Johnson Controls Frick Vyper 305/254 Horsepower Manual Download

Page: 1 / 72

Form 100.200-IOM (SEP 2013)

INSTALLATION - OPERATION - MAINTENANCE

File:

SERVICE MANUAL - Section 100

Replaces:

100.200-IOM (SEP 2012)

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 COULD RESULT IN DAMAGE OR IMPROPER

OPERATION OF THE UNIT.

305 / 254 Horsepower

437 / 362 Horsepower

Please check www.jci.com/frick for the latest version of this publication.

Summary of Contents for Frick Vyper 305/254 Horsepower

Page 1: ...3b 3c THIS MANUAL CONTAINS RIGGING ASSEMBLY START UP AND MAINTENANCE INSTRUCTIONS READ THOROUGHLY BEFORE BEGINNING INSTALLATION FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DAMAGE OR IMPROPER...

Page 2: ...TECTION 28 MOTOR RTD THERMAL PROTECTION 29 TEMPERATURE CONTROL VALVE WIRING 29 DRAWING NOTES 30 MOTOR COOLING BLOWER WIRING 30 ANALOG BOARD WIRING 31 QUANTUM LX COMMUNICATIONS WIRING 32 INSTALLATION C...

Page 3: ...Valve 34 Figure 32 Step 4 Close the Drain and Refill the Unit 34 Figure 33 Step 5 Reapply power and Unplug J2 34 Figure 34 Step 6 Top Off the Cooling System 34 Figure 35 Step 7 Replace the Pipe Plug a...

Page 4: ...ic con trol equipment All safety precautions consistent with opera tion of high current and voltage electrical equipment should be strictly enforced JOB INSPECTION Immediately upon arrival examine all...

Page 5: ...GING AND HANDLING The Vyper cabinet unit is best moved via lifting lugs on the top sides of the cabinet Special care must be exercised not to damage the pump or peripheral equipment on the rear of the...

Page 6: ...in the INSTALLATION section of this manual Verify that all control power 120 VAC communications analog wiring and 460 VAC power are in separate metallic conduits Properly shielded and grounded analog...

Page 7: ...tables in this manual to calculate what they should be 7 Verify proper operation of the motorized coolant mixing valve on the back of the drive Locate the Coolant mixing valve on the back of the driv...

Page 8: ...operating frequency range of the drive The unit is started with the compressor fully unloaded until the frequency reaches the minimum operating frequency range In addition the drive is capable of oper...

Page 9: ...feet Adequate service clearances including door swing must be maintained around the Vyper Care should be taken to ensure that the Vyper and it s associated piping and wiring do not obstruct the acces...

Page 10: ...GER PRESSURE DROP In order to adequately size piping and booster pump require ments the pressure drop of the coolant across the heat Figure 3 Minimum Flow Rates GLYCOL exchanger must be known Figure 4...

Page 11: ...g procedures for electronic equipment instal lation These procedures do not override any rules by the NEC but are to be used in conjunction with the NEC code and any other applicable codes With exclus...

Page 12: ...from various locations can create multiple potentials resulting in ground loop currents A single ground wire 10 AWG or 8 AWG from the electronic control panel that is bonded to the control power neut...

Page 13: ...e grounded at both ends When not required to be in metal or other material by na tional or local codes conduits for the power feed 3 phase of constant speed starters may be PVC When not required to be...

Page 14: ...ure Route the conduit to the sides or bottom of the panel and use a conduit drain If the conduit must be routed to the top of the panel use a sealable conduit fitting which is poured with a sealer aft...

Page 15: ...ng shutdown protection for a Quantum panel the panel may not see the loss of the 3 phase voltage on the motor because the UPS may prevent the motor starter contactor from dropping out With the starter...

Page 16: ...nce the Vyper has a 0 95 minimum power factor at all operational loads and conditions Capacitors can be located at one or several places on a distribution system Solid state motor controllers may not...

Page 17: ...fiers SCRs and 3 diodes One SCR and one diode are contained in each module Three modules are required to covert the three phase input AC voltage to DC voltage 1SCR 3SCR The modules are mounted on a li...

Page 18: ...SPEED DRIVE INSTALLATION 100 200 IOM SEP 13 Page 18 Figure 10 Vyper Elementary Wiring Diagram NOTE Drawings for specific units can be found in the door of the Vyper drive or check with Frick Engineer...

Page 19: ...module does not rupture if a failure were to occur on the DC link of the Filter Power Unit THE THREE PHASE INDUCTOR provides some impedance for the filter to work against It effectively limits the rat...

Page 20: ...VYPER VARIABLE SPEED DRIVE INSTALLATION 100 200 IOM SEP 13 Page 20 Figure 12 Harmonic Filter Elementary Wiring Diagram NOTE Typical Check with engineering for latest drawings...

Page 21: ...nd shutdowns as sociated with the Vyper coolant temperature reading These wil also be factory set for a Low Temp alarm and shutdown at 85 F and 80 F with a 90 second delay when running The High Temp A...

Page 22: ...VYPER VARIABLE SPEED DRIVE INSTALLATION 100 200 IOM SEP 13 Page 22 Liquid Cooled Vyper P I Diagram Economized...

Page 23: ...VYPER VARIABLE SPEED DRIVE INSTALLATION 100 200 IOM SEP 13 Page 23 Liquid Cooled Vyper P I Diagram Noneconomized...

Page 24: ...d also helps to maintain the rigidity of the cabinet during service The channel assembly VSD cabinet is mounted on two extension brackets welded to pads on the system s oil separator All package mount...

Page 25: ...e top left of the cabinet that designates the point of entry for the incoming power This is the only acceptable point of entry for power into a Vyper drive For remote mounted 305 and 437 HP Vyper driv...

Page 26: ...ernal capacitors resistors to discharge the DC bus and allow for safe maintenance of the unit Failure to do so may cause serious injury or death Also ensure that all power has been removed from the le...

Page 27: ...tor Size Termination Torque 3 8 lug Compression 216 240 in lb ELECTRICAL CONDUITS All power wiring must be contained in metallic conduit All compressor motor wiring must be in a separate metallic cond...

Page 28: ...VYPER VARIABLE SPEED DRIVE INSTALLATION 100 200 IOM SEP 13 Page 28 Figure 20 Motor Thermistor Protection WIRING DIAGRAM OPTIONS...

Page 29: ...e speed drive systems Frick employs two types of thermal protection for motors One method uses thermistors and one method uses RTDs Figures 20 25 show the wiring scheme for both options MOTOR Thermist...

Page 30: ...VYPER VARIABLE SPEED DRIVE INSTALLATION 100 200 IOM SEP 13 Page 30 MOTOR COOLING BLOWER WIRING Figure 23 Motor Cooling Blower Wiring Figure 24 Notes for Figures 20 23 and 25 DRAWING NOTES...

Page 31: ...VYPER VARIABLE SPEED DRIVE INSTALLATION 100 200 IOM SEP 13 Page 31 ANALOG BOARD WIRING Figure 25 Analog Board Wiring...

Page 32: ...blower fans if present Mounting a Verify that the Vyper Drive is properly mounted to the floor or wall for remote mounts or to the package for package mounted units b Verify that the Vyper power lead...

Page 33: ...drive operation THREE INSTALLATION STEPS Installation of the Vyper can be done in a few easy steps Before beginning the Setup Procedures be sure that the cabinet has the proper electrical connections...

Page 34: ...il the fluid level re mains constant about one inch form the top of the manifold See Figure 34 Step 7 Replace and tighten the plug on the top of the mani fold using an adjustable wrench See Figure 35...

Page 35: ...ential pressure the motor speed will increase to meet the capacity requirement When the slide valve reaches the Capacity Control Slide Valve setpoint the motor speed can increase At this point the sli...

Page 36: ...r can select either the Vyper or the Har monic Filter setup screens See Figure 39 The flydown menu allows the user to select either the Vyper Drive setup or if the Harmonic Filter is installed the dis...

Page 37: ...ring the VSD memory and resetting the kWh record Standby Time The VSD enters Standby mode when there is no load on the VSD The VSD capacitor banks remain charged and the compressor output is 0 Hz Stan...

Page 38: ...indicate the status of the field They are displayed as the following 0 no off 1 yes on VSD Operating Mode Harmonic Filter Present Harmonic Filter Operating Mode Water Pump Energized Precharge Relay E...

Page 39: ...ompressors via the SFS 229 Frick Interface Board This is accomplished through the reception of a Speed Command value in rotations per minute and a Run Command signal from the Quantum LX control panel...

Page 40: ...on The screen shown in Figure 43 will appear Type 2 into the User Level field Enter Level 2 password Return to the menu and the Home screen The home screen will now provide additional information as s...

Page 41: ...pacity Regulations and Package spe cific information Verify that Screw Compressor with Vyper is selected under the package Drive field This will allow the Vyper specific screens to be displayed See Fi...

Page 42: ...set to PID Channel 5 Use the table below to program the proper settings Parameter Value Name Drive Cooling Control Running Action Forward Control Point Vyper Coolant Device Source Analog Board 2 Devi...

Page 43: ...ng the motor and the drive from high currents High Motor Amps Load Inhibit Force Unload Delay Warning 5 SEC Shutdown 5 SEC Applied Motor FLA Calculation IF USE Mtr Nameplate SF 1 0 Mtr Nameplate FLA 1...

Page 44: ...Inhibit Applied Motor FLA x 1 1 374 A Force Unload Applied Motor FLA x 1 12 380 A Warning Applied Motor FLA x 1 13 384 A Shutdown Applied Mtr FLA x 1 15 391 A High Motor Amps Load Inhibit 357 Force U...

Page 45: ...A Shutdown Applied Mtr FLA x 1 15 339 A High Motor Amps Load Inhibit 310 Force Unload 324 Delay Warning 330 5 SEC Shutdown 337 5 SEC Example 4 What are the High Motor Amp setpoints if a 437 HP Vyper...

Page 46: ...r The Rate of Decrease setting works in conjunction with the Cycle Time setting to provide variability in the desired speed change step rate The Vyper has an internally set rate of deceleration of 6 0...

Page 47: ...ating compressors for the base load This allows the required quick response and also prevents the rapid cycling on and off of the other compressors in the system Some additional Vyper features require...

Page 48: ...advance to the Compressor Safeties Screen Figure 51 Compressor Safeties Screen 1 2 Figure 52 2 1 Turndown Suggested Control Strategy Step 2 Refer to Figure 51 Use the cursor arrow and Tab keys to navi...

Page 49: ...for the operation shown in Figure 52 VFD Proportional Band This is the value above the Capac ity Control setpoint for forward action at which the output to the drive will match the maximum output set...

Page 50: ...com munication address with the Quantum LX Panel To config ure the switches for proper communication set switches 1 through 6 to the OFF position Place switch 7 in the ON position The resulting MODBU...

Page 51: ...e trim pot control until the desired Job FLA setting is achieved The Quantum LX screen will provide feedback to the operator as the adjust ment is made Close the Vyper cabinet and secure with the door...

Page 52: ...to operate properly The switches should be set at the factory but it is good practice to verify the settings before starting the Vyper The switches should be set as shown in Figure 62 Figure 61 Frick...

Page 53: ...ndicators RX TX Logic Board to Quantum LX 8 J16 Communications Cable Logic Board to Quantum LX 9 Communications Indicators RX TX Logic Board to Filter Board 10 J15 Communications Cable Logic Board to...

Page 54: ...e tubing has a milky white coating this indicates that the coolant is corroding the inside of the cooling system and oxidizing the aluminum If any of these conditions exist the coolant may have bacter...

Page 55: ...A The input current to the Vyper may be considerably lower compared to the output current This is due to the power factor at the input to the Vyper being greater than 0 95 and nearly unity when the Ha...

Page 56: ...oftware generates for the basic compressor package there are warnings and shutdowns that are associated with the Vyper drive operation These can be initiated by the Quantum LX panel or the Vyper drive...

Page 57: ...C Baseplate Temperature Occurs when the Phase C baseplate temperature reaches 165 F and this will unload the Slide Valve FRICK VYPER FAULT CODES Quantum LX Failure Code Quantum LX Failure Message 1 V...

Page 58: ...r each board and they must be correctly installed There are a total of seven 7 EPROMs in each Vyper system These EPROMs are cre ated as a set and cannot be intermixed All pins must be properly inserte...

Page 59: ...pt applying to Phase C Inverter Baseplate Temperature Fault 13 Low Phase B Inverter Baseplate Temperature Message Quantum Fault 13 Quantum LX Low Phase B Inverter Baseplate Temperature The phase bank...

Page 60: ...r board and relayed to the Vyper Logic board to initiate a system shut down The single phase control uses circuitry to detect the loss of any one of the three input phases The trigger board will detec...

Page 61: ...these conditions connect a 12 VDC source such as a battery charger used to charge automobile batteries and apply 12 VDC between the positive bus and negative bus plates on power unit while measuring...

Page 62: ...is generated when communications between the Quantum LX Panel and the Frick Interface board or the Frick Interface board and Vyper Logic board is disrupted for a least 22 seconds Check the shielded c...

Page 63: ...board Fault 50 Harmonic Filter High DC Bus Voltage Message Quantum Fault 50 Quantum LX Harmonic Filter High DC Bus Voltage Fault The harmonic filter s DC link voltage is continuously moni tored and if...

Page 64: ...be equal to or greater than 50 VDC 41 VDC for 50 HZ 1 10 second after the filter precharge relay is energized Also the filter s DC bus voltage must be equal to or greater than 525 VDC 425 VDC for 50...

Page 65: ...should be replaced If the voltages are not equal check the wiring between the bleeder resistors 12RES and 13RES and the filter power unit Also check the value of these resistors They should be 3000 oh...

Page 66: ...the line frequency is within range RECOMMENDED SPARE PARTS 305 254 HP NOTE This list is based on one unit When stocking for more than one unit the quantity should be adjusted to meet your individual r...

Page 67: ...ronic 1 ALL 025 40386 000 Board SCR Trigger 60 Hz 1 ALL 031 02060 001 Board SCR Trigger 50 Hz 1 ALL 031 02060 002 Kit VSD Power Module IGBT with Gate Driver Board 1 437 362 371 04164 001 437 362 HP OP...

Page 68: ...transformer 13 multiple ground conductors 12 NEC code book 11 NEMA rating 14 Optical Isolation 15 parallel connect 14 plant supply transformer 13 point to point wiring 11 Quantum LX panel 15 refriger...

Page 69: ...r 9 21 heat exchanger 21 32 33 56 horseshoe jumper 58 I IGBT 60 IGBT Module 61 IGBT module 56 IGBT transistor 61 impedance 8 input fuses 60 INSTALLATION 4 16 AC line choke 17 Analog Board Wiring 31 An...

Page 70: ...verage Current 38 Baseplate Temperature 38 Capacity Regulations 41 Clear Standby Time 37 Clear VSD Memory 38 Comm 1 41 Converter Heatsink Temp 38 Current Phase 38 Current Value Timer 38 DC Bus Voltage...

Page 71: ...T1 lug 55 temperature sensor 17 61 temperature sensors 32 test button 56 thermistors 28 thermistor sensor 61 Three Phase Inductor 19 timeout 66 Total Demand Distortion 59 Total Harmonic Distortion 8...

Page 72: ...age 72 Johnson Controls 100 CV Avenue Waynesboro PA 17268 1206 USA Phone 717 762 2121 FAX 717 762 8624 www jci com frick Form 100 200 IOM 2013 09 Supersedes 100 200 IOM 2012 09 Subject to change witho...

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