Frick HPS 36 Installation Manual Download Page 48

HPS Rotary Screw Compressor Units

070.700-IOM (MAR 21)

Page 48

Forms

Compressor motor setpoints and information

Motor Name Plate 

VFD

 Manufacturer ________________

 

Motor Amps  ___________ 

Maximum Drive Output ___ %   

  

Frame Size ______________ 

 V 

 ___________ 

Minimum Drive Output  ___ %  

  

H.P. ____________________

  Service Factor  ___________ 

Remote Control

 RPM 

 ___________________ 

 Horsepower 

 ___________ 

Rate Of Increase ________ %   Delay ____   Sec 

Serial # _________________                

 

CT Factor  ___________ 

Rate Of Decrease _______ %   Delay ____   Sec 

Service Factor ___________ 

Recycle Delay

 _________ Min 

  

 

 

Voltage

 _________________ 

High Motor Amps

 ______  

Capacity Control 

 

 

 Hz _____________________

 

Load Inhibit______________ 

Drive Speed Reaches  ________

Design 

 _________________ 

  Force Unload__________ 

 

 Code ___________________ 

 

Warning

________ Delay ___ Sec 

Skip Frequency Bands

 

Bearing Type

 ________________ 

 Shutdown________ Delay ___ Sec 

Bottom Top

 

Motor Coupling 

 _____________

 

 _______ 

______

Low Motor Amps

 

 _______ 

______

Shut Down _______ Delay ______ Sec 

 _______ 

______

Confirmed Running Motor Amps

 _______ 

 _______ 

______

Starting Motor Amps Ignore Period 

 ________ Sec 

 _______ 

______

pDrive coolant setpoints

Drive Standby Time ______ 

Drive Coolant Low Temp. Alarm______ Delay ______ Shutdown ______ Delay ________

 

High Temp. Alarm

______ Delay ______ Shutdown ______ Delay ________

PHD Monitoring setpoints 

Condenser control

Compressor Bearing  

 ____________ 

Condenser Control Setpoint  _______________ 

Suction End 

Delay 

Discharge End 

Delay 

Digital Controls    

Step Order

High Warning

 _____

gF

 _____

  Sec 

High Warning

 _____

gF

 _____ Sec 

Module A 

________

High Shutdown

 ____

gF

 _____

  Sec 

High Shutdown

 ____

gF

 _____ Sec 

Module B 

________

 

Module C 

________

Motor Bearing

  _____________ 

Module D 

________ 

Shaft Side  

Delay 

Opposite Shaft Side 

Delay

 

Step Up Dead Band 

_________PSI

High Warning

 ______ F _____

  Sec 

High Warning

 ______ F _____ Sec  

Step Up Delay 

________ Sec

High Shutdown

 _____ F _____

  Sec 

High Shutdown

 _____ F _____ Sec 

Step Down Dead Band  _________PSI                

 

Step Down Delay 

________ Sec

Motor Stator

 _________________

 

High Pressure Override 

_________PSI                

 

High Pressure Override Delay

 _____ Sec

Stator 1 

Delay 

Stator 2  

Delay

High Warning

 _____F ______

  Sec 

High Warning

 _____F ______ Sec 

Analog Controls

 Analog Output A 

 ___________

High Shutdown

 ____F ______

  Sec 

High Shutdown

 ____F ______

  Sec 

 

Analog Output B 

 ___________

 

Proportional Band  ________PSI

Stator 3  

Delay

 

Integration Time 

 _______ Sec

High Warning

 _____F ______

Sec 

High Limit 

 ________PSI 

High Shutdown

 ____F ______ Sec 

Low Limit  _______ Sec        

Miscellaneous

Remote Capacity Deadband _______ % 

Max Slide Valve Timer _______  1/10 Sec

High Compressor Oil Pressure  

 ________________

 

Max Discharge Pressure 

 ___________PSI  

Shutdown ____PSI Delay  ____

Sec 

Max Discharge and Oil Temp

 ________°F

Unit Serial # 

Frick Order No:   

P and ID Setpoints

Name 

_________________  __________ 

_________________  ____________

Control 

____________ 

____________ 

____________ 

____________

Action  

__________________  ____________ 

__________________  ____________

Control point 

__________________  ____________ 

__________________  ____________ 

Device source  

______________ 

__________ 

______________ 

____________

Device channel 

____________ 

____________ 

____________ 

____________

Setpoint 

____________ 

____________ 

____________ 

____________

Dead band 

____________ 

____________ 

____________ 

____________

Prop. band 

____________ 

____________ 

____________ 

____________

Integral gain 

____________ 

____________ 

____________ 

____________

Summary of Contents for HPS 36

Page 1: ...tions may result in personal injury or death damage to the unit or improper operation Rotary Screw Compressor Units All Refrigerants Models 36 42 and 60 HPS Form 070 700 IOM MAR 2021 Installation Oper...

Page 2: ...tems 23 Single port liquid injection 23 Suction check valve bypass 23 Low ambient operation 24 Initial start up 24 Initial start up procedure 24 Quantum HD EZ COOL liquid injection adjustment procedur...

Page 3: ...e to superheat the entering vapor tem perature to the compressor to 10 F or 5 6 C above the refriger ant saturation temperature This ensures that all refrigerant at the compressor suction is in the va...

Page 4: ...ERENCE SHEET 2 AND GENERATED BY SAP ASSEMBLY P 534C2933H01 USA US2430129999900010 10241A89999999R 100 CUMBERLAND VALLEY AVENUE WAYNESBORO PA 17268 ROTARY SCREW COMPRESSOR MODEL NO MAX DRIVER SPEED MAX...

Page 5: ...package vibration from be ing transferred to the building structure It may be neces sary to use rubber or spring isolators or a combination of both to prevent the transmission of compressor vibration...

Page 6: ...24 22 30 5 16 18 720C0313H03 58 79 1 2 20 23 31 5 16 24 41 56 3 8 24 22 30 5 16 18 720C0313H04 58 79 1 2 20 23 31 5 16 24 41 56 3 8 24 22 30 5 16 18 720C0313H05 58 79 1 2 20 23 31 5 16 24 41 56 3 8 2...

Page 7: ...ay set screws are tightened before the shaft clamping bolts are tightened then the hubs can be cocked on the shaft Notice Do not use any lubricant on these bolts Holding charge and storage Each HPS co...

Page 8: ...n Controls Frick The heaters are energized only when the unit is not in operation Warning Do not energize the heaters when there is no oil in the unit because the heat ers burn out The oil heat ers ar...

Page 9: ...using refrigerant isolation valves for the oil cooler Notice The component and piping arrangement shown in the following figure is intended only to illustrate the operating principles of thermosyphon...

Page 10: ...the heat exchanger A chemical cleaning process extends the life of the plate and shell heat exchanger It is important to establish regular cleaning schedules Cleaning A 3 solution of phosphoric or oxa...

Page 11: ...compressors run at partial load In the case of a flash vessel there is no need for the redundancy of a back pressure regulating valve on the vessel and each of the multiple compressors Omit the back p...

Page 12: ...ing a smaller check valve is increased pressure drop during full load conditions If ex tended periods of low compressor loading are anticipated use an automated non modulating full port ball valve in...

Page 13: ...Figure 18 Point to point wiring diagram Current transformer CT ratios See the following table for the CT ratio for various motor sizes with a 5 amp second ary Table 6 CT ratios HP Voltage 200 230 380...

Page 14: ...Table 7 Minimum CT burden ratings Burden rating Maximum distance from Frick panel ANSI VA Using 14 Awg Using 12 Awg Using 10 Awg B 0 1 2 5 15 ft 25 ft 40 ft B 0 2 5 35 ft 55 ft 88 ft B 0 5 12 5 93 ft...

Page 15: ...f the three phase wire sizing use Frick drawing 649D4743 as a reference for correctly sizing con trol wires and other wiring specifications Throughout this document the term Electronic Control Panel i...

Page 16: ...le ground potentials and is also a relatively poor con ductor As a result this is not an acceptable method for correct operation of electronic equipment There must be a ground for the three phase powe...

Page 17: ...quirements For variable frequency drives VFD of any type thread ed metallic or threaded PVC coated metallic is required for both the power feed line side from the source and between the VFD output and...

Page 18: ...ectronics and create a short circuit when powered is applied If you must drill the panel take the following precautions First call the panel manufacturer before drilling into the panel to be sure you...

Page 19: ...ft 609 6 m total cable length Refer to Frick drawing 649D4743 for more detail Comm Port Protection Surge suppression for the comm ports may not be the best method because suppression is required to di...

Page 20: ...ng VA rating based on the requirement of the job If a phase loss oc curs a high motor amp shutdown can occur If the prob lem continues an analysis of the facility s power supply quality may be necessa...

Page 21: ...quid injection port at 1 30 Vi Two main oil injection ports at 1 05 and 1 30 to meet application requirements All bearing and control oil vented to lower pressure locations inside compressor allowing...

Page 22: ...rator to develop oil pressure rapidly on initial start in order to lubricate the compressor without requiring an oil pump even in cold ambient temperatures with all pres sures equalized For cascade an...

Page 23: ...oil cooling WCOC or glycol cooled Single port liquid injection The single port liquid injection system is desig ned to per mit liquid refrigerant injection into one port on the com pressor at any giv...

Page 24: ...rge temperature of the compressor After determining this temperature you can adjust the hand expansion valve accordingly The ideal discharge temperature is within 5 F 2 8 C or of the theoreti cal disc...

Page 25: ...arge Temperature is below this setpoint the Liquid Injection solenoid output de energizes until the Discharge Temperature raises above this setpoint EZ Cool status Discharge Temperature The actual Dis...

Page 26: ...ith medium speed according to a digital Input signal High represents that ICAD is operating the ICM valve like an ON OFF solenoid valve with high speed ac cording to a digital input signal See Figure...

Page 27: ...se the VFD speed by 100 rpm increments and physically check the entire package for elevated en ergy at each stage until the minimum speed range is reached 3 As you identify the high energy hot spots c...

Page 28: ...condition at power cut when fail safe is installed 1 Close valve 2 Open valve 3 Maintain valve position 4 Go to OD given by j12 Digital input function j09 1 2 1 Define function when Dl is ON short ci...

Page 29: ...ressor with liquid refrigerant While screw compressors are probably the most tolerant to ingestion of some refrigerant liquid of any compressor type available today they are not liquid pumps Make cert...

Page 30: ...as follows 1 If a single oil filter is installed press the STOP key on the control panel to shut down unit Then open the discon nect switches for the compressor and oil pump motor starters If dual oi...

Page 31: ...tag on the bottom at the 6 o clock position Caution Seat element in center of locating tabs on separator bulkhead 6 Replace the coalescer filter retainer and nut Tighten the nut to 21 ft lb 28 47 N m...

Page 32: ...n As directed by oil analysis Clean oil strainers n n n n n n n n n n n Clean liquid strainers n n n n n n n n n n n Replace coalescers n n n Check and clean suction strainer n n n n n n n n n n n Che...

Page 33: ...leaks abnormal vibration noise and correct operation and maintaining a log Perform the initial oil analysis and vibration analysis at start up and continue as indicated in the Maintenance schedule Vi...

Page 34: ...d by WEG 4 364 L5809 frames Remove and clean bearing caps of excess grease after 8800 hr Procedure Warning With the motor shutdown inject approximately half of the total grease quantity to be used and...

Page 35: ...system may have a tendency to overfeed The high suction superheat condition moreover may only be temporary When system conditions return to normal the unit s liquid injection overfeeds and the oil tem...

Page 36: ...mm the valve can sustain damage In this case it is important to remove only two screws one from each side In the threaded holes from which the two screws have been removed insert studs with nuts and...

Page 37: ...ther The test is complete Replacing pressure transducers 1 Shut off control power 2 Close the applicable transducer isolation valve Notice To change the discharge pressure transducer PE 3 it is necess...

Page 38: ...Shut off control power 2 Remove DIN connector plug from transmitter See Figure 39 3 Unscrew knurled ring and remove transmitter unit 4 Apply thermal compound to new sensor assembly insert into thermal...

Page 39: ...2 Remove the DIN connector plug from the transmitter 3 Loosen the set screws 4 Remove the electronic switch head 5 Install the new electronic switch head 6 Tighten the set screws 7 Apply the DIN conn...

Page 40: ...essor Volumizer ii vi control for further detail Check motor valve operation and calibration Check calibration of analog output Low oil temperature Equalizing pressure too low Raise pressure Suction s...

Page 41: ...O SERIAL NO MAX ALLOWABLE PRESSURE PSIG MAX DRIVER SPEED RPM WAYNESBORO PA 17268 XXX A A SB 3 TRANSDUCER MOUNTING 12 75 502 12 70 500 KEYWAY Discharge Flange 3 Class 600 SD 2 SC 5 SB 2 SD 1 SL 0 BP 1...

Page 42: ...TER ZV POSITION VALVE BP 1 DISCHARGE BYPASS SB 2 INLET BEARING BALANCE PISTON SB 3 DISCHARGE BEARINGS SHAFT SEAL UNLOADER PLUG OIL FEED SC 5 INLET PRESSURE SC 6 DISCHARGE PRESSURE SC 7 SEAL WEEPAGE SC...

Page 43: ...PV 1 HTR 1 HTR 2 4 4 TE TAL C 1 M 1 TE 2 TAH 2 TAHH 2 YY 1 PE 3 PAH 3 CV 1 TE 1 HIGH SIDE COOLING LOAD 4 TALL PAHH 3 NV 1 NV 3 STR 1 2 LG LG 3 1 LSLL 1 LS TI 1 PI 1 HTR 3 SM 1 SC 6 SB 2 SB 3 SC 5 SD 1...

Page 44: ...HPS Rotary Screw Compressor Units 070 700 IOM MAR 21 Page 44 Forms Operating log sheet Cascade Forms...

Page 45: ...compressor motor wiring __ Confirm no high voltage wiring enters the control panel at any point __ Check current transformer for correct sizing and instal lation __ Check all point to point wiring be...

Page 46: ...Serial __________________________ Input Voltage______________ Voltage Range____________ Phase______________ Hz______________ Current_____________ Output Voltage_________ Phase_________ Hz ________ Max...

Page 47: ...When Below _______ Force Unload _____ PSIG _____ PSIG Override Discharge Pressure ________ Warning _____ PSIG _____ PSIG Port Value ________ Warning Delay _____ Sec _____ Sec Pressure Input _________...

Page 48: ...Shutdown_____ gF______ Sec Module B ________ Module C ________ Motor Bearing ______________ Module D ________ Shaft Side Delay Opposite Shaft Side Delay Step Up Dead Band _________PSI High Warning___...

Page 49: ...et______________ Subnet Mask __________ Web Server Port __________ Compressor operating log sheet Starter operating log sheet Date Average current Time Current phase A Hour meter reading Current phase...

Page 50: ...________ Manufacturer and size of coupling _____________________________ Motor manufacturer RAM_____________________________________ Motor serial number _________________________________________ Rpm _...

Page 51: ...3 discharge pressure 21 disconnect switches 29 disc packs 6 disc type check valves 11 drive coupling 23 dry nitrogen 7 29 dual dip tube method 10 dual setpoint 12 DX vessel 11 E economizer back pressu...

Page 52: ...values 36 valve body 36 valve housing 36 stop valve 36 temperature transmitter 37 vibration analysis 33 vibration data sheet 50 vibration readings 33 manual solenoid 31 manway bolts 31 manway cover 3...

Page 53: ...r 23 temperature sensor replacement 39 DIN connector plug 38 thermal well 38 transmitter unit 38 troubleshooting digital board 1 38 thermosyphon 9 thermosyphon oil cooling 9 thermosyphon oil cooling c...

Page 54: ...ue Waynesboro PA 17268 1206 USA Phone 717 762 2121 FAX 717 762 8624 www johnsoncontrols com Frick Form 070 700 IOM 2021 03 Supersedes Nothing Subject to change without notice Published in USA 02 21 PD...

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