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HPS Rotary Screw Compressor Units

070.700-IOM (MAR 21)

Page 46

Forms

Start-up report

Sold to:

_______________________________________

Contact name:

__________________________

Date:

__________________

End user:

______________________________________

Contact name:

__________________________

phone:

__________________

End user address:

_______________________________________________________________________

Fax No:

__________________

City, State, Zip:

_________________________________ Start-up representative __________________

Unit general information

Unit Model # ___________________________________________

Customer Package Identification #

_________________________

Compressor Serial # ____________________________________  Separator National Board # ________________________________
Unit Serial # ___________________________________________  Oil Cooler National Board # _______________________________
Evaporator National Board # ______  Serial # _______________  Condenser National Board # ________  Serial # _______________
Oil Pot National Board # _________________________________  H.P. Receiver National Board # ______
Economizer National Board # ____________________________  Suction Accumulator National Board # ______________________

Refrigerant

_____________ Oil Filters ________________ Lube Oil Type _________

Design Operating Conditions

Oil Cooling

_____________________________________

___________

0

Suct. / _________

0

Disch.

Controls information

Processor Type ____________________

Program Software Ver #

_______ and Date __________ UL Serial # __________________

Digital I/O Board #1 Serial #

_________________________________ Software Ver # __________and Date ____________________

Digital I/O Board #2 Serial #

________________________________ Software Ver # __________and Date ____________________

Analog Board #1 Serial #

___________________________________ Software Ver # __________and Date ____________________

Analog Board #2 Serial #

___________________________________ Software Ver # __________and Date ____________________

Compressor motor starter/drive information

Manufacturer __________________________ Part # ___________________ Model # ______________________
Starter Type ___________________________ Serial # _________________________

Input Voltage

_____________

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.

________ Date ___________P/N ________________________

Harmonic Filter Serial # __________________

Prog. Ver.

________ Date ___________P/N ________________________

Frick Interface Serial # ___________________

Prog. Ver.

________ Date ___________P/N ________________________

CT Location Checked

CT Phase ______ CT Ratio ______ Transition Time _________ DBS Ver.# _____________

Cooling fan information

Motor HP ______ RPM _________ Service Factor ___________ V _________ Hz _________ FLA _______

Cooling Fans

_______

Special options

_____________________

___________________________

_________________________

________________________

Prestart checks

Installation, Foundation

Compressor PHD Setup

Coolant Installed

Position of all valves

Motor PHD Setup

4-20 Coolant Loop Pump Setup

Correct

oil charge

Motor Winding RTD’s Setup

Coolant Loop Temp Setup

All wiring connections

Motor Bearing RTD’s Setup

Cooling Fan Motor I/O Setup

Starter Cleanliness

Motor Temperature Thermistor Setup

Cooling Fan Rotation Checked

All control panel settings

4-20 Motor Drive Signal Calibrated

Oil pump motor rotation

4-20 CT Channel 16 Setup

Cold alignment

Motor rotation

4-20 Output Calibration – Liquid Makeup Valve, Coolant Temp Valve, Economizer Makeup Valve

Configuration

Capacity

Channel Direction Package

Mode 1 _____________

___________

____________ Compressor

______________

Mode 2 _____________

___________

____________ Pump

______________

Mode 3 _____________

___________

____________

Dual Pump ______________

Mode 4 ____________

___________

____________ Drive

___________________________

VFD Hi & Low PI Control

___________

____________

Refrigerant

__________ K-Factor _________

Miscellaneous

Filter _____________________________

Sequencing

________________ PowerPac ____________

Condenser

________________

Screen Saver ________________

Page 2

Unit Serial #

_____________________________

Frick Order No:

____________________________

Frick order No:

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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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