Johnson Controls Frick PowerPac Installation Operation & Maintenance Download

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Form 170-600 IOM (2011-06)

Supersedes: S170-600 IOM (2008-06)

Subject to change without notice

Published in USA • 0112 PDF

JOHNSON CONTROLS

100 CV Avenue
Waynesboro, PA 17268-1206 USA
Phone: 717-762-2121 • FAX: 717-762-8624

www.johnsoncontrols.com/frick

Summary of Contents for Frick PowerPac

Page 1: ... JUN 08 Dist 3 3a 3b 3c THIS MANUAL CONTAINS RIGGING ASSEMBLY START UP AND MAINTENANCE INSTRUCTIONS READ THOROUGHLY BEFORE BEGINNING INSTALLATION FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR DEATH DAMAGE TO THE UNIT OR IMPROPER OPERATION Please check www johnsoncontrols com frick for the latest version of this publication ...

Page 2: ...restart Checklist 10 CHECKING MOTOR COMPRESS OR ROTA TION 10 COMPRESSOR MOTOR COUPLING INSTALLATION 10 COMPRESSOR UNIT OIL 11 EVACUATION 11 Charging Refrigerant 11 Draining REFRIGERANT 11 SYSTEM pumpdown 11 Operating log 12 High Pressure Regulating System 12 Purging THE SYSTEM 13 Automatic oil return system 13 MAINTENANCE 14 Troubleshooting and Capacity Measurement 14 Capacity measurement 14 Incor...

Page 3: ...and application the equip ment must be properly selected and connected to a properly de signed and installed system The Engi neering plans piping layouts etc must be detailed in accor dance with the best practices and local codes such as those outlined in ASHRAE literature A refrigeration compressor is a VAPOR PUMP To be certain that it is not being subjected to liquid refriger ant carryover it is...

Page 4: ...imple mechanism that adjusts the compressor volume ratio during operation to the most efficient of three possible volume ratios depend ing on system requirements The SGC Compressor includes a patented method of varying the internal volume ratio to match the system pressure ratio Either compressor reduces the power penalty associated with over under compression The compressor unit is a Frick standa...

Page 5: ... the actual operating conditions The cassettes are assembled bolted together in a frame made for the actual design pressure The refriger ant evaporates inside the cassettes and brine is cooled on the outside The evaporator in Figure 2 is of the flooded type which means that it is filled with boiling refrigerant This liquid leaves the liquid separator and is led to the evaporator through the drop l...

Page 6: ...ght glass Position 9 A horizontal liquid separator is specifically designed for critically charged units with small variations in liquid level This level must not be more than 2 inches 51 mm above the bottom of the liquid separator The separation of liquid from gas is achieved efficiently by leading the return lines to both ends of the liquid separator This reduces the gas velocity in the liquid s...

Page 7: ...ified general arrangement drawings from Johnson Controls Frick to determine the mounting locations and to allow for recom mended clearances around the unit for ease of operation and servicing Foundations must be in compliance with local building codes and materials should be of industrial quality The floor shall be a minimum of 6 inches 152 mm of re inforced concrete Housekeeping pads are recommen...

Page 8: ... concerning additives to the system before installing the system Warranty does not include any damage that may occur due to harmful impurities in the system Brine water systems For the most efficient operation of the unit ensure a full flow of either water or brine through the evaporator Full flow is achieved by using either of systems A or B in Figure 6 Attention is drawn to the fact that all coo...

Page 9: ... with the equipment Enclosures should be checked for accumulated water and drained as applicable The packaged equipment and all vessels should be visually inspected for rust paint fade paint blisters and surface im perfections that may have occurred as a result of handling and storage damage The paint may indicate some visual not functional deterioration especially epoxy paint coatings Water spots...

Page 10: ...ve spacer The split hub is clamped to the shaft by tightening the clamp screws Torque is transmitted from the motor through an elastomeric gear which floats freely between the hubs Because of the use of a motor compressor adapter housing no field alignment is necessary 1 Inspect the shaft of the motor and compressor to ensure that no nicks grease or foreign matter is present 2 Inspect the bores in...

Page 11: ...nect the vacuum pump to valve position 414 see piping diagram and evacuate the unit to a vacuum of approximately 4 to 5 mm Hg A thermostatic vacuum meter may be used to measure the pressure If necessary charge dry air or nitrogen until the pressure reaches 1 bar Evacuate again to 4 to 5 Hg e Usually the unit has been charged with oil from the factory If not see the procedure about Oil Charging in ...

Page 12: ...ed with a gas ballast valve Use this valve as much as possible in order to prevent the condensation of water vapor in the vacuum pump Important Never use the refrigeration compressor to pump down a system For pumpdown to be satisfactory the final pressure must be lower than 2 7 in H2O 5 mm Hg Note There is a risk that any water still present in the refrigeration system may freeze if the ambient te...

Page 13: ... taken to prevent and minimize leakage of refrigerant from refrigeration and air conditioning systems to the atmosphere NOTE The occurrence of air is usually an indication of poor maintenance or lack of thoroughness at installation If the chiller contains air it tends to gather on the high pressure side of the system NOTE R 717 systems should be purged on a regular basis to avoid atmospheric air a...

Page 14: ...CK THE MAIN SWITCH Make sure that the motor cannot start up inadvertently Make sure that there is no over pressure and no refrigerant in the part to be dismantled Close all necessary stop valves Use the prescribed tools and check that they are properly maintained and in good working condition In explosion proof areas use tools suited for this specific purpose Also use electrical protection equipme...

Page 15: ...er solution 2 Call a doctor immediately Skin burns from liquid splashes or concentrated vapor 1 Wash immediately with large quantities of water and continue for at least 15 minutes Remove contaminated clothing carefully while washing 2 Call a doctor immediately 3 After washing apply wet compresses saturated with a sterile isotonic 0 9 NaCl solution salt water to affected areas until medical assist...

Page 16: ...pen water container in which the remnants of R 717 refrigerant will be absorbed Send the water containing R 717 to an authorized incineration plant Cooling agents Standard PowerPac units are designed to use glycol or water as the cooling agent Other cooling agents include Salt solutions brines of calcium chloride CaCl2 or sodium chloride NaCl In general all brines must be considered harmful to nat...

Page 17: ...onfirm no high voltage wiring enters the micro panel at any point __ Check current transformer for correct sizing and instal lation __ Check all point to point wiring between the micro and motor starter __ Confirm all interconnections between micro motor starter and the system are made and are correct __ Ensure all electrical panels are free from installation debris METAL PARTICLES and moisture Af...

Page 18: ...________ Voltage Range____________ Phase______________ Hz______________ Current_____________ Output Voltage_________ Phase_________ Hz _ _______ Max FLA _ ________Max LRA ______ Min Load FLA_____ Job FLA_ _____ Logic Board Serial ___________________ U33 Prog Ver _________ Date____________P N ________________________ U34 Prog Ver _________ Date____________P N ________________________ U45 Prog Ver _...

Page 19: ... Unload _____ PSIG _____ PSIG Override Discharge Pressure ________ Warning _____ PSIG _____ PSIG Port Value ________ Warning Delay _____ Sec _____ Sec Pressure Input __________________ Shutdown _____ PSIG _____ PSIG Fixed Pressure Setpoint __________________ Shutdown Delay _____ Sec _____ Sec Maximum Discharge Pressure _______________ PSIG Highest Cap To Permit Start _______________ Balance Piston...

Page 20: ...t 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 ___...

Page 21: ..._ ____________ ____________ Integral Gain ____________ ____________ ____________ ____________ Communications Compressor ID_______ Comm 1 Comm 2 Comm 3 Baud Rate_ _________ Baud Rate ___________ Baud Rate_ ___________ Data Bits __________ Data Bits_ ____________ Data Bits_ ____________ Stop Bits __________ Stop Bits ____________ Stop Bits_ ____________ Parity _____________ Parity _______________ Pa...

Page 22: ...turer RAM_ ____________________________ Motor Serial Number _ ________________________________ RPM _________ Frame Size ____________ H P ___________ Refrigerant Ambient Room Temperature _ ____________ F Operating Conditions VIBRATION DATA SHEET SUCTION DISCHARGE OIL SEPARATOR Slide Valve Position Press Press Press Temp F V I Ratio Temp F Temp F Temp F F L A Compressor Inboard Coupling End Vertical...

Page 23: ...temperature 14 Excessive condensing pressure 14 First Aid 15 noncondensable gases 14 Oils 16 PSM procedures 16 Troubleshooting 14 Ventilating 16 VIBRATION DATA SHEET 22 mechanical float valve 12 motor alignment 10 motorized expansion valve 12 N nitrogen charge 9 noncondensable gases 13 O oil pump 4 oil separator 5 operating log 12 P plate heat exchanger 5 PowerPac 1 3 4 8 9 10 11 12 13 14 16 press...

Page 24: ...0 IOM 2008 06 Subject to change without notice Published in USA 0112 PDF 2012 Johnson Controls Inc ALL RIGHTS RESERVED Johnson Controls 100 CV Avenue Waynesboro PA 17268 1206 USA Phone 717 762 2121 FAX 717 762 8624 www johnsoncontrols com frick ...

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