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HPS Rotary Screw Compressor Units

070.700-IOM (MAR 21)

Page 29

Maintenance

General information

This section provides instructions for normal main tenance,

a maintenance program, troubleshooting, and correction
guides, and P and I diagrams. For wiring diagrams and

information about the

Quantum™

control panel, refer

090.040-M

Warning

This section must be read and un der stood before
attempting to perform any main tenance or service
to the unit.

Normal maintenance operations

When performing maintenance you must take several

precau tions to ensure your safety.

Warning

1. If unit is running, press [stop] key.
2. Disconnect power from unit before performing any

maintenance.

3. Wear appropriate safety equipment when com-

pressor unit is opened to atmosphere.

4. Ensure adequate ventilation.
5. Take necessary safety precautions required for the

refrigerant being used.

Warning

Close all compressor package isolation valves before
servicing the unit. Failure to do so may result in seri-
ous injury.

General maintenance

Correct maintenance is important in order to ensure long

and trouble-free service for your screw compressor unit.

The following points are some areas critical to good com

pressor operation:

•

Keep refrigerant and oil clean and dry, avoid mois

ture contamination. After servicing any portion of the
refrigera tion system, evacuate to remove moisture
before returning to service. Water vapor condensing
in the compressor while running, or more likely while
shut down, can cause rusting of critical components and

reduce life.

• Keep suction strainer clean. Check periodically, par-

ticularly on new systems where welding slag or pipe
scale could find its way to the compressor suction.

Excessive dirt in the suction strainer could cause it to

collapse, dumping particles into the compressor.

• Keep

oil filters clean. If filters show increasing pressure

drop, indicating dirt or water, stop the compressor and
change filters. Running a compressor for long periods
with high filter pressure drop can starve the compressor

for oil and lead to

premature bearing failure.

• Avoid

slugging compressor 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
certain to maintain adequate superheat and correctly
size

suction accumulators to avoid dumping liquid re

frigerant into compressor suction.

Keep liquid injection valves correctly adjusted and in

good condition to avoid flooding compressor with liquid.

Liquid can cause a reduction in compressor life and in
extreme cases can cause complete failure.

•

Protect the compressor during long periods of shut
down. If sitting for long periods without running, it is

advisable to evacuate the compressor to low pressure

and charge with dry nitrogen or oil. This is particularly

true on systems known to contain water vapor.

• Perform a preventive maintenance inspection any time

a compressor exhibits a noticeable change in vibra tion

level, noise, or performance.

Compressor shutdown and start-up

For seasonal or prolonged

shutdowns, perform the follow-

ing procedure:

1. Reduce the system pressure to the appropriate condi-

tion.

2. Press the

STOP

key to cease operation of the com-

pressor.

3. Open disconnect switches for the compressor motor

and oil pump starters.

4. Turn on the oil heater circuit breaker.
5.

Close the suction and discharge service valves, and the

liquid injection and economizer service valves if ap-
plicable.

Attach

CLOSED TAGS

Shut off the cooling water or glycol supply valve to the

oil cooler, if applicable.

Attach

CLOSED TAG

7. Protect the oil cooler from ambient temperatures be-

low freezing or remove water heads.

To start up after a seasonal or prolonged shutdown,

per-

form the following procedure:

1. Restore and turn on any water necessary for the op-

eration of the system that may have been drained or
shut off.

Open suction and discharge service valves, and liquid

injection and economizer service valves, if applicable.

Remove tags.

3. Close the disconnect switches for the compressor, mo-

tor, and oil pump starters.

4. Turn off the oil heater circuit breaker.
5. Perform checkpoints on prestart check list, then start

the unit.

General instructions for replacing

compressor unit components

Notice

See Publication

070.660-SM

for procedures covering

replacement motor and compressor mounting.

Содержание HPS 36

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

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

Страница 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___...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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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