Frick HPSH Rotary Screw Compressor Installation Operation and Maintenance Guide

Form 070.750-IOM (MAY 2014)

INSTALLATION - OPERATION - MAINTENANCE

File: SERVICE MANUAL - Section 070

Replaces: 070.750-IOM (JUN 2012)

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

HPSH

ROTARY SCREW COMPRESSOR

MODEL 1510

THIS MANUAL CONTAINS RIGGING, ASSEMBLY, START-UP,

AND MAINTENANCE INSTRUCTIONS. READ THOROUGHLY

BEFORE BEGINNING INSTALLATION. FAILURE TO FOLLOW THESE

INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR DEATH,

DAMAGE TO THE UNIT, OR IMPROPER OPERATION.

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

070.750-IOM (MAY 14)

Page 2

HPSH ROTARY SCREW COMPRESSOR

INSTALLATION - OPERATION - MAINTENANCE

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.

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

Contents

GENERAL INFORMATION

 

 

 

 

 

 

 

 

 

 

 

 



 

 

 

 

 

INSTALLATION

 

 

 

 

 

 

 

 

 

 



 











OPERATION













MAINTENANCE













 

 

 

 



















 



  



WARNING

CAUTION

DANGER

NOTICE

070.750-IOM (MAY 14)

Page 3

HPSH ROTARY SCREW COMPRESSOR

INSTALLATION - OPERATION - MAINTENANCE

THE INFORMATION CONTAINED IN THIS

DOCUMENT IS SUBJECT TO CHANGE

WITHOUT NOTICE

GENERAL INFORMATION

PREFACE



     

     



NOTICE

Frick screw compressor repair must only be done by

skilled mechanics who have completed training at

Frick screw compressor school.

        



     









CORRECT INSTALLATION

PROPER OPERATION

REGULAR, SYSTEMATIC MAINTENANCE

       







         





















HPSH compressors have small clearances and the com-

pressor package and system must be built with a very

high degree of cleanliness.

DESIGN LIMITATIONS

       

       



       





       



JOB INSPECTION

       



         



STANDARD BARE COMPRESSOR







TRANSIT DAMAGE CLAIMS







       

    



COMPRESSOR IDENTIFICATION







NOTICE

When inquiring about the compressor or unit, or or-

dering repair parts, provide the MODEL and SERIAL

NUMBERS from the data plate. See Figure 1.

Figure 1 - Identication Data Plate





EXAMPLE: 10240A90000015Z

GLOBAL ADDITIONAL

PLANT DECADE MONTH YEAR SEQ NO. REMARKS

     





070.750-IOM (MAY 14)

Page 4

HPSH ROTARY SCREW COMPRESSOR

INSTALLATION - OPERATION - MAINTENANCE

       



    



Figure 2 - Refrigerant Name Plates

Figure 3 - Name Plate and Vi Locations

       



rpm m3/h cfm

  

  

  

  

LONG TERM STORAGE







      









        













   

















Compressor Long Term Storage Log

Model Serial No.









1½ Turn

Rotor

Housing

Charge

Added

Visual

Inspection

Per Qai-3 Charge Checked By Date

070.750-IOM (MAY 14)

Page 5

HPSH ROTARY SCREW COMPRESSOR

INSTALLATION - OPERATION - MAINTENANCE





PREPARING COMPRESSOR FOR STORAGE

 







 



          

     





  

 



MAINTAINING COMPRESSOR

 



 





         



 

        



Contact Johnson Controls-Frick Service with any ques-

tions regarding long term storage.

DESCRIPTION

HPSH COMPRESSOR

       





    















    















         



    

















        











WARNING

Compressor rotation is clockwise when facing the

compressor drive shaft. The compressor should never

be operated in reverse rotation, as damage will result.







COMPRESSOR LUBRICATION SYSTEM

















  







CAPACITY REGULATION AND FIXED VOLUME RATIO VI







        





         











070.750-IOM (MAY 14)

Page 6

HPSH ROTARY SCREW COMPRESSOR

INSTALLATION - OPERATION - MAINTENANCE

OIL PUMP (OPTIONAL)



(CoolWare will provide a warning when the

oil differential pressure is too low)

         

   







        



CONSTRUCTION DETAILS

HOUSING:





ROTORS:        



       





BEARINGS: 













BALANCE PISTON:



   





Shaft Seal:











UNLOADING VALVE:



        

      





MOTOR MOUNT:









DESIGN LIMITS



Please also use CoolWare™ to determine the limits for a

specic application.

       



NOTES FOR DESIGN LIMITS TABLE:

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 lter 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

  

  

  

  

  

  

  

  

  

  

  

  

  

  

  

  

  

  

DESIGN LIMITS (OPERATING)

070.750-IOM (MAY 14)

Page 7

HPSH ROTARY SCREW COMPRESSOR

INSTALLATION - OPERATION - MAINTENANCE

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 efciency.

Figure 4 - Requirement for Viscosity as function of speed

VIBRATION AND SOUND DATA

 











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

    

    

    

    

    

    











        









070.750-IOM (MAY 14)

Page 8

HPSH ROTARY SCREW COMPRESSOR

INSTALLATION - OPERATION - MAINTENANCE

INSTALLATION









        



         

      





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

OUTLINE DIMENSIONS

      

  







HOLDING CHARGE AND STORAGE









          









WARNING

Holding-charge shipping gauges (if mounted) are rated

for 2.1 bar (30 psig) and are for checking the shipping

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.

CAUTION

THIS EQUIPMENT HAS BEEN PRESSURIZED WITH

NITROGEN GAS. TEMPORARY VALVES & GAUGES

HAVE BEEN INSTALLED.

1. RELIEVE PRESSURE PRIOR TO OPENING LINES OR

MAKING FIELD CONNECTIONS.

2. REMOVE CHARGING VALVES OR GAUGES PRIOR

TO PRESSURIZING SYSTEM.

3. REFER TO INSTALLATION OPERATION AND MAIN-

TENANCE MANUAL FOR ADDITIONAL INFORMA-

TION.

ESCAPING GAS MAY CAUSE INJURY

RIGGING AND HANDLING









Figure 6 - Lifting Rings

FOUNDATION



          

    

CAUTION

Allow proper spacing for servicing (see Dimensional

Outline Drawing).



          





         

      





070.750-IOM (MAY 14)

Page 9

HPSH ROTARY SCREW COMPRESSOR

INSTALLATION - OPERATION - MAINTENANCE



        







       





        







          













    

CUSTOMER CONNECTIONS





 

 

 

   

      

















COMPRESSOR OIL

WARNING

DO NOT MIX OILS of different brands, manufacturers,

or types. Mixing of oils can cause excessive oil foam-

ing, nuisance oil level cutouts, oil pressure loss, gas or

oil leakage and catastrophic compressor failure. Cool-

Ware will select a specic Frick oil for the refrigerant

being used. Depending on the application, a different

oil can be selected provided it is of the proper viscos-

ity and is compatible with the refrigerant and com-

pressor elastomers.

NOTICE

The Frick oil charge shipped with the unit is the best

suited lubricant for the conditions specied at the

time of purchase. If there is any doubt due to the re-

frigerant, operating pressures, or temperatures, refer

to Frick Oil publication E160-802 SPC.

OIL PUMP













CAUTION

If oil pressure exceeds 55 PSI above compressor dis-

charge it could cause catastrophic compressor failure

due to male axial bearing failure. See CoolWare for

your application’s requirements.

COMPRESSOR ROTATION IS CLOCKWISE WHEN FACING

THE END OF THE COMPRESSOR SHAFT.





ALLOWABLE FLANGE LOADS - METRIC

NOZ. MOMENTS (Nm) LOAD (N)

SIZE AXIAL VERT. LAT. AXIAL VERT. LAT.

ND (In.) MRMCMLP VCVL

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)

SIZE AXIAL VERT. LAT. AXIAL VERT. LAT.

NPS MRMCMLP VCVL

1 25 25 25 50 50 50

1.25 25 25 25 50 50 50

1.5 50 40 40 100 75 75

2 100 70 70 150 125 125

3 250 175 175 225 250 250

4 400 200 200 300 400 400

5 425 400 400 400 450 450

6 1000 750 750 650 650 650

8 1500 1000 1000 1500 900 900

10 1500 1200 1200 1500 1200 1200

14 2000 1800 1800 1700 2000 2000

070.750-IOM (MAY 14)

Page 10

HPSH ROTARY SCREW COMPRESSOR

INSTALLATION - OPERATION - MAINTENANCE

MOTOR MOUNTING USING TUNNEL

 





           



 





Figure 7 - Motor Mounting

 







 



   





 



Figure 8 - Welding to Motor Support Bracket

 



 













MOTOR MOUNTING (FOOT MOUNTED ONLY)

 





          



 





           

        



       



COMPRESSOR/MOTOR COUPLING REQUIREMENTS.



























         



 

         

















COUPLING ALIGNMENT REQUIREMENTS

(FOOT MOUNTED ONLY)

       

         











Maximum radial runout is .004” total indicator reading.

Maximum axial runout is .004” total indicator reading.

070.750-IOM (MAY 14)

Page 11

HPSH ROTARY SCREW COMPRESSOR

INSTALLATION - OPERATION - MAINTENANCE





















OIL HEATER(S)







OIL FILTER(S)

       



         

b

       



OIL COOLING REQUIREMENTS

















       











         

        























       

 



  

















       



     









  

         







DEHYDRATION / EVACUATION TEST

 



Pass



Fail  





ELECTRICAL INSTALLATION













Compressor Suction

Compressor Oil

(Discharge PSIG)

Compressor

Suction

Figure 8 - Schematic of unloader plug and solenoid

valve, shown loaded, solenoid “b” energized

070.750-IOM (MAY 14)

Page 12

HPSH ROTARY SCREW COMPRESSOR

INSTALLATION - OPERATION - MAINTENANCE

OPERATION

OPERATION AND START-UP INSTRUCTIONS





       









        



THE FOLLOWING SUBSECTIONS MUST BE READ AND

UNDERSTOOD BEFORE ATTEMPTING TO START OR OP-

ERATE THE UNIT.

LOW AMBIENT OPERATION















INITIAL START-UP





INITIAL START-UP PROCEDURE







        



 





       





 

          





      



NORMAL START-UP PROCEDURE

       



 

 









CONTROL SYSTEM

       







070.750-IOM (MAY 14)

Page 13

HPSH ROTARY SCREW COMPRESSOR

INSTALLATION - OPERATION - MAINTENANCE

MAINTENANCE

GENERAL INFORMATION



    



WARNING

THIS SECTION MUST BE READ AND UNDERSTOOD BE-

FORE ATTEMPTING TO PERFORM ANY MAINTENANCE

OR SERVICE TO THE UNIT.

NORMAL MAINTENANCE OPERATIONS







  













GENERAL MAINTENANCE

        

      



  

       







      

        



 









 

        





         

  



 





         

        



        

         







     







CHANGING OIL

WARNING

DO NOT MIX OILS of different brands, manufacturers,

or types. Mixing of oils may cause excessive oil foam-

ing, nuisance oil level cutouts, oil pressure loss, gas or

oil leakage and catastrophic compressor failure. 







 

 

 

      



 



 

         



 

 















RECOMMENDED MAINTENANCE PROGRAM





       

       

        







        



VIBRATION ANALYSIS





070.750-IOM (MAY 14)

Page 14

HPSH ROTARY SCREW COMPRESSOR

INSTALLATION - OPERATION - MAINTENANCE





  



 



 

         



        

         



OIL QUALITY AND ANALYSIS

   









 



      





 



OPERATING LOG



         



      











TROUBLESHOOTING GUIDE



         









ABNORMAL OPERATION

ANALYSIS AND CORRECTION

        



 

 

 

 









 

       



 

 

 

 



 

 

 















         





         

















        



070.750-IOM (MAY 14)

Page 15

HPSH ROTARY SCREW COMPRESSOR

INSTALLATION - OPERATION - MAINTENANCE

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 nEvery 6 Months

Replace Oil Filters nAs 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

Vibration Analysis nEvery 6 Months, More Frequently If Levels Increase

Replace Shaft Seal When Leak Rate Exceeds 7 - 8 Drops Per Minute

TROUBLESHOOTING THE HPSH COMPRESSOR

 

NOTICE

Unless the Service Technician has been certied by

Johnson Controls–Frick to rebuild our compressors,

troubleshooting the compressor is limited to identify-

ing the probable cause. If a mechanical problem is sus-

pected, contact Johnson Controls–Frick Service. DO

NOT ATTEMPT TO DISASSEMBLE COMPRESSOR.

BARE COMPRESSOR REPLACEMENT





 



 



 

 





    





 



 

 



 







SHUTDOWN DUE TO IMPROPER OIL PRESSURE (HIGH

STAGE AND BOOSTER)

The compressor must not operate with incorrect oil

pressure.



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

NOTICE

Refer to the Service Parts List manual, 070.750-SPL1_

HPSH, for detailed parts list.

070.750-IOM (MAY 14)

Page 16

HPSH ROTARY SCREW COMPRESSOR

INSTALLATION - OPERATION - MAINTENANCE

TROUBLESHOOTING THE OIL PUMP AND SYSTEM

SYMPTOM PROBABLE CAUSES and CORRECTIONS







Check that service valves are open.

Check PSID across lters.

Clean.

Readjust or repair.

Repair or replace.







            

Readjust both valves.

 Clean.

Repair or replace.





Set main oil injection and oil pressure for maximum head pressure

condition.





Replace.

Allow oil to warm up and check again.

Open valves fully.

070.750-IOM (MAY 14)

Page 17

HPSH ROTARY SCREW COMPRESSOR

INSTALLATION - OPERATION - MAINTENANCE

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

Thickness of Shims Added

070.750-IOM (MAY 14)

Page 18

HPSH ROTARY SCREW COMPRESSOR

INSTALLATION - OPERATION - MAINTENANCE

Date:  

  

   









 









  







VIBRATION DATA SHEET

SUCTION DISCHARGE OIL SEPARATOR Slide Valve Position %

Press # Press # Press # Temp °F Vi Ratio

Temp °F Temp °F Temp °F F.L.A. %

Compressor Inboard

(Coupling End)

Vertical Direction

____.____ IPS Overall

Compressor Inboard

(Coupling End Male)

Axial Direction

____.____ IPS Overall

Motor Inboard (Coupled End)

Horizontal _______ . ______ IPS Overall

Vertical _______ . ______ IPS Overall

Axial _______ . ______ IPS Overall

Compressor Outboard

(Nondrive End)





Compressor Inboard

(Coupling End Female)





Motor Outboard (Noncoupled End)

  

  

  

 

Final Hot Alignment

Total Thickness of Shims Added

Face Rim

070.750-IOM (MAY 14)

Page 19

HPSH ROTARY SCREW COMPRESSOR

INSTALLATION - OPERATION - MAINTENANCE

PID EXAMPLE FOR A HEAT PUMP PACKAGE (PRELIMINARY)

070.750-IOM (MAY 14)

Page 20

HPSH ROTARY SCREW COMPRESSOR

INSTALLATION - OPERATION - MAINTENANCE

PID EXAMPLE FOR A CO2 CASCADE COMPRESSOR PACKAGE (PRELIMINARY)

Frick HPSH Rotary Screw Compressor Installation Operation and Maintenance Guide

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