Frick HPS 36 Скачать руководство пользователя страница 3

HPS Rotary Screw Compressor Units

070.700-IOM (MAR 21)

Page 3

General Information

General Information 

Preface

This manual describes the installation, operation, and 
maintenance procedures of Frick HPS Rotary Screw 
Compres sor  Units.

For information about the functions of the Quantum

 HD 

control panels, communications, specifications, and wiring 
diagrams, see publication series 

090.040-O, 090.040-M, 

090.040-CS

, and 

090.040-SPC

.

It is most important that these units be correctly applied 

to an adequately controlled refrigeration system. Consult 
your authori zed Frick representative for their expert guid

-

ance in this determination.

Performance and continued satisfaction with these units 

depends on the following factors:

•   Correct installation
•   Correct operation
• 

 Regular, systematic maintenance

To ensure correct installation and application, select 

the appropriate equipment and connect to a correctly 

designed and installed system. The engineering plans, 

piping layouts, and other system design materials must be 

detailed in accordance with the best practices and local 
codes, such as those outlined in ASHRAE literature.

A refrigeration compressor is a vapor pump. 

To ensure 

that working fluid in the liquid state is not being ingested, 

ensure the following points:

• 

 Select controls carefully. Ensure they are in good oper

-

ating condition. 

• 

 Correctly size piping and arrange 

traps, if they are 

necessary. 

•   Check that the suction line has an 

accumulator or slug

-

ging protection.

• 

 Know the load surges and make provisions for control. 

• 

 Check that operating cycles and standstill periods are 

reasonable. 

• 

 Size high side components in the system and compres

-

sor design limits.

It is best practice 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 vapor state.

Design limitations

The compressor units are designed for operation within 

the pressure and temperature limits, 

which are specified 

by Johnson Controls-Frick and the Johnson Controls-Frick 
selection software CoolWare™.

Job inspection

Immediately upon delivery examine all crates, boxes and 

exposed compressor and com ponent surfaces for dam age. 
Unpack all items and check against shipping lists for any 
discrepancy. Examine all items for damage in transit.

Transit damage claims

All claims must be made by consignee. This is an ICC 
requirement. Request immediate inspection by the agent 

of the carrier and be sure the correct claim forms are 
execut ed.

Report damage or shortage claims im mediately to Johnson 

Controls Inc., Frick Sales Ad ministration Depart ment, in 
Waynes boro,  PA.

Compressor and unit identification

Each compressor unit has 2 identifica tion data plates. The 

unit data plate in 

Figure 1

 containing the unit model, serial 

number, and Frick sales order number, mounted on the 
side of the Quantum

™ 

HD control panel. The compressor 

data plate in 

Figure 2

 contains the compressor model and 

serial number, mounted on the compressor body.

Indicates an imminently hazardous situation that, if not avoided, results in death or serious injury.

Indicates a potentially hazardous situation or practice that, if not avoided, results in death or 

serious injury.

Safety precaution definitions

Indicates a potentially hazardous situation or practice that, if not avoided, results in damage to 

equipment and/or minor injury.

Indicates an operating procedure, practice, or portion thereof that is essential to highlight.

 Warning
 

 

Caution

 

 Danger

Notice

Figure 1: Unit data plate

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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