HPSH ROTARY SCREW COMPRESSOR

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INSTALLATION - OPERATION - MAINTENANCE

File: EQUIPMENT MANUAL - Section 070 Replaces: NOTHING

Dist: 3, 3a, 3b, 3c

HPSH

ROTARY SCREW COMPRESSOR

MODEL 1510

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

THIS MANUAL CONTAINS RIGGING, ASSEMBLY, START-UP,

AND MAINTENANCE INSTRUCTIONS. READ THOROUGHLY

BEFORE BEGINNING INSTALLATION. FAILURE TO FOLLOW THESE

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Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a potentially hazardous situation or practice which, if not avoided, will result in death or serious injury.

SAFETY PRECAUTION DEFINITIONS

Indicates a potentially hazardous situation or practice which, if not avoided, will result in damage to equipment and/or minor injury.

NOTE:

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

THE INFORMATION CONTAINED IN THIS

DOCUMENT IS SUBJECT TO CHANGE

WITHOUT NOTICE

GENERAL INFORMATION

PREFACE

This manual has been prepared to acquaint the owner and serviceman with the INSTALLATION, OPERATION, and MAINTENANCE procedures as recommended by Johnson Controls-Frick for HPSH Rotary Screw Compressors.

NOTE: Frick screw compressor repair must only be done by skilled mechanics who have completed training at Frick screw compressor school.

It is most important that these compressors be properly applied to an adequately controlled refrigerant or gas sys-tem. Your authorized Johnson Controls-Frick representa-tive should be consulted for his expert guidance in this de-termination.

Proper performance and continued satisfaction with these units is dependent upon:

CORRECT INSTALLATION PROPER OPERATION

REGULAR, SYSTEMATIC MAINTENANCE

To ensure correct installation and application, the equip-ment must be properly selected and connected to a prop-erly designed and installed system. The engineering plans, piping layouts, etc. must be detailed in accordance with the best practices and local codes, such as those outlined in ASHRAE and EN codes.

A screw compressor is a vAPOR PUMP. To be certain that it is not being subjected to pumping liquid it is necessary that controls are carefully selected and in good operating condi-tion; the piping is properly sized and traps, if necessary, are correctly arranged; the suction line has an accumulator or slugging protection; that load surges are known and provi-sions are made for control; operating cycles and stand still periods are reasonable; and that high side components are sized within system and compressor design limits.

HPSH compressors have small clearances and the com-pressor package and system must be built with a very high degree of cleanliness.

DESIGN LIMITATIONS

HPSH compressors are designed for operation within the pressure and temperature limits, which are specified by Johnson Controls-Frick and the Johnson Controls-Frick se-lection software COOLWARE. They are primarily used for compressing refrigerant gas and most hydrocarbon gasses. If your application is for sour gas, there are special require-ments to protect the compressor. Contact Johnson Con-trols-Frick Compressor Engineering for application details.

JOB INSPECTION

Immediately upon delivery examine all crates, boxes and exposed compressor and component surfaces for damage.

Unpack all items and check against shipping lists for any discrepancy. Examine all items for damage in transit.

STANDARD BARE COMPRESSOR

Items not included with bare compressor that are available as sales order options: Motor Mount, Connection Fittings, Coupling, Solenoid valve for Plug valve.

TRANSIT DAMAGE CLAIMS

All claims must be made by consignee. This is an ICC re-quirement. Request immediate inspection by the agent of the carrier and be sure the proper claim forms are execut-ed. Report damage or shortage claims immediately to Johnson Controls-Frick Sales Administration Department, in Waynesboro, PA.

COMPRESSOR IDENTIFICATION

Each compressor has an identification data plate, contain-ing compressor model and serial number mounted on the compressor body.

NOTE: When inquiring about the compressor or unit, or ordering repair parts, provide the MODEL and SERIAL NUMBERS from the data plate. See Figure 1.

Figure 1 - Identification Data Plate

Rotary screw compressor serial numbers are defined by the following information:

EXAMPLE: 10240A90000015Z

GLOBAL ADDITIONAL PLANT DECADE MONTH YEAR SEQ NO. REMARKS

1024 0 A 9 0000015 Z

Month: A = JAN, B = FEB, C = MAR, D = APR, E = MAY, F = JUN, G = JUL, H = AUG, k = SEP, L = OCT, M = NOv, N = DEC. Additional Remarks: R = Remanufactured; Z = Deviation from Standard Configuration.

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Figure 2 - Refrigerant Name Plates

Figure 3 - Name Plate and Vi Locations

Table HPSH 1510: Geometrical swept volume at common drive speeds, rpm. rpm m3/h cfm 2950 292.8 172.2 3550 352.4 207.5 4200 416.9 245.5 6000 595.6 350.8

LONG TERM STORAGE

Long term storage (6 months to 5 years) provisions are re-quired, regardless of storage environment, if start-up and/ or useful operation does not occur within six (6) months of equipment shipment. Special provisions may be required for storage of less than six (6) months if the storage area is subject to unusual environment such as high humidity, large changes in temperature, dusty atmosphere, etc.

The standard Johnson Controls-Frick Warranty for an HPSH screw compressor covers 12 months from start-up or 18 months from shipment, whichever comes first. It is recom-mended that arrangements be made with the local Johnson Controls-Frick service organization (arranged through fac-tory service) regarding surveillance and maintenance dur-ing the storage period. It will be the customer’s responsibil-ity to submit a monthly report showing the condition of the unit and noting any discrepancies to the guidelines listed herein. Failure to comply with this Long Term Storage Rec-ommendation may void the warranty.

Long term storage of equipment may lead to the deteriora-tion of components over the period of time. Synthetic com-ponents in the compressor may deteriorate over time even if they are kept flooded with oil. A warm and dry environ-ment is essential to minimize environenviron-mental and corrosion damage.

Compressor Long Term Storage Log

Model Serial No.

Compressor, Motor Oil Pump and Refrigerant Pump

Shaft Rotation

1½ Turn

Rotor Housing

Charge ChargeAdded

Visual Inspection

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The following guidelines must be followed to maintain the SCREW COMPRESSOR WARRANTY.

PREPARING COMPRESSOR FOR STORAGE

1. Evacuate compressor to remove moisture. An evacua-tion line is to be connected to the one Schrader valve provided with the compressor. The valve is connected to the SD-1 port on the rotor housing.

2. Break vacuum with dry nitrogen and bring pressure to zero psig.

3. Pump oil into the same ports mentioned in step 1. Johnson Controls-Frick recommends break-in oil P/N 111q0831809 for storage purposes. The amounts of oil needed per compressor are:

157 mm – 2.8 Gal

4. After compressor is oil charged, pressurize compressor to 1.0 bar (15 psig) with nitrogen.

MAINTAINING COMPRESSOR

1. Ensure that the 0.3 – 1.0 bar (5-15 psig) nitrogen charge is maintained with 1.0 bar (15 psig ) preferred.

2. Rotate the male rotor shaft every two weeks. Mark the shaft to ensure the rotor does not return to the original position.

3. The compressor must be stored inside a dry building environment.

4. Grease the male rotor shaft to prevent rust.

5. Record all information in a “Compressor Long Term Storage Log.”

Contact Johnson Controls-Frick Service with any ques-tions regarding long term storage.

DESCRIPTION

HPSH COMPRESSOR

The Frick HPSH rotary screw compressor utilizes mating asymmetrical profile helical rotors to provide a continuous flow of vapor and is designed for both high-pressure and low-pressure applications. The compressor incorporates the following features:

1. Designed for variable speed drive, 1000 to 6,000 rpm. Fixed speed 2950 rpm or 3550 rpm possible.

2. No slide valve for capacity regulation - just a simple ro-bust capacity control plug valve to reduce starting torque requirement and provide overload protection. Plug valve is operated with a 4-way solenoid valve.

3. Fixed volume vi ratio: 1.7, 2.9 and 4.0 are available as standard. No moveable slide stop valve.

3. High capacity roller bearings to carry radial loads at both the inlet and outlet ends of the compressor.

4. Heavy duty angular contact ball bearings to carry axial loads on the rotors.

5. Balance piston located in the inlet end of the male rotor reduces axial loads on the male axial bearings.

6. Housings are designed for 60 bar (870 psig) working pressure.

8. Economizer port at 1.05 vi, primarily intended for CO2

applications.

9. Liquid injection port at 1.30 vi.

10. Two main oil injection ports at 1.05 and 1.30 to meet application requirements.

11. All bearing and control oil vented to lower pressure lo-cations inside compressor allowing operation without an oil pump for most applications.

12. Shaft seal housing designed to maintain operating pres-sure on seal well below discharge prespres-sure for increased seal life.

13. Oil injected into the rotors to maintain good volumetric and adiabatic efficiency.

14. Shaft rotation clockwise facing compressor drive end, suitable for all types of drives. SEE WARNING.

Compressor rotation is clockwise when facing the compressor drive shaft. The compressor should never be operated in reverse rotation, as damage will result.

15. Suction flange is ANSI B16.1 Class 400. Discharge flange is ANSI B16.1 Class 600.

16. Integral suction strainer.

COMPRESSOR LUBRICATION SYSTEM

The lubrication system on a HPSH screw compressor unit performs several functions:

1. Provides lubrication to bearings and seal.

2. Provides a cushion between the rotors to minimize noise and vibrations.

3. Helps keep the compressor cool and prevent overheating. 4. Provides oil supply to hydraulically operate the plug valve on and off.

4. Provides oil pressure to the balance piston to help in-crease bearing life.

5. Provides an oil seal between the rotors to prevent rotor contact or gas bypassing.

CAPACITY REGULATION AND FIXED VOLUME RATIO VI

The design without a moveable slide valve under the rotors provides a very robust design. However, the fixed volume ratio must be selected close to the ideal value to provide reliable and efficient operation. The simple plug valve is provided to allow start-up and safe operation at low dif-ferential and other not-normal operations.

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OIL PUMP (OPTIONAL)

A demand oil pump is required for low differential pressure applications (CoolWare will provide a warning when the

oil differential pressure is too low). Oil being supplied to

the compressor from the oil separator is at system dis-charge pressure. Within the compressor, oil porting to all parts of the compressor is vented back to a location in the compressor’s body that is at a pressure lower than com-pressor discharge pressure. All oil entering the comcom-pressor is moved by the compressor rotors, out the compressor outlet, and back to the system oil separator.

CONSTRUCTION DETAILS

HOUSING: All HPSH screw compressor castings are

60-40-18 ductile iron to ensure structural integrity and mechanical and thermal stability under all operating conditions.

ROTORS: The rotors are machined from AISI-1141 steel to

the exacting tolerances of the latest industry standard asymmetric profile. The six-lobed male rotor is directly connected to the driver. The eight-lobed female rotor is driven by the male on a thin oil film.

BEARINGS: Antifriction bearings with L10rated life in excess

of 50,000 hours (using Frick SuperFilters™_{) at design}

condi-tions are used for reduced frictional horsepower and supe-rior rotor positioning, resulting in reduced power consump-tion. Cylindrical roller bearings are provided to handle the radial loads and the thrust loads are absorbed by angular contact bearings.

BALANCE PISTON: The male rotor is equipped with a

bal-ance piston to reduce load on the male axial bearing. Oil pressure provides the force and therefore shall be within limits of discharge pressure, 1.5 bar (22 psi) below and 3.3 bar (50 psi) above discharge pressure.

Shaft Seal: The compressor shaft seal is a single-face

bal-anced type with a spring-loaded, 2-piece, carbon station-ary surface riding against a hardened rotating seat. The seal is capable of withstanding static pressure up to 90 bar (1305

psig). During operation it is vented to low pressure to pro-vide extended life.

UNLOADING VALVE: Reduced power requirement at

start-up is achieved by use of a plug valve. The plug valve re-duces torque by approximately 10%. Also, the plug valve provides overload protection in more situations: power overload, low oil pressure, low compression ratio, and high internal compression.

MOTOR MOUNT: The HPSH series is designed with a

drive-end flange that mates with a cast iron motor mount (avail-able as a sales order option). The motor mount is precision machined so that it ensures proper alignment of the com-pressor and motor coupling.

DESIGN LIMITS

Information is provided in the table below.

Please also use CoolWare™_{to determine the limits for a}

specific application.

CR = Compression ratio. Absolute discharge pressure di-vided by absolute suction pressure.

NOTES:

1. The UNISAB and Quantum panels have several layers of control functions to secure reliable operation. De-pending on many operating conditions, they will unload the plug valve and reduce or increase speed to keep the compressor running in a safe way. Only as the last resort will they initiate an alarm and ultimately stop the com-pressor.

2. In CO2 application using miscible oil types POE and

PAG, it is extremely critical to keep water content to the lowest possible - down to 10 PPM is the goal. The in-stallation must have large filter dryers with replaceable elements that can be effectively serviced and vacuum dried before being put back in service.

3. Maximum discharge temperature depends on oil type used. Please see Frick oil data for more detail.

Condition Min Max

Swept volume 99.3 m3/h (3,507 ft3/h) at 1000 rpm 595.6 m3/h (21,033 ft3/h) at 6000 rpm

Suction pressure 3 bar (43.5 psig) 20 bar (290 psig)

Discharge pressure 15 bar (217.5 psig) 50 bar (725 psig) CR at volume ratio vi = 1.7, see note 4 CR > 1.1 Recommend CR < 4.0 CR at volume ratio vi = 2.9, see note 4 CR > 2.2 Recommend CR < 8.0 CR at volume ratio vi = 4.0, see note 4 CR > 3.0 Recommend CR < 12.0

Suction temperature -60°C (-76°F)

-Discharge temperature, see note 3 40°C (104°F) -R744 cascade 150°C (300°F)

Discharge superheat 10 k

-Speed ( min. limit depend on oil viscosity) 600 rpm 6000 rpm Oil viscosity, speed depending, see fig. 1 7 cst effective at 6000 rpm 100 cst Oil temperature, see also viscosity limits 20 °C (68°F) 93°C (200°F) Oil quality, particle count. ISO 4406 16/14/11

-Oil flow, 1 to 3% of swept volume typical 17 lpm (4.5 gpm) 300 lpm (79.3 gpm) at 6000 rpm Oil pressure, for balance piston 1.5 bar (21.8 psi ) < discharge P. 3.3 bar (47.9 psi) > discharge P. Oil pressure, lubrication, see note 1 (1.5 * suction P. + 1) bar

-Oil filter pressure drop - 1.2 bar (17 psi)

Water content in oil, see note 2 - 50 PPM (10 PPM)

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4. At lower CR, the plug valve will unload. UNISAB and Quantum have further advanced logics and may unload plug valve at higher CR to maintain optimum efficiency.

Figure 4 - Requirement for Viscosity as function of speed

VIBRATION AND SOUND DATA

The rotors balance grade is G 2.5 according to ISO 1940. The male rotor drive end has a keyway and has been bal-anced with a half key in the keyway, to be considered as a round, full body shaft.

Effective vibration velocity should not exceed 5 mm/s (0.2 inch/s) anywhere on the compressor.

Male rotor, # of lobes 6 Main Exciting Frequencies (Hz) Female rotor, # of lobes 8

Driver Speed, rpm Typical Exiting Member / Event 3000 3600 4200 6000

Male rotor, rotational, 1st order 50 60 72 100 Male rotor, rotational, 2nd order 100 120 144 200 Female rotor, rotational, 1st 37.5 45 54 75 Female rotor, rotational, 2nd 75 90 108 150 Discharge gas pulsation, 1st 300 360 432 600 Discharge gas pulsation, 2nd 600 720 864 1200 vibration level on the package can be higher, especially on piping elements and when the natural frequency of an ele-ment falls together with one of the exciting frequencies. If the vibration level gets too high (about 12 mm/s (0.5 inch/s)), a skip frequency function in the control system shall be ac-tivated. When activated, the motor will run through the critical speed very fast, not causing any continuously high vibration.

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INSTALLATION

HPSH compressors are primarily designed for connecting to an electric drive motor using a tunnel mount. If the applica-tion requires it, the compressor can also be driven with a foot mounted motor. The tunnel mount (see Figure 5) en-sures proper alignment of the compressor and motor so that the shaft seal and coupling will operate properly. The rotor and bearing design set limitations must not be ex-ceeded (See CoolWare). Refer to Johnson Controls-Frick Compressor Control Panel instruction 090-022 O for addi-tional information on setpoint limits.

Figure 5 - HPSH shown with motor mount (tunnel). OUTLINE DIMENSIONS

Complete dimensions and connection information can be found on the outline drawing which can be requested by contacting Johnson Controls-Frick Sales. Port locations are shown on the drawings at the back of this manual. See Ta-ble of Contents.

HOLDING CHARGE AND STORAGE

Every HPSH compressor is pressure and leak tested at the Johnson Controls – Frick Factory and then thoroughly evac-uated and charged with dry nitrogen to ensure its integrity during shipping and short term storage prior to installation. All compressors must be kept in a clean, dry location to prevent corrosion damage. Compressors that will be stored for more than two months must have their nitrogen charge checked periodically (see pages in GENERAL INFORMATION for complete instructions).

Holding-charge shipping gauges (if mounted) are rated for 2.1 bar (30 psig) and are for checking the ship-ping charge only. They must be removed before pressure testing and operating the system. Failure to remove these gauges may result in catastrophic failure of the gauge resulting in serious injury or death.

Access valves are bronze and they must be replaced with steel plugs when package is assembled.

RIGGING AND HANDLING

The compressor can be moved with rigging, using a crane or forklift, by hooking into the two lifting rings at each end of the main housings. The compressor lifting rings shall only be used to lift the compressor itself.

Figure 6 - Lifting Rings

FOUNDATION

Each HPSH Rotary Screw Compressor is shipped mounted on a wooden skid, which must be removed prior to unit installation.

Allow proper spacing for servicing (see Dimensional Outline Drawing).

The first requirement of the compressor foundation is that it must be able to support the weight. The HPSH 1510 weighs approximately 367 kg (810 lb).

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The best insurance for a trouble-free installation is to firm-ly anchor the compressor to a suitable foundation using proper bolting and by preventing piping stress from being imposed on the compressor. Once the compressor is rigged into place, its feet must be shimmed to level it. There must be absolutely no stresse transferred to the compressor body due to bolting of the feet and flanges.

The compressor motor mount is not designed to carry the unsupported weight of the motor. The full motor weight must be supported using the motor lifting point during the motor installation process. After the necessary bracket to support the motor has been welded into place on the pack-age and the rear motor feet and the motor mount have been bolted into place, the weight of the motor can rest on the support bracket and the motor mount.

In any screw compressor installation, suction and discharge lines should be supported in pipe hangers (preferably with-in 2 ft. of vertical pipe run) so that the lwith-ines won’t move if disconnected from the compressor. See table for Allowable Flange Loads.

CUSTOMER CONNECTIONS

As a minimum you must connect to the following locations in addition to suction and discharge.

SB-2 Inlet Bearings and Balance Piston

SB-3 Shaft seal, outlet end bearings, and unloader plug SM-1 or SM-2 Main oil injection (See CoolWare for port

required by operating conditions) Other connections are available for instrumentation and service as noted on the Dimensional Outline drawing. The electrical connections for the unloader plug solenoid valve coils must be connected to your control system.

The oil supply system for the compressor must be designed for a total pressure drop of no more than 1 bar (15 psi) with a new oil filter element. This is critical for the proper op-eration of the balance piston which is used to ensure the life of the male axial bearing.

COMPRESSOR OIL

DO NOT MIX OILS of different brands, manufacturers, or types. Mixing of oils can cause excessive oil foaming, nuisance oil level cutouts, oil pressure loss, gas or oil leakage and catastrophic compressor failure. CoolWare will select a specific Frick oil for the refriger-ant being used. Depending on the application, a different oil can be selected provided it is of the proper viscosity and is compatible with the refrigerant and compressor elastomers.

NOTE: The Frick oil charge shipped with the unit is the best suited lubricant for the conditions specified at the time of purchase. If there is any doubt due to the refrig-erant, operating pressures, or temperatures, refer to Frick Oil publication E160-802 SPC.

OIL PUMP

If your HPSH compressor application requires an oil pump, it is recommended that a strainer be mounted upstream to protect it. Frick supplied pumps are a positive displacement gear type that must have a safety relief valve to ensure the oil pressure will not be more than 50 psi above compressor discharge pressure for all models.

If oil pressure exceeds 55 PSI above compressor discharge it could cause catastrophic compressor failure due to male axial bearing failure. See CoolWare for your ap-plication’s requirements.

COMPRESSOR ROTATION IS CLOCKWISE WHEN FACING THE END OF THE COMPRESSOR SHAFT.

Confirm motor will rotate the compressor clockwise before installing the coupling.

MOTOR MOUNTING USING TUNNEL

1. Attach the motor mount (tunnel) to the compressor. 2. As the motors for this compressor will be big and heavy, all 4 feet of the motor must be supported and the weight brought down to the oil separator close to the center of mass.

ALLOWABLE FLANGE LOADS - METRIC NOZ. MOMENTS (Nm) LOAD (N)

SIZE AXIAL VERT. LAT. AXIAL VERT. LAT. ND (In.) MR MC ML P VC VL 1 34 34 34 222 222 222 1.25 34 34 34 222 222 222 1.5 68 54 54 445 334 334 2 136 95 95 667 556 556 3 339 237 237 1001 1112 1112 4 542 271 271 1334 1779 1779 5 576 542 542 1779 2002 2002 6 1356 1017 1017 2891 2891 2891 8 2034 1356 1356 6672 4003 4003 10 2034 1627 1627 6672 5338 5338 14 2712 2440 2440 7562 8896 8896

ALLOWABLE FLANGE LOADS - ENGLISH NOZ. MOMENTS (ft-lbf) LOAD (lbf)

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3. The motor mounting design must allow for proper posi-tioning of the motor mounting bracket on the package sep-arator pad by welding it in place (see Figures 7 and 8).

Figure 7 - Motor Mounting

4. Bolt the motor feet mount that shall attach the motor feet to the motor. Hand tighten the bolts. Apply shims be-tween motor feet and mount so it will be possible later to adjust alignment if needed.

5. Use a scale to weigh the motor, including mount, prior to assembly.

6. Bolt the motor to the motor mount (tunnel) while the motor weight is still supported by the scale and torque bolts to 339 Nm (250 ft-lb).

7. Weld motor support bracket to mount as shown in Fig-ures 7 and 8.

Figure 8 - Welding to Motor Support Bracket

8. Weld motor support bracket to separator pad as shown in Figures 7 and 8.

9. verify the actual scale reading is within +/- 10% of the original motor weight.

10. If reading is less remove shims and reshim. 11. If reading is higher remove shims and reshim.

12. Repeat from step 9 until scale reading is within +/- 10% with bolts tightened.

13. Remove scale.

MOTOR MOUNTING (FOOT MOUNTED ONLY)

1. Thoroughly clean the motor feet and mounting pads of grease, burrs, and other foreign matter to ensure firm seat-ing of the motor.

2. Attach the motor to the base using bolts and motor raising blocks, if required.

3. Weld the four kick bolts (not included with compressor) into place so that they are positioned to allow movement of the motor feet.

4. After the motor has been set, check to see that the shafts are properly spaced for the coupling being used. Check the appropriate Dimensional Outline drawing for the minimum clearance required between the shaft ends to change the shaft seal.

COMPRESSOR/MOTOR COUPLING REQUIREMENTS.

HPSH compressors are arranged for direct motor drive and require a flexible drive coupling to connect the compressor to the motor. Coupling must be suitable for variable speed. Compressor drive shaft end has a keyway and is balanced with a half key mounted. That means the coupling must also be balanced with a half key mounted in the keyway. If you are using the Johnson Controls–Frick motor mount, the mount is machined to ensure that motor-to-compres-sor alignment is within specification (see the section “MO-TOR MOUNTING USING TUNNEL” for mounting details). If you are using a foot mounted motor, it is essential that the coupling be properly aligned to ensure proper bearing and seal performance.

1. Coupling must be selected and installed so that it doesn’t transmit any axial load to the compressor shaft. 2. Set up the minimum distance between compressor shaft and motor shaft to allow for seal removal (see Outline drawings).

3. Coupling must be able to take up any misalignment be-tween motor and compressor. It is critical to the life of the shaft seal that misalignment is kept to the minimum possi-ble value. Be sure to follow the coupling manufacturer’s guidelines for checking and correcting any misalignment. See the next section for Johnson Control–Frick’s require-ments.

COUPLING ALIGNMENT REQUIREMENTS (FOOT MOUNTED ONLY)

Coupling alignment must be performed prior to start-up. After the compressor has been installed on the job site, alignment must be checked again and if necessary correct-ed prior to start-up. After a few hours operation, the align-ment must be checked while the package is still hot. Cor-rect hot alignment is critical to ensure the life of the shaft seal and compressor bearings.

Maximum radial runout is .004” total indicator reading. Maximum axial runout is .004” total indicator reading.

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Indicator bracket sag must be checked as all brackets have some flexibility. The best way to measure this is to attach the dial indicator and bracket on a pipe at the coupling span distance. Zero the indicator in the 12:00 position, and ro-tate the pipe so the indicator is in the 6:00 position. The reading on the indicator in the 6:00 position is the bracket sag. This value must be included in the dial indicator read-ings when affixed to the coupling for an accurate alignment.

OIL HEATER(S)

Your package must be equipped with oil heaters that pro-vide sufficient heat to prevent condensation from occurring during shutdown cycles.

OIL FILTER(S)

Use of filter elements other than Johnson Controls-Frick must be approved in writing by Johnson Controls-Frick En-gineering or a warranty claim may be denied. Typical oil filter specification b₅= 75 according to ISO 4572 is required to obtain the recommended oil cleanliness class 16/14/11 according to ISO 4406.

OIL COOLING REQUIREMENTS

Compressor oil needs to be cooled to control the discharge temperature, maintain proper oil viscosity, and to preserve the life of the oil. The discharge temperature depends on application and operation condition (see CoolWare). For a CO2 compressor, it is typically about 60°C (140°F). For an

ammonia heat pump, it can be 120°C (250°F).

There are applications that it is normal to have discharge temperatures as high as 150°C (300°F). An ammonia heat pump is one example. The higher discharge temperature permits higher process fluid temperatures to be achieved. Another application that typically requires higher discharge temperatures as high as 150°C (300°F) is natural gas gath-ering at the wellhead. Moisture is normally present in the gas and it is imperative that the discharge temperature be at least 17°C (30°F) higher than the discharge dew point temperature for the gas. Run CoolWare with the “Water Saturated” block checked to get the discharge dew point temperature for your application. Oil temperatures as high as 93°C (200°F) can be used to achieve the necessary dis-charge temperature to prevent moisture from condensing in the oil separator. Contact Johnson Controls–Frick for ad-ditional information for natural gas compression.

The main oil injection line that is connected to port SM1 or SM2 must have a regulating valve to permit adjustment of the oil flow to maintain the desired discharge temperature at all times. A nonreturn valve is also required in order to prevent gas from flowing backward into the oil system un-der start-up and transition of operating conditions. The regulating valve may have to have a motor so the actual opening/flow can be controlled by the control panel. This is often a needed for heat pumps where a certain capacity, water temperature, and efficiency is expected. It may also be a requirement when the speed turndown is significant e.g. from 6000 rpm to 1000 rpm as the relative oil flow may get too high at the lower speed range. Consult Coolware and the factory.

The use of a thermostatic three-way bypass mixing valve is recommended to keep the minimum supply oil temperature above 50°C (120°F). The valve will provide warm oil to the compressor quickly, reducing the pressure drop caused by cold, viscous oil. This ensures proper oil flow and tempera-ture over the full range of operating conditions. For some applications this valve needs to be a motor-operated valve controlled by the control panel. This is e.g. needed for a heat pump where the oil is cooled to a lower temperature than the condensing temperature. In such an application there is a risk the discharge temperature is getting too low at low speed, therefore some hot oil must bypass the oil cooler. Discharge temperature shall be minimum 10°C (18°F) above condensing temperature. Consult Coolware and factory, also please study PID diagram examples (see Table of Contents).

DEHYDRATION / EVACUATION TEST

Evacuate the system to 1000 microns. valve off the vacuum pump and hold vacuum for one hour.

Pass – vacuum cannot rise more than 500 microns during one hour hold period.

Fail – vacuum rise is more than 500 microns during one hour hold period. Identify and repair any system leaks. Re-peat vacuum test until requirements are met.

ELECTRICAL INSTALLATION

The only electrical connection to be made to the compres-sor is for the 4-way hydraulic valve controlling the plug. CAPACITY PLUG vALvE and solenoid valve (Solenoid valve not included)

Solenoid is a standard DO3/CETOP, see schematic Solenoid “a” and “b” must be electrically connected. To load, energize solenoid “b”

To unload, energize solenoid “a”

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OPERATION

OPERATION AND START-UP INSTRUCTIONS

The Frick HPSH Rotary Screw Compressor will be a compo-nent in an integrated system. As such, the compressor re-quires some specific operation and conditions to ensure trouble-free running.

The information in this section of the manual provides the logical step by step instructions to properly start up and op-erate the HPSH Rotary Screw Compressor in your unit. Only matters which may influence the proper operation of the Frick HPSH compressor are included.

THE FOLLOWING SUBSECTIONS MUST BE READ AND UNDERSTOOD BEFORE ATTEMPTING TO START OR OP-ERATE THE UNIT.

LOW AMBIENT OPERATION

It is recommended that package oil separators be insulated as a minimum requirement to preserve the heat generated by the oil heaters, to prevent condensation, and to secure lubrication at start-up. Heat pumps must always have the oil separator insulated as a minimum. Heat pumps will often require the complete suction line to be insulated in order to prevent condensation and possible slugging.

INITIAL START-UP

Prior to the start-up, the prestart check must be accom-plished. Refer to the compressor package IOM.

INITIAL START-UP PROCEDURE

Having performed the prestart check, the compressor unit is ready for start-up. It is important that an adequate gas load be available to load test the unit at normal operating conditions. The following points should be kept in mind during initial start-up.

1. For proper and safe operation, the compressor must be run at the proper speed and discharge pressure. Exceeding design conditions creates a potential hazard.

2. Immediately after start-up, adjust oil cooling system and again after 1 to 3 hours when operating condition are within expected parameters.

3. Pull and clean suction strainer after 24 hours of opera-tion. If it is excessively dirty, repeat every 24 hours until system is clean. Otherwise, follow the normal maintenance schedule.

4. Perform vibration analysis if preventive maintenance desired.

NORMAL START-UP PROCEDURE

1. Confirm system conditions permit starting the com-pressor.

2. Start.

3. Observe the compressor unit for mechanical tightness of the external piping, bolts and valves. Ensure that the ma-chine has no oil and vapor leaks. If any of these occur, shut down the compressor and correct the problem as neces-sary using good safety precautions.

CONTROL SYSTEM

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MAINTENANCE

GENERAL INFORMATION

This section provides instructions for normal maintenance, a recommended maintenance program, troubleshooting and correction guides, and typical P and I diagrams.

THIS SECTION MUST BE READ AND UNDERSTOOD BE-FORE ATTEMPTING TO PERFORM ANY MAINTENANCE OR SERVICE TO THE UNIT.

NORMAL MAINTENANCE OPERATIONS

When performing maintenance you must take several pre-cautions to ensure your safety:

1. IF UNIT IS RUNNING, PRESS [STOP] kEY.

2. STOP MOTOR AND LOCk OUT STARTER BEFORE PER-FORMING ANY MAINTENANCE.

3. WEAR PROPER SAFETY EqUIPMENT WHEN COMPRES-SOR UNIT IS OPENED TO ATMOSPHERE.

4. ENSURE ADEqUATE vENTILATION.

5. TAkE NECESSARY SAFETY PRECAUTIONS REqUIRED FOR THE GAS BEING USED.

GENERAL MAINTENANCE

Proper maintenance is important in order to assure long and trouble-free service from your screw compressor. Some areas critical to good compressor operation are: 1. keep oil clean and dry, avoid moisture contamination. After servicing any portion of the refrigeration 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 breakdown of oil and refrigerant, which can generate corrosive agents breaking down bearings and other vital components in a short time.

2. keep suction strainer clean. Check periodically, particu-larly 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 parti-cles into the compressor.

3. 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 of oil and lead to premature bearing failure. Dual oil filters are recommended so that the filters can be changed without shutting down the package.

4. Avoid slugging the compressor with liquids (refrigerant and/or oil). While screw compressors are probably the most tolerant (of any compressor type available today) about in-gestion of some liquid, they are not liquid pumps. Make certain a properly sized suction accumulator is used to avoid dumping liquid into compressor suction.

5. Protect the compressor during long periods of shut-down. If the compressor will be sitting for long periods without running, it is advisable to evacuate to low pressure and charge with dry nitrogen or oil. This is particularly true on systems known to contain water vapor.

6. Preventive maintenance is recommended including measuring of vibration and performing oil analyses. Inspec-tion is recommended any time a compressor exhibits a no-ticeable change in vibration level, noise or performance.

CHANGING OIL

DO NOT MIX OILS of different brands, manufacturers, or types. Mixing of oils may cause excessive oil foaming, nuisance oil level cutouts, oil pressure loss, gas or oil leakage and catastrophic compressor failure.

Shut down the unit when changing oil. At the same time, all oil filter cartridges must be changed and all oil strainer ele-ments removed and cleaned. The procedure is as follows: 1. Stop the compressor unit.

2. Lock out the motor starter.

3. Close the suction and discharge service valves

4. Using appropriate equipment, lower the compressor pressure to -15 mm (-.59 in.) of mercury.

5. Open the drain valve(s) and drain oil into a suitable con-tainer.

6. Drain the oil filter(s) and the oil coolers.

7. Remove the old filter cartridges, and then install new ones.

8. Remove, clean, and reinstall elements in the strainers. 9. Evacuate the unit.

10. Open the suction service valve and pressurize the unit to system suction pressure. Close the suction valve and leak test.

11. Add oil.

12. Open the suction and discharge service valves 13. Remove the lockout from the motor starter. 14. Start the unit

RECOMMENDED MAINTENANCE PROGRAM

In order to obtain maximum compressor performance and ensure reliable operation, a regular maintenance program should be followed. The compressor should be checked regularly for leaks, abnormal vibration, noise, and proper operation. A log should also be maintained. Oil analysis should be performed on a regular basis. It is a valuable tool that can identify the presence of moisture, acid, metallics and other contaminants that will shorten compressor life if not corrected. In addition, an analysis of the compressor vibration should be made regularly.

VIBRATION ANALYSIS

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1. Always take vibration readings from exactly the same places and at exactly the same percentage of load. 2. Use vibration readings taken from the new unit at start-up as the base line reference.

3. Evaluate vibration readings carefully as the instrument range and function used can vary. Findings can be easily misinterpreted.

4. vibration readings can be influenced by other equip-ment operating in the vicinity or connected to the same piping as the unit.

OIL QUALITY AND ANALYSIS

High quality and suitable oil is necessary to ensure com-pressor longevity and reliability. Oil quality will rapidly dete-riorate in systems containing moisture and air or other con-taminants. In order to ensure the quality of the oil in the compressor unit:

1. Only use Frick oil or high quality oils approved by John-son Controls-Frick for your application.

2. Only use Frick SuperFilter™ elements. Substitutions must be approved in writing by Johnson Controls-Frick En-gineering or warranty claim may be denied.

3. Participate in a regular, periodic oil analysis program to maintain oil and system integrity.

OPERATING LOG

The use of an OPERATING LOG (See Table of Contents) per-mits thorough analysis of the operation of a system by those responsible for its maintenance and servicing. Con-tinual recording of gauge pressures, temperatures, and other pertinent information, enables the observer and ser-viceman to be constantly familiar with the operation of the system and to recognize immediately any deviations from normal operating conditions. It is recommended that read-ings be taken at least daily.

TROUBLESHOOTING GUIDE

Successful problem solving requires an organized approach to define the problem, identify the cause, and make the proper correction. Sometimes it is possible that two rela-tively obvious problems combine to provide a set of symp-toms that can mislead the troubleshooter. Be aware of this possibility and avoid solving the “wrong problem”.

ABNORMAL OPERATION

ANALYSIS AND CORRECTION

Four logical steps are required to analyze an operational problem effectively and make the necessary corrections: 1. Define the problem and its limits.

2. Identify all possible causes.

3. Test each cause until the source of the problem is found. 4. Make the necessary corrections.

The first step in effective problem solving is to define the limits of the problem. The following list of abnormal system conditions can cause abnormal operation of the HPSH com-pressor:

1. Oil flow too high at low speed.

2. Discharge temperature too close to condensing tem-perature.

3. Insufficient or excessive gas load. 4. Excessively high suction pressure. 5. Excessively high discharge pressure.

6. Excessively high or low temperature coolant to the oil cooler.

7. Excessive liquid entering the compressor (slugging). 8. Insufficient oil cooling.

9. Excessive oil cooling 10. Incorrect gas line sizing. 11. Improper system piping.

12. Wrong operation of hydraulic operated plug valve. 13. Problems in electrical service to compressor. 14. Moisture present in the system.

Make a list of all deviations from normal compressor opera-tion. Delete any items, which do not relate to the symptom and separately list those items that might relate to the symptom. Use the list as a guide to further investigate the problem.

The second step in problem solving is to decide which items on the list are possible causes and which items are additional symptoms. High discharge temperature and high oil temperature readings on a display may both be symp-toms of a problem and not causally related.

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MAINTENANCE SCHEDULE

This schedule should be followed to ensure trouble-free operation of the compressor unit.

FREQUENCY OR HOURS OF OPERATION (MAXIMUM) MAINTENANCE ₂₀₀

1000 5000 8000 ₁₀,000 ₁₅,000 ₂₀,000 ₂₅,000 ₃₀,000 ₃₅,000 ₄₀,000 ₄₅,000 ₅₀,000 ₅₅,000 ₆₀,000 ₆₅,000 ₇₀,000 ₇₅,000 ₈₀,000 ₈₅,000 ₉₀,000 ₉₅,000

Change Oil As Directed By Oil Analysis

Oil Analysis n Every 6 Months

Replace Oil Filters n n n n n n n n n n n

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

Vibration Analysis n Every 6 Months, More Frequently If Levels Increase Replace Shaft Seal When Leak Rate Exceeds 7 - 8 Drops Per Minute

TROUBLESHOOTING THE HPSH COMPRESSOR

SYMPTOM PROBABLE CAUSES and CORRECTIONS

NOTE: Unless the Service Technician has been certified by Johnson Controls–Frick to rebuild our compressors, troubleshooting the compressor is limited to identifying the probable cause. If a mechanical problem is suspect-ed, contact Johnson Controls–Frick Service. DO NOT AT-TEMPT TO DISASSEMBLE COMPRESSOR.

BARE COMPRESSOR REPLACEMENT

The following procedure is required only when a bare com-pressor is replaced in the field.

1. verify that main power to the unit is disconnected and tag the switch.

2. Remove all tubing, piping, and wiring that is connected to the compressor.

3. Disconnect the coupling from the motor shaft.

4. While supporting the motor and compressor assembly with a crane, remove the bolts at the motor feet, and then at the compressor feet.

5. Thoroughly clean the compressor and motor feet and mounting pads of burrs and other foreign matter to ensure firm seating of the compressor.

6. Thoroughly clean the new compressor and remove all cover plates and protection etc.

7. Install new gaskets and sealing in all connections. 8. Set the new compressor in place and shim feet where required.

9. Reattach the drive coupling.

10. The shaft alignment must be checked if a factory pro-vided motor mount is not used.

11. Complete tubing, piping and wiring.

SHUTDOWN DUE TO IMPROPER OIL PRESSURE (HIGH STAGE AND BOOSTER)

The compressor must not operate with incorrect oil pressure.

Refer to CONTROL SETUP.

RECOMMENDED SPARE PARTS - CURRENT DESIGN

DESCRIPTION

HPSH 1510

Complete Bearing Kit

534C2311G01

O-ring Kit

534B1335H01

Shaft Seal Kit

534C2310G01

Balance Piston Kit

534A1123G01

Compressor Tool Kit

534C2307G01

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TROUBLESHOOTING THE OIL PUMP AND SYSTEM

SYMPTOM PROBABLE CAUSES and CORRECTIONS

PUMP WILL NOT PRODUCE ENOUGH OIL PRESSURE AT START-UP

Check that service valves are open.

Filter cartridges may be blocked. Check PSID across filters. Strainer may be blocked. Clean.

Oil pressure regulator set too low or stuck open. Readjust or repair. Pump worn out. Repair or replace.

OIL PRESSURE RAPIDLY DROPS OFF WHEN COMPRESSOR STARTS

Main oil injection throttling valve too wide open or oil pressure regulating valve improperly adjusted. Readjust both valves.

NOISE and vIBRATION Pump strainer blocked. Clean. Pump worn out. Repair or replace. OIL PRESSURE DROPS AS HEAD

PRESSURE INCREASES Normal behavior. Set main oil injection and oil pressure for maximum head pressure condition. MAIN UNIT FILTER PSID IS TOO

HIGH Filters clogged with dirt. Replace. _{Oil is too cold. Allow oil to warm up and check again.}

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ALIGNMENT LOG – FOR ELECTRIC MOTOR DRIVER

DRIVE TRAIN ALIGNMENT

Ambient Temperature at Time of Alignment _______ Oil Separator Temperature at Time of Alignment_________ Motor Coupling Type ___________ Size ___________ Distance Between Coupling Hub Faces __________ Soft Foot Check OK as Found Shimming Required Amount of Shims used to Correct __________ Indicator Readings in in./1000 mm Indicator Clamped to Motor Compressor

Indicator Readings Facing Compressor Motor Magnetic Center Checked Marked N/A Compressor Coupling Hub Runout ___________ Motor Coupling Hub Runout ____________

Initial Cold Alignment

Initial Hot Alignment

Final Hot Alignment

OPERATING LOG SHEET

Date

Time

Hour Meter Reading Equip. Room Temp. Suction Pressure Suction Temperature Suction Superheat Discharge Pressure Discharge Temperature Corresponding Temperature Oil Pressure Oil Temperature Oil Filter Pressure Drop Separator Temperature Slide Valve Position Volume Ratio (VI) Motor Amps / FLA % Capacity Control Setpoint Oil Level

Oil Added

Seal Leakage (Drops/Min.)

Face

Rim

Thickness of Shims Added

Face

Rim

Thickness of Shims Added

Face

Rim

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Soft Foot Soft Foot

Motor Inboard

Compressor Inboard Compressor Inboard (Coupled End)

(Coupling End) (Coupling End Male) Horizontal . IPS Overall vertical Direction Axial Direction vertical . IPS Overall . IPS Overall . IPS Overall Axial . IPS Overall

Date: __________________________________________ Sales Order Number: ________________________________ End User: _______________________________________ Installing Contractor: ________________________________ Address: __________________________________________ Service Technician: __________________________________

Equipment ID (As in Microlog): ____________________ Compressor Serial Number: __________________________ Unit Serial Number: _________________________________ National Board Number: _____________________________ Running Hours: _____________________________________ Manufacturer and Size of Coupling: ____________________ Motor Manufacturer: ________________________________ Motor Serial Number: ________________________________ RPM: ________ Frame Size: ___________ H.P. __________ Refrigerant:

Ambient Room Temperature: ____________°F Operating Conditions:

VIBRATION DATA SHEET

Final Hot Alignment

SUCTION

DISCHARGE

OIL

SEPARATOR

Slide Valve Position

%

Press # Press # Press # Temp °F V.I. Ratio

Temp °F Temp °F Temp °F F.L.A. %

Total Thickness of Shims Added

Motor Outboard (Noncoupled End)

Horizontal . IPS Overall vertical . IPS Overall Axial . IPS Overall Compressor Outboard Compressor Inboard

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CONNECTION LEGEND

PORT

LABEL DESCRIPTION

CONNECTION SIZE

SB-2 Balance Piston and Inlet _{Bearing Oil Feed} 3/4-16UNF-2B SB-3 Discharge Bearings, Shaft Seal, _{and Unloader Plug Oil Feed} 3/4-16UNF-2B

SC-5 Inlet Pressure 9/16-18UNF-2B

SC-6 Discharge Pressure 9/16-18UNF-2B

SC-7 Seal Weepage 1/8-27 NPTF

SC-8 Clased Thread Drain 3/4-16UNF-2B SD-1 Coalescer Bleed 9/16-18UNF-2B SD-2 Liquid Injection Bleed 9/16-18UNF-2B SL-0 Liquid Injection Bleed 3/4-16UNF-2B SM-1 Main Oil Injection 1Z\zn -12UN-2B SM-2 Main Oil Injection, Vi = 1.05 3/4-16UNF-2B

SV-1 Economizer 1B\zn -12UN-2B

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Index

Symbols

4-way hydraulic valve 11

A

Ammonia heat pumps 11 asymmetric profile 6 axial load 10 axial runout 10

B

balance piston 5, 6, 9 ball bearings 5 Bearings 6

C

capacity regulation 5 Compression ratio 6 compressor 12 Compressor oil 11 Compressor rotation 5, 8, 9 compressor shaft 10 compressor suction 13 condensing temperature 11 contaminants 13 CoolWare 8 corrosion 4 coupling 10, 11, 15 Coupling alignment 10

D

demand oil pump 6 dial indicator 11 direct motor drive 10 Discharge gas pulsation 7 discharge pressure 5, 6 discharge temperature 6, 11 Drive Train Alignment 17

E

Economizer port 5 electric drive motor 8 Evacuate 5

F

filter elements 11 foundation 8 Frick SuperFilters™₆

G

gas bypassing 5 gas compression 8 gauge pressures 14 Grease 5

H

heat pumps 11 Holding-charge 8 hot alignment 10 Housing 6 HPSH compressors 8

I

identification data plate 3

L

lifting rings 8 Long term storage 4

M

maintenance 13 Maintenance Schedule 15 misalignment 10 mixing valve 11 moisture 5 moisture contamination 13 motor 8, 17 motor coupling 6 motor mount 6, 9

motor mounting bracket 10 motor shaft 15

N

natural gas 11 nitrogen 5

O

oil analyses 13 oil charge 9

oil cooling system 12 oil differential pressure 6 oil filter cartridges 13 oil filters 13 Oil flow 14 oil heaters 11 Oil pressure 6, 9 oil pump 5, 9 oil separator 6

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JOhNSON CONTROLS 100 CV Avenue • P.O. Box 997 Waynesboro, PA 17268-0997 USA Phone: 717-762-2121 • FAX: 717-762-8624 www.johnsoncontrols.com/frick

Form 070-750 IOM (2010-12) Supersedes: NOTHING Subject to change without notice Published in USA • 1210 PDF