position and open generously sized ports to the suction side. Aportion of the volume of gas compressed is therebytransported back to the suction side. The system isdesigned for 3 stages of regulation (100, 75, &50 %). By the use of intermittent switching analmost stepless characteristic can be achieved.

ControlControl is accomplished electrically via thesolenoid valves located on the discharge flange.

Part Load Operation/Start Unloading Full Load Operation

Control Piston

Solenoid Coil (De-energized) Control OilSolenoid Coil(Energized)

Caution: Screw compressors may only beoperated in one direction of rotation (reverserotation will cause severe damage)!

The very small gap (a few µ) between the rotorsthemselves and the housing is dynamically sealedwith oil, the oil is directly injected into the profilespaces, and to the roller bearings.

The size and geometry of the discharge portdetermine the so-called �built-in volume ration (Vi)�of the compressor. This ratio must be in a definedrelationship to the operating pressure ratio in orderto avoid losses in efficiency due to over or undercompression. For this reason screw compressorsare manufactured with different discharge portconfigurations specific to the application.

With the Contour semi � hermetic screwcompressors a newly developed system for fully au-tomatic Vi-control has been incorporated. Thedischarge port is automatically optimized for thenominal operating conditions (pressure ratio). Witha lower pressure ratio in the system a part of thecompressed gas flows directly to the dischargechamber via a valve mechanism in the rotorhousing (by-passing the discharge port). The flowvolume remaining in the profiles is thus reduced,the corresponding pressure is reduced and overcompression is avoided. This self-regulatingsystem achieves a high efficiency over a wideapplication range.

Figure 2Compressor Cyle

Figure 3Capacity Control System Details

1

3

2

V1V1Voc

P1

P2

Poc 1 Compression behavior2 Losses due to over-compression3 Compression with Vi Control

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Capacity Control

Compressor Model Full Load Step 1 Step 2 Start Unloading(100%) (approx.75%)* (approx. 50%)*

SHM1-3000/3500/4000 CR=lllll CR=mmmmm CR=mmmmmSHL1-2000/2500/3000SHM2-3000/3500/4000 CR1=l CR1=m CR1=m CR1=mSHL2-2000/2500/3000 CR2=l CR2=l CR2=m CR2=mSHM1-5000/6000 CR1=l CR1=m CR1=m CR1=mSHL1-4000/5000 CR2=l CR2=l CR2=m CR2=mSHM1-7000/8000/9000 CR1=l CR1=l CR1=m CR1=mSHL1-6000/7000/7500 CR2=l CR2=m CR2=m CR2=m* Effective capacity stages are dependent on operating conditions

lllll = Solenoid valve energized

mmmmm = Solenoid valve de-energized

Figure 4aLocation of Capacity Control Solenoids

SHM1 3000, 3500, 4000SHL1 2000, 2500, 3000

Figure 4bLocation of Capacity Control Solenoids

SHM1 5000, 6000, 7000, 8000, 9000SHL1 4000, 5000, 6000, 7000, 7500

2.4 Mounting the Compressor

The Contour Screw Compressor itself is providedas a motor/compressor unit. It is only necessary tomount the complete unit correctly and to make theelectrical and pipe connections.

The compressor must be installed horizontally. Theuse of anti-vibration mounting pads is recommendedto reduce the transmission of noise or vibrations.The anti-vibration mounting pads are packedseparately from the compressor.

With direct mounting on water-cooled condensersthe use of anti-vibration mounting is essential inorder to prevent possible stress fracturing of the heatexchanger tubes.

The installation of the anti-vibration mounting padsis shown in Figure 5. The bolts should only betightened so that deformation of the upper rubberdisc is just visible.

CR2 CR1

Figure 4cLocation of Capacity Control Solenoids

SHM2 3000, 3500, 4000SHL2 2000, 2500, 3000

CR

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Figure 5Mounting Pad Installation

2.5 Oil Circulation

The compressor oil is obtained from the external oilseparator that also serves as the oil reservoir. Dueto the pressure difference between the separator/reservoir and the injection point, an exactlymeasured quantity of oil is injected into thecompression chamber and the bearings of the

compressor. The oil is then transported together withthe refrigerant vapor in the direction ofcompression, where in addition to lubrication it alsoforms a dynamic seal between the rotors and thecompressor housing and the rotors, to theseparator/reservoir. The oil and vapor are separatedin the upper portion of this vessel. The oil flowdownward to the reservoir section of the vesselwhere it again flow to the compressor. The vaporexits the top of the vessel and flow to the condenser.Depending on operating conditions the circulatingoil will need to be cooled in an oil cooler. Undercertain conditions direct refrigerant injection can beused to achieve the required oil cooling.

The standard accessory kit of the Contour Screwcompressor includes the necessary items for the oilinjection line (oil filter, oil flow switch, oil solenoidvalve, sight glass and misc. fittings). In addition aline of oil separators is also available. Oil cooling bythermosyphon or Jet Kool principal is alsoavailable but require individual design andcomponent selection.

Figure 6Oil Circuit

9/16”

5/8”

1. Compressor2. Oil filter3. Oil flow switch4. Oil solenoid valve5. Oil sight glass6. Oil separator/receiver7. Oil level control8. Oil thermostat9. Oil heater10. Oil cooler (if required)11. Check valve12. Solenoid valve (Off cycle by-pass)13. Isolation valve

FZ

6

7

89102

3

4 5

1

12 13

11

∅∅∅∅ 1/4"

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2.6 Oil Cooling

In systems with higher thermal loading, oil cooling is required. The following operating conditions must beconsidered:

� Minimum evaporating temperature� Maximum suction gas superheat temperature� Maximum condensing temperature� System operation (capacity control, economizer operation, etc.)

Types of Oil Cooling

Figure 7aWater-cooled oil cooling

Figure 7bAir-cooled oil cooling

Figure 7cThermosyphon oil cooling

Figure 7dDirect refrigerant Injection oil cooling

General Recommendations for Oil Coolers

� The oil cooler should be installed in closeproximity to the compressor.

� The piping should be designed so that no vaporaccumulations can occur and to eliminate thepossibility of the oil charge draining back to theoil separator during shut down periods.Preferably the oil cooler should be located be-low the compressor/oil separator.

� Pressure drop on the oil side of the oil coolershould be less than 7 psig during normaloperation.

� The oil flow solenoid valve should be installedas close as possible to the compressor to limitthe amount of oil draining to the compressorduring shut down periods (eliminate thepossibility of flooding the compressor with oil).

� A full port ball valve should be installed in the oilline after the oil cooler to facilitate servicing.

� The oil cooler must be thermostaticallycontrolled (see table)

ϑ

ECO

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Temperature Setting

Temperatureregulator for

oil cooler

Bypass valve

Sensor Location Refrigerant

Nominal Maximum

Discharge Gas LineR-22

R-134a

R-22

R-134a

Discharge Gas Line

54° above condensingtemperature




203°F

176°F

185°F

176°F

� To facilitate the heating of the oil circuit and toreduce the pressure drop with cold oil an oil by-pass (or possibly heating of the oil cooler duringoff cycle) is required under the following condi-tions:- When the oil temperature in the oil cooler

can drop below 68°F during a long off cycle.- When the volume of oil in the oil cooler and

associated piping is greater than 7 gal.

Note: The oil bypass valve should have amodulating control function. The use of solenoidvalves (intermittent control) requires a controlthermostat with high sensitivity and minimum switch-ing differential (temperature fluctuation) of 20°.

Water Cooled Oil Cooler

Temperature control by the use of a thermostaticwater regulator (temperature range up to 212°F) isrecommended.

Air Cooled Oil Cooler

Temperature control by the use of a thermostaticswitch to turn on and off cooler fans or steplessspeed control of the fan motors is recommended(temperature range up to 212°F).

Direct Refrigerant Injection

� This method of oil cooling is limited to an oilcooling capacity (oil cooler load) that equivalent

Evaporating Condensing Viscosity DischargeRefrigerant Temperature Temperature Oil type cSt @ 40 °F Temperature Manufacturer

HFC -4 to 70 °F 160 °F Solest 170 170 CPI

CPIR22 -60 to 55 °F 140 °F CP-4214-150 150

3.1 Table of Lubricants

to 10% of the compressors refrigeratingcapacity due to the dilution of the oil at higherinjection ratios.

� Only specially designed expansion valves thatregulate by discharge gas temperature aresuitable (Danfoss TEAT20, Sporlan Y1037, Alcoseries 935) with a temperature setting of 195°F.

� The sensing bulb must be installed on thedischarge line approximately 8 inches from thecompressor. The pipe should be cleaned to a�bright metal� and coated with heat transfer pasteand held in place with pipe clamps.

� To ensure bubble free liquid to the expansionvalve, the connection to the main liquid lineshould be in a horizontal run and slope downaway from the main liquid line.

� Additional items required to be installed in theinjection line include; solenoid valve (wired inparallel to the compressor motor), fine meshfilter and liquid sight glass.

Thermosyphon Cooling

Design and technical information available onrequest for specific applications.

3. Lubricants

In addition to lubrication oil also provides thedynamic sealing of the rotors. Special demandsresult from this with regard to viscosity, solubility andfoaming characteristics. Only approved oils maytherefore be used.

Approximately140 °F

Maximum212°F

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Important Considerations

The operating limits of the compressors must beadhered to (refer to section 5.3).

� The lower limit value indicated for the dischargegas temperature shown is only a referencevalue. The discharge gas temperature must beat least 54°F above the condensingtemperature.

� The sensor of the oil cooler temperaturecontroller must be installed on the discharge lineof the compressor approximately 8 inches fromthe compressor. The thermostat orregulator should be adjusted to maintain an oiltemperature that is 54°F above the condensingtemperature.

� Ester oils such as Solest 170 are extremely hy-groscopic and careful handling is required.Moisture is chemically bonded with these oilsand cannot, or only insignificantly, be removedby evacuation. Dispose of waste oil in anecologically beneficial way (chloritic oil ispollutive waste).

� A revised design may be necessary fordirect-expansion evaporators with finned tubeson the refrigerant side (consultation with coolermanufacturer).

The above information is intended as a guide forgeneral possible applications only. This informationdoes not have the purpose of confirming certain oilcharacteristics or their suitability for a particular use.

3.2 Mixing Of Lubricants Oil Changes

Different lubricants may not be mixed withoutagreement from Copeland Corp. Especially in thecase of an oil change, this is however onlynecessary in exceptional cases for systems withscrew compressors using HCFC and HFCrefrigerants (acid formation, contaminated oil).

4. Incorporation into the Refrigeration Circuit

Semi hermetic screw compressors, SHM/SHLseries, can be used for all refrigeration systems fromair conditioning to low temperatureapplications. The capacity range can be easilyexpanded due to the simple and economic Cope-land compound technology.

4.1 General Design Recommendation / Pipe Lay-out

The screw compressors can be incorporated intothe system in a similar way to reciprocating

compressors. Only the oil circuit will differ. Pipingshould be designed in compliance with acceptedcriteria especially in regard to flow velocities (oilreturn). The pipe layout and the systemconstruction must be designed so that thecompressor cannot be flooded with oil or liquidrefrigerant during shutdown periods. A simplesafeguard against this is to first pipe the dischargeand suction lines downward from the compressor.As an additional precaution (also provides simpleprotection against liquid slugging during starting)for systems with direct expansion either agooseneck after the evaporator or installation of thecompressor above the level of the evaporator isrequired (not essential with �pump down�system). A solenoid valve should also be installedin the liquid line directly before the expansion valve.

The use of flooded evaporators with HCFC/HFCrefrigerants require a separate oil return from theevaporator or low pressure receiver. TH e bleedpoint (preferably several) should be located in theoil rich liquid phase. The oil should be returned tothe suction of the compressor, but only after theliquid refrigerant has been evaporated. In systemswith widely varying liquid levels, such as liquid overfeed systems, a bleed point from the lowest pointafter the circulating pump should be used.

Further Recommendations for Unit Constructionand Pipe Layouts

Due to the low level of vibration and discharge gaspulsation, the suction and discharge lines canusually be installed without flexible connections ormufflers. The piping must however be sufficientlyflexible and must not exert any strain on thecompressor. Pipe runs parallel to the compressorare preferred. The distance from the compressoraxis should be kept as small as possible and theparallel section of piping should be at least as longas the compressor.

An oil heater is installed in the sump section of theoil separator to prevent high concentrations of re-frigerant diluting the oil during shutdown periods.An adjustable thermostat that should be set atapproximately 160°F. controls the heater. Inaddition, an off cycle by-pass that reduces thepressure in the oil separator to suction pressureand reduces the refrigerant saturation of the oil,can also be installed. An added benefit to this is toadditional reduce the start loading of thecompressor. A check valve after the oil separator,and a ¼� Ø equalizing line, with a solenoid valve,between the oil separator and the suction of thecompressor must be installed. The solenoid can onlybe opened when all the compressors in the systemare off.

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A generously sized good quality liquid line filter drieris required to provide the system with a high degreeof dehydration and help maintain the chemicalstability of the system.

The installation of a suction filter (25 µ) isrecommended to protect the compressor fromdamage due to dirt or debris especially during theinitial start of the system.

Figure 8Typical Application

4.2 Guide Lines for Special System Consider-ations

In installations where the system is exposed to lowambient temperatures or the high pressure side isexposed to high temperatures (heat pumps),additional insulation of the oil separator is required.

In systems where the where the compressor or thesuction line/accumulator can reach a lowertemperature than the evaporator a pump down cyclemust be employed.

For systems with multi-circuit condensers and/orevaporators additional safeguards are necessary.When individual circuits are turned off, liquidrefrigerant will migrate to the evaporator/ condenser(temperature and pressure equalization is notpossible), the installation of an additional check valvein the discharge line and an automatic sequentialswitching arrangement for the compressor arerequired. The same also applies for plants withindividual circuits where temperature and pressureequalization cannot occur during long shutdownperiods. In some cases it may be necessary toinstall a suction accumulator or utilize a pump downcircuit.

Systems with reverse cycling or hot gas defrostrequire individually designed safeguards to protectthe compressor against liquid slugging and increasedoil carry-over. In addition a complete system review

is recommended. A suction accumulator should beinstalled to protect against liquid slugging. To avoidincreased oil carry-over, due to a rapid reduction ofpressure in the oil separator, it is necessary tomaintain the oil temperature is at least 54 to 72°Fabove the condensing temperature, during thechange over. In addition the installation of apressure regulator directly after the oil separator isrecommended to limit the reduction in pressure. Un-der certain circumstances it is also possible to stopthe compressor shortly before the change over pro-cedure and then to start it again after a pressureequalization has taken place. The compressor mustbe operating with the necessary minimum pressuredifferential within 30 seconds (see application limits,section 6.3).

4.3 Condenser Pressure Regulation

In order to guarantee consistent good quality oilsupply to the compressor and to maintain oilseparator efficiency a closely stepped or steplesscondenser pressure regulation is required. Rapiddepressurization of the oil separator can lead toexcessive foaming, oil migration and possible shutdown by the oil level sensor. Insufficient oil supplyand corresponding shutdown can also occur withinsufficient of delayed build up of condenserpressure. An additional pressure regulator in thedischarge line, after the oil separator, may benecessary with the following operating conditions:

� Extreme part load conditions and/or long shutdown periods with outdoor installation of thecondenser in low ambient areas.

� High suction pressure during start up inconjunction with low temperatures of the heattransfer fluid on the high-pressure side, criticalstart conditions.

� Hot gas defrost, reverse cycle operation.� Booster applications, low pressure differention

from suction to discharge.

4.4 Start Unloading

Due to the compression characteristics of screwcompressors, high suction pressure during start upcan lead to high mechanical loading and insufficientoil supply. Effective unloading is thereforenecessary. In addition, compressors of this size andcapacity usually require a means to reduce thestarting current, such as part winding starting.

Start unloading can be achieved by the followingmethods:

� Integrated start unloading, see section 2.3.Standard on all SHM & SHL compressors.

TC

LZ TC

PRV

FZ

PC

6 mm (1/4")

1

23

4

5

67

8

9

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� Limited start unloading is possible by the useof an off cycle by-pass, see GeneralRecommendations section 4.1, with lowtemperature operation in conjunction with apressure limiting TX-valve or a crankcasepressure regulator. This method is howeverlimited to single compressor systems ofspecifically designed parallel compressorsystems.

NOTE: An external start unloading bypass as istypically used with reciprocating compressorscannot be utilized with screw compressors due topossible damage of the compressor.

4.5 Capacity Regulation

The requirement for capacity regulation isdependent on the system design and requirements.The following methods are available:

� Integrated capacity regulation, see section 2.3.Standard on all SHM & SHL compressors

� Frequency Inverter� Parallel operation, see section 4.6, possibly

combined with any of the above methods.

4.6 Parallel operation

The Copeland Contour SHM & SHL seriescompressors are particularly suitable for parallel op-eration due to the use of the external oilseparator/receiver.

Important advantages of the Copeland Contourcompound technology:

� Extension to the limited capacity provided by asingle compressor, up to six (6) compressorscan be compounded.

� Compounding compressors of similar ordiffering capacities.

� Possible to compound systems with differingsuction temperatures.

� Extended capacity regulation.� Simple oil distribution with single oil separator/

receiver.� Higher degree of operational safety, not

dependent on a single compressor.� Simple and economical installation.

Oil separators and other accessories are availablethat allow up to six (6) compressors in a single cir-cuit.

Figure 9Parallel compounding with a common oil separator and a water-cooled oil

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LZ TC

PRV

TC

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6 7

8

2

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Figure 10Parallel compounding with a common oil separator and a air-cooled oil cooler

Figure 11Parallel compounding for varying suction temperatures

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LZ TC

PRV

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3

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5

67

10

12

FZ FZ FZ FZ

LZ TC

PRV

TC TC

t <0 t >0

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Figure 12Parallel compounding with common oil separator, water-cooled oil cooler and oil pump

Legend1 � Compressor2 � Oil Solenoid Valve3 � Oil Flow Switch4 � Oil Filter5 � Off Cycle By-pass6 � Oil Separator with Heater & level control

7 � Condensing Pressure Regulator (if required)8 � Water Cooled Oil Cooler9 � Condenser10 � Air Cooled Oil Cooler11 � Oil Pump12 � Mixing Valve

4.7 Economizer Operation

Copeland Contour compressors are equipped withan additional inlet connection for EconomizerOperation. Economizing can be accomplished byeither utilizing a subcooling circuit or two stagerefrigerant expansion. This mode of operationincreases the refrigeration capacity as well as theef ficiency of the system. The higher thecompression ratios the greater the benefits of thismode of operation will be.

4.8 Two-Stage Systems

Although screw compressors can be efficiently usedwith high compression ratios, there are a number ofapplications where two-stage compression can bebeneficial. This type of system is particularlybeneficial for systems with different suction

temperatures, low and medium temperatures as anexample, or for systems that require especially lowevaporating temperatures.

Typical applications would include large floodedcentral systems with low pressure receivers andpumped circulation, blast freezers which mayoperate as a single stage system during the initialphase, relatively high evaporating temperatures, butmust also provide high capacity and efficiency at lowevaporating temperatures, final phase.

Compressor Design� High pressure stage: SHM series� Low pressure stage: SHL series� Special booster design� Operation without an oil pump requires a

minimum differential pressure of 36 psi with amaximum pressure drop in the oil line from theseparator to the compressor of 5 psi

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LZ TC

TC TC

12

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6

8

11

12

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Figure 13Two stage system with independent low and high pressure compressors

5. Electrical

5.1 Motor Design

The compressors are supplied as standard with partwinding motors (�PW�).

Starting methods (connections according to Fig. 14):

� Part winding start to reduce the starting cur-rent

� Direct on-line start (DOL)

Part - Winding Start Direct – On – Line Start

PW2 PW2

T1 T1 T1 T1 T1 T1 T1 T1 T1 T177777

L1L1L1L1L11 1

88888 L1L1L1L1L1 L1L1L1L1L1

L2L2L2L2L22 2

99999 L2L2L2L2L2 L2L2L2L2L2

L3L3L3L3L333333 33333

L3L3L3L3L3 L3L3L3L3L3

T2 T2 T2 T2 T2 T2 T2 T2 T2 T2

Figure 14Motor Connections

5.2 Selection of Electrical Components

When selecting cables, contactors and fuses themaximum operating current / maximum motor powermust be used (see section 6.2).

Note: Nominal power is not the same as maximummotor power.

The following current values appear in the partwindings:

PW1 PW250% 50%

Both of the contactors should be selected for at least60% of the maximum operating current.

FZ FZ FZ

LZ TC

PRV

TC

HPLP

LZ TC

PRV

PC

12

3

4

5

6

11

7

89

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5.3 Protection Devices

The Copeland Contour screw compressors uses theESC-200 protection device, see form no. 99-19 forfeatures, installation and operating instructions.

6. Selection of Compressor

6.1 Compressor Summary

Copeland at present offers 16 different semi hermeticscrew compressors and thereby covers an exten-sive range of applications. With the ability of parallelcompounding of up to 6 compressors on a singlecircuit, the capacity range can be significantly ex-tended and a high operational reliability and the bestefficiency under part load conditions can be achieved

6.2 Technical Data

CompressorModel No. Motor H.P.

CapacityControl Weight

Connection SizesSuction Discharge

Dimensions

Semi-Hermetic Screw Compressors

SHM1-3000 SHL1-2000 3,567SHM2-3000 SHL2-2000 3,567SHM1-3500 SHL1-2500 4,273SHM2-3500 SHL2-2500 4,273SHM1-4000 SHL1-3000 5,015SHM2-4000 SHL2-3000 5,015SHM1-5000 SHL1-4000 5,933SHM1-6000 SHL1-5000 6,992SHM1-7000 SHL1-6000 8,193SHM1-8000 SHL1-7000 9,394SHM1-9000 SHL1-7500 10,665

MediumTemperatureApplications

LowTemperatureApplications

DisplacementCFH

SHM1-3000 30 100%, 75% 375 1 5/8� 2 1/8� 29.8 x 17.05 x 16.93SHL1-2000 20 366

SHM2-3000 30 100% 375 1 5/8� 2 1/8� 29.8 x 17.05 x 16.93SHL2-2000 20 75%, 50% 366

SHM1-3500 35 100%, 75% 385 1 5/8� 2 1/8� 29.8 x 17.23 x 16.93SHL1-2500 25 374

SHM2-3500 35 100% 385 1 5/8� 2 1/8� 29.8 x 17.23 x 16.93SHL2-2500 25 75%, 50% 374

SHM1-4000 40 100%, 75% 400 1 5/8� 2 1/8� 29.8 x 17.23 x 16.93SHL1-3000 30 392

SHM2-4000 40 100% 400 1 5/8� 2 1/8� 29.8 x 17.23 x 16.93SHL2-3000 30 75%, 50% 392

SHM1-5000 50 100% 524 1 5/8� 2 1/8� 35.98 x 20.00 x 17.13SHL1-4000 40 75%, 50% 515

SHM1-6000 60 100% 541 1 5/8� 2 1/8� 35.98 x 20.00 x 17.13SHL1-5000 50 75%, 50% 524

SHM1-7000 70 100% 671 2 1/8� 3 1/8� 40.20 x 20.59 x 16.62SHL1-6000 60 75%, 50% 653

SHM1-8000 80 100% 691 2 1/8� 3 1/8� 40.20 x 20.59 x 16.62SHL1-7000 70 75%, 50% 682

SHM1-9000 90 100% 739 2 1/8� 3 1/8� 43.03 x 20.59 x 16.62SHL1-7500 75 75%, 50% 717 41.06 x 20.59 x 16.62

L x W x H

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Electrical RatingsLow Temperature Applications

CompressorModel No.

Voltage LRA RLA MCCR-22

MCCR-404A

SHL1-2000 208/230 492 81 114460 246 41 57575 N/A N/A N/A N/A

SHL2-2000 208/230 492 81 114460 246 41 57575 N/A N/A N/A N/A

SHL1-2500 208/230 436 85 120460 218 42 60575 N/A N/A N/A N/A

SHL2-2500 208/230 436 85 120460 218 42 60575 N/A N/A N/A N/A

SHL1-3000 208/230 532 104 146460 266 52 73575 N/A N/A N/A N/A

SHL2-3000 208/230 532 104 146460 266 52 73575 N/A N/A N/A N/A

SHL1-4000 208/230 655 136 228460 313 65 109575 N/A N/A N/A N/A

SHL1-5000 208/230 743 165 240460 355 79 115575 N/A N/A N/A N/A

SHL1-6000 208/230 939 186 247460 449 89 118575 N/A N/A N/A N/A

SHL1-7000 208/230 1015 215 299460 485 103 143575 N/A N/A N/A N/A

SHL1-7500 208/230 1224 249 314460 585 119 150575 N/A N/A N/A N/A

Medium Temperature Applications

CompressorModel No.

Voltage LRA RLA MCCR-22

MCCR-404A

SHM1-3000 208/230 436 92 106 130460 218 46 53 65575 N/A N/A N/A N/A

SHM2-3000 208/230 436 92 106 130460 218 46 53 65575 N/A N/A N/A N/A

SHM1-3500 208/230 532 121 138 170460 266 60 69 85575 N/A N/A N/A N/A

SHM2-3500 208/230 532 121 138 170460 266 60 69 85575 N/A N/A N/A N/A

SHM1-4000 208/230 622 130 156 182460 311 65 78 91575 N/A N/A N/A N/A

SHM2-4000 208/230 622 130 156 182460 311 65 78 91575 N/A N/A N/A N/A

SHM1-5000 208/230 743 165 215 258460 355 79 103.6 124575 N/A N/A N/A N/A

SHM1-6000 208/230 939 205 278 334460 449 98 133 160575 N/A N/A N/A N/A

SHM1-7000 208/230 1015 251 280 295460 485 120 134 141575 N/A N/A N/A N/A

SHM1-8000 208/230 1224 263 293 343460 585 126 140 164575 N/A N/A N/A N/A

SHM1-9000 208/230 1435 305 341 358460 686 146 163 171575 N/A N/A N/A N/A

6.3 Application Ranges

200-20-40-60 40 6040

140

120

100

80

60

SHMSHL

SH=40°F

SCT[°F]

SST [°F]

R-22 Operating Envelope

200-20-40-60 40 6040

140

120

100

80

60

SHMSHL

SH=40°F

SCT [°F]

SST [°F]

R-404A/R-507 Operating Envelope

16



6.4 Screw Compressor Accessories

Compressor Applications Kit (one required per compressor)

Kit includes: oil filter housing, oil filter element, flow switch, solenoid valve & coil, sight glass, rotation switchwith vibration damper, fittings and O-rings.

SHM SHL 115 volt 230 volt

Series 1 30/35/40 HP Series 1 20/25/30 HP 560-0001-01 560-0001-00


Series 1 50/60 HP Series 1 40/50 HP 560-0001-03 560-0001-02


Electronic Module (one required per compressor)

ESC200 Standard Module 560-0002-00

ESC200E Eschelon Module 560-0002-01

Oil Separator 115 volt 230 volt

18 liter low profile (1-2 compressors) 560-0003-00 560-0003-01

18 liter top outlet (1-2 compressors) 560-0003-02 560-0003-03

40 liter top outlet (up to 3 compressors) 560-0003-04 560-0003-05



Oil Separator Kit (one required per pack)

Oil Separator Kit (one required per pack)

Size Low Temperature Medium TemperatureMaximum CFH Maximum CFH

18 Liter 10,600 CFH 7,770 CFH

40 liter 23,300 CFH 15,540 CFH

90 liter 46,615 CFH 31,080 CFH

140 liter 46,615 CFH 46,615 CFH

Compressors listed in U.L. File No. SA 7129The following models require a Furnas 958 Overload Relay;

� SHL1-4000/5000/6000/7000/7500� SHM1-5000/6000/7000/8000/9000

17



6.5 Dimensional Drawings

18



19



20



21



22



23



24



25



26



Copeland CorporatonSidney, Ohio 45365-0669

copeland tae1309

Documents

2fz fz fz

low evaporating temperatures

automatic vi control

vibration mounting pads

insufficient oil supply

contour screw compressors

common oil separator

special system considerations