Frick EZ-Cal High Pressure Cut-Out Test Block and Calibration Kit Operating instructions

Brand: Frick

Model: EZ-Cal High Pressure Cut-Out Test Block and Calibration Kit

Type: Operating instructions

EZ-CAL™ HIGH PRESSURE CUT-OUT

TEST BLOCK & CALIBRATION KIT

Form 160.100-IO (APR 2018)

INSTALLATION - OPERATION

File: SERVICE MANUAL - Section 160

Replaces: 160.100-IO (FEB 2018)

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

Revised:

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

INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR DEATH,

DAMAGE TO THE UNIT, OR IMPROPER OPERATION.

160.100-IO (APR 2018)

Page 2

EZ-CAL™ HIGH PRESSURE CUT-OUT TEST BLOCK & CALIBRATION KIT

INSTALLATION - OPERATION

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

Preface ..............................................................................3

Design Limitations ............................................................. 3

Unit Inspection .................................................................. 3

Transit Damage Claims ...................................................... 3

Kit Maintenance ................................................................ 3

Test Block Dimensional Outline & Port Locations .............. 4

INSTALLATION

Retrot Installation ............................................................ 5

OPERATION

Operation Instructions & Testing ....................................... 7

Principles of Operation ......................................................7

Operation Procedure Example ...........................................8

WARNING

CAUTION

DANGER

NOTICE

160.100-IO (APR 2018)

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EZ-CAL™ HIGH PRESSURE CUT-OUT TEST BLOCK & CALIBRATION KIT

INSTALLATION - OPERATION

General Information

PREFACE

This manual has been prepared to acquaint the owner and

serviceman with the INSTALLATION and OPERATION pro-

cedures as recommended by Frick® Industrial Refrigeration

for the EZ-CAL™ High Pressure Cut-out Test Block and

Calibration Kit.

Both ASHRAE 15 and IIAR-2 safety standards prohibit the use

of an intervening stop valve in the compressor discharge line

leading to the high-pressure-limiting device (High Pressure

Cut-out, or HPCO).

The IIAR-6 standard will require testing of the HPCO yearly

to show the function of the device to shut down an operating

compressor. The standard does not allow removal and bench

testing of the HPCO or testing on a shutdown compressor.

There is a safe, simple calibration solution that complies

with safety standards.

The Frick EZ-CAL™ test block is designed to be installed be-

tween the compressor discharge connection and the HPCO.

The unit provides a simple calibration method in compliance

with safety standards, while reducing the risk of prematurely

lifting a safety relief valve with a resultant ammonia release.

It is most important that these units be properly applied to an

adequately controlled refrigeration system. Your authori zed

Frick® representative should be con sulted for their expert

guidance in this determination.

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 HPCO unit

should be connected to a properly designed and installed

system.

NOTICE

Trained personnel are required for

handling and installation.

DESIGN LIMITATIONS

The compressor units are designed for operation within the

pressure and temperature limits as shown in Frick® publica-

tion 070.610-SED.

UNIT INSPECTION

Immediately upon delivery examine the box and components

for dam age. Unpack all items and check against shipping lists

for any discrepancy. Examine all items for damage in transit.

TRANSIT DAMAGE CLAIMS

All claims must be made by consignee. This is an ICC 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 im mediately to John-

son Controls, Frick® Sales Ad ministration Depart ment, in

Waynes boro, PA.

KIT MAINTENANCE

If, in the course of regular use, any component in the

EZ-CAL™ block or calibration kit fails to work or any com-

ponent becomes damaged, the damaged component should

be discarded and replaced with a new one.

160.100-IO (APR 2018)

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EZ-CAL™ HIGH PRESSURE CUT-OUT TEST BLOCK & CALIBRATION KIT

INSTALLATION - OPERATION

EZ-CAL™ TEST BLOCK DIMENSIONAL OUTLINE & PORT LOCATIONS

NOTES:

1. Dimensions are in inches unless indicated otherwise.

2. Constructed of 316/316L ASTM A479.

3. Max. Press./Temp. Rating: 2,500 psi from -55°F to 150°F (-48°C to 65°C), 1,000 psi up to 300°F (148°C).

4. Recommended tubing from EZ-CAL™ block to the compressor is stainless steel, minimum 3/8".

(3 7/8)

(1 5/8)

1/4 NPT

INLET

(7/16)

(1 3/16)

1/4 NPT PRESSURE

TRANSDUCER PORT

2X (



5/16)

MOUNTING HOLES (1 1/8)

(1 1/8)(1 1/4)

(5 7/8)

(3)

(2 1/2)

QUICK CONNECT

WITH BODY PROTECTOR

(



3/8) LATCH LOCK

(LOCKS IN THIS

POSITION ONLY)

Figure 1. Test Block Dimensional Outline

160.100-IO (APR 2018)

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EZ-CAL™ HIGH PRESSURE CUT-OUT TEST BLOCK & CALIBRATION KIT

INSTALLATION

Installation

MOTOR

COMPRESSOR

SUCTION

DISCHARGE

EZ-CAL™ HPCO

CALIBRATION BLOCK

DISCHARGE PRESSURE & HPCO

TRANSDUCER

LOCKABLE '2' POSITION

VALVE (RUN/CALIBRATE)

TEMPORARILY INSTALLED

FOR FIELD CALIBRATION

PERMANENTLY

INSTALLED

TEST PORT CONNECTION

MASTER GAUGE

HAND OIL PUMP

REFRIGERATION

OIL SUMP

CONNECTION HOSE

TO TEST PORT

HIGH PRESSURE CUT-OUT CALIBRATION DIAGRAM

RUN POSITION

CALIBRATE POSITION

DISCH PRESSURE

RETROFIT INSTALLATION

During installation of the test block, care should be taken

to minimize total system volume from the test block to

the HPCO. Directly installing the HPCO discharge pressure

transducer on the test block will keep the volume low, and

be much easier to pressurize during testing.

WARNING

This section must be read and un der stood before

installing or performing any main tenance or service

to the unit.

When installing or performing service you must take several

precau tions to ensure your safety:

1. If unit is running, press [stop] key.

2. Disconnect power from unit before performing any

maintenance.

3. Wear proper safety equipment when compressor unit

is opened to atmosphere.

4. Ensure adequate ventilation.

5. Take necessary safety precautions required for the re-

frigerant being used.

WARNING

Close all compressor package isolation valves prior to

servicing the unit. Failure to do so may result in seri-

ous injury.

NOTICE

Recommended tubing from the EZ-CAL™ block to the

compressor is stainless steel, minimum 3/8".

Figure 2. HPCO Calibration Diagram

160.100-IO (APR 2018)

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EZ-CAL™ HIGH PRESSURE CUT-OUT TEST BLOCK & CALIBRATION KIT

INSTALLATION - OPERATION

This page intentionally left blank.

160.100-IO (APR 2018)

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EZ-CAL™ HIGH PRESSURE CUT-OUT TEST BLOCK & CALIBRATION KIT

OPERATION

Operation

OPERATION INSTRUCTIONS & TESTING

The Frick® EZ-CAL™ test block, 720B0129H01, is designed to

be installed between the compressor discharge connection

and the discharge pressure limiting device, (the high pressure

cut-out, or HPCO).

Figure 3. Test Block in Test & Run Position

Figure 4. Test Block in Run Position

The valve is lockable in the RUN position.

PRINCIPLES OF OPERATION

TEST BLOCK

The test block functions as a low pressure drop check valve,

not a stop valve, in the line from the discharge pressure

source to the HPCO. In the RUN position the HPCO is fully

open to the discharge pressure source.

In the TEST position an external pressure source is con-

nected to the test connection quick connect and when the

valve is switched to TEST position, the external source is

connected directly to the HPCO. This allows the function of

the HPCO and pressure setting to be conrmed by applica-

tion of external pressure while comparing the compressor

discharge pressure reading to a master gauge.

Once the HPCO is conrmed to trip the compressor at the

correct set point, the valve is switched back to run mode and

any high pressure trapped above the check valve is relieved

back to the system. Should an actual high pressure event

occur, even during testing, the check valve in the test block

will open and expose the HPCO to the high pressure level,

still allowing protection of the compressor during testing of

the HPCO.

One EZ-CAL™ test block should be installed permanently on

each compressor and only be used when the HPCO is to be

tested. They can be locked in the RUN position during normal

operation, but the compressor is still protected from a high

pressure event in either operational position.

NOTICE

Leaving the test block valve in the TEST position after

testing is complete can trap the external pressure be-

tween the HPCO and the test port.

The only risk by leaving the test block valve in the TEST posi-

tion after testing is complete is trapping the external pressure

between the HPCO and the test port. The discharge pressure

reading on the control panel would not see the decrease in

discharge pressure as the system is returned to normal op-

eration. Returning the test block valve to RUN position after

test opens a direct two-way connection between discharge

pressure and the HPCO transducer or switch.

During installation of the test block, care should be taken

to minimize total system volume from the test block to the

HPCO. Directly installing the HPCO on the test block will

keep the volume low, and be much easier to pressurize

during testing.

TEST PUMP CALIBRATION KIT (720B0129G01)

Figure 5. Calibration Kit in Hard Case with Hose

The test pump calibration kit comes complete with hydraulic

test pump, a 15 foot quick connect hose, oil reservoir, and

calibrated master gauge – all suitable for use with refrigera-

tion oil as the pressurizing media.

The pump is used to connect to the quick connect test port

on the test block. Once the test block is switched to the TEST

position, operation of the test pump will allow the technician

to raise the pressure measured at the HPCO until the run-

ning unit is proven to stop at the correct cut-out pressure.

The actual cut-out pressure can be compared between the

pressure display on the control panel and the master gauge

included with the test pump. If the reading is beyond the

permissible tolerance (generally 2.5% of cut-out pressure),

the control panel should be recalibrated to read correctly

at the set point.

160.100-IO (APR 2018)

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EZ-CAL™ HIGH PRESSURE CUT-OUT TEST BLOCK & CALIBRATION KIT

OPERATION

If used to test a pressure switch, and the switch does not

function to stop the compressor at the correct set point,

the switch should be properly adjusted or replaced, and

re-tested to show proper cut-out within tolerance. Once

testing is complete the pump can be removed at the quick

connect to the block, and the block can be switched back

to the RUN position.

Any test refrigeration oil used during the testing will drain

harmlessly into the compressor sump without introducing

non-condensable gas to the system. The test pump is then

ready to calibrate the next compressor HPCO.

OPERATION PROCEDURE EXAMPLE

1. Each technician that is using this test block and test

pump for calibration should be trained in general ammonia

refrigeration safety practices (or other refrigerants used).

All technicians need to be aware they are dealing with high

pressure toxic or ammable gases and due caution is es-

sential to assure safety. We suggest that each facility review

this example procedure and modify as necessary to assure

safety in their facility.

NOTICE

The test block and calibration kits are refrigerant spe-

cic and the refrigerant to be used must be specied

at time of order. O-ring material will vary between

different refrigerants.

2. The test block and calibration kits are refrigerant specic

and must be ordered with the refrigerant to be used specied.

O-ring material will vary between different refrigerants.

3. Remove test pump from hard carrying case. Inspect for

any damage.

4. Familiarize yourself with the components and operation

of the pump and gauge.

GAUGE

ZERO MAX

MIN

CONFIG

ENTER

Needle Bleed Valve

Vernier Control

Top Port 1/4” FNPT

Gauge Display

Side Port 1/8” FNPT

for optional Relief

Valve only (P/N 1010050)

Fill Port and Cap

Media

Reservoir

Stroke Limiter

Fill Line

Figure 6. Calibration Kit Pump and Gauge

5. Select an oil that is compatible with the refrigeration

system being calibrated and with the MECP10K pump. Frick

oils 3, 9, 9S, 11, and 11S are all suitable for ammonia systems,

but it is not recommended to change the oil used in the

pump back and forth. Pick an oil for the pump and always

use the same oil and pump together to avoid O-ring swell

or shrinkage issues.

6. The pump is equipped with a safety relief valve set to

500 psi to avoid overpressure of the pump or hose during

the test. This safety valve is adjustable with an allen wrench.

It is advisable to test the function of the safety valve with

CAUTION before the rst time the pump is used to be sure it

will not open at a normal test pressure. The hose and pump

are designed for operation pressures well above normal

refrigeration pressure.

7. Fill the reservoir to the ll line with clean refrigeration oil

then reinstall the ll plug nger tight. During use do not let

the reservoir drop below 50% of the reservoir capacity. (Do-

ing so may allow air to be introduced into the test system).

Figure 7. Oil Reservoir and Fill Plug

160.100-IO (APR 2018)

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EZ-CAL™ HIGH PRESSURE CUT-OUT TEST BLOCK & CALIBRATION KIT

OPERATION

8. Use only the provided hose between the pump and block.

The provided hose is rated for the system pressures it will

be exposed to, and has internal check valves to prevent

leakage of refrigerant into the pump or from the hose once

disconnected.

Figure 8. Adjust gauge to zero

9. Press enter to turn on the gauge. If the reading is not

zero, press zero to adjust for atmospheric pressure.

10. The male-end of the hose connects to the test block.

Figure 9. Hose Connection (Male End)

11. The female-end of the hose connects to the test pump

and gauge unit.

Figure 10. Hose Connection (Female End)

12. Close needle bleed valve on pump, clockwise, and posi-

tion Vernier dial about middle position. Insert quick connect

tting labeled “pump end” into the hand pump quick connect

at red guide sleeve. It should “click” into place.

Figure 11. Calibration Pump Vernier Dial

13. The hose can trap high pressure oil or gas between the

pump and the check valve. Read the gauge reading to see

if internal pressure is trapped in the hose from the last use.

The pressure can be “carefully” bleed off to the reservoir by

slowly opening the bleed valve. If air or refrigerant is trapped

in the hose it can foam the oil in the reservoir, so open the

bleed slowly if pressure is shown on the gauge. Once pres-

sure is relieved close the bleed valve, (turn clockwise).

14. On rst use the hose should be lled with oil to avoid

pushing air into the system. Push the stroke limiter into the

prime mode position to allow the handles to have maximum

travel. Hold the center post of the block end quick connect

in while working the pump handles until oil comes out of the

hose end.

NOTE: this can take many strokes of the pump depending on

the volume of the hose and whether the pump has been used

in a while. It is important to hold the reservoir reasonably

level to allow the pump to properly ll between strokes. Slow

operation of the pump is more effective than fast operation,

to give the plunger time to properly ll on each pump stroke.

15. See image below.

GAUGE

ZERO MAX

MIN

CONFIG

ENTER

Figure 12. Avoiding air in the hose/system

160.100-IO (APR 2018)

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EZ-CAL™ HIGH PRESSURE CUT-OUT TEST BLOCK & CALIBRATION KIT

OPERATION

16. Once uid starts to exit the end of the hose switch the

valve on the test block to test position and connect the hose

to the test port on the test block.

Figure 13. Block in TEST Position

17. Insert the hydraulic hose (block end) into the test port of

the test block.

Figure 14. Attaching Hydraulic Hose

18. Equipment is now ready for testing. The block valve is

shown in the test position.

Figure 15. Block remains in TEST Position

19. Squeeze the pump handles until the master gauge starts

to show a sharp rise in pressure.

Figure 16. Checking Reading on Gauge

20. The person conducting the test should be able to see the

reading from the discharge pressure sensor on the control

panel begin to rise and follow the pressure increase created

by the test pump once the pump pressure exceeds the dis-

charge pressure. As the test pressure begins to approach the

cut-out set-point, the stroke limiter button can be pushed in,

(from the back side of pump), while the handles are squeezed

together to put the pump in “pump mode” where the pres-

sure increase can be controlled more precisely. NOTE: Failure

to use the stroke limiter will greatly reduce the mechanical

advantage the user has and will limit the maximum pressure

that can be generated with reasonable handle pressure.

21. See below.

Figure 17. Using the Stroke Limiter

22. As the test pressure approaches the cut-out set point, the

nal pressure adjustment can be made by turning the Vernier

dial. The Vernier is capable of ne pressure adjustment but

only a few psi.

160.100-IO (APR 2018)

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EZ-CAL™ HIGH PRESSURE CUT-OUT TEST BLOCK & CALIBRATION KIT

OPERATION

23. See below.

Figure 18. Vernier Dial Adjustment

24. If the HPCO fails to stop the compressor from operating

when the HPCO reaches its set point, repairs will be required.

The transducer on discharge pressure will need to be re-

calibrated to the master gauge, within allowable tolerance,

(IIAR-6 proposes a maximum disagreement of 2.5% of set

point pressure). A HPCO switch will need to be adjusted (if

possible), or replaced.

25. See nal image on 23.

26. Once the HPCO is proven to stop the compressor within

allowable tolerance at set point, the calibration is complete

and should be documented.

27. The block end of the test hose can be removed from the

test block while the test valve is still in the test position.

Internal check valves are used to prevent oil leakage in either

direction.

Figure 19. Detaching Hydraulic Hose

28. The test block valve can then be switched back to run

position, You should observe the panel reading dropping

back to the normal discharge pressure reading once the

valve position is switched to run. The compressor can be

restarted, as necessary, and the test block can be locked in

run position with the lock ring in the handle.

Figure 20. Block in RUN Position

29. There is still oil pressure trapped in the hose after the test.

This can be left in the hose if it will be used immediately to

calibrate another compressor. If not being used immediately,

the pressure can be slowly bled off by opening the bleed valve

on the pump. There should be no refrigerant trapped in the

hose if the above procedure was followed. But, use CAUTION

when bleeding the hose in case any gas is in the hose, as it

will cause bubbles in the oil reservoir which can spray oil

out of the reservoir, Unless a check valve fails to function

there should never be ammonia vapor in the test hose, but

always open the bleed valve cautiously as any vapor in the

hose will be fed back to the reservoir.

30. Once the testing and calibration is complete the pump

and hose can be drained of oil and safety quick connect plugs

can be inserted in the test port connectors on the block and

pump to keep the connections clean.

Figure 21. Using Safety Quick Connect Plugs

31. To assure the master gauge is accurate to NIST (National

Institute of Standards and Technology) it should be calibrated

to a dead weight tester or master calibration gauge on a

scheduled basis with certicate and date maintained.

JOHNSON CONTROLS

100 Cumberland Valley Avenue

Waynesboro, PA 17268-1206 USA

Phone: 717-762-2121 • FAX: 717-762-8624

www.johnsoncontrols.com/frick

Form 160.100-IO (2018-04)

Supersedes: 160.100-IO (2018-02)

Subject to change without notice

Published in USA • 04/18 • PDF

April 2018 Form Revisions

p.4 – Added block dimensions and port locations

p.5 – Added tubing notice

– Added Figure numbers throughout

Frick EZ-Cal High Pressure Cut-Out Test Block and Calibration Kit Operating instructions

Frick EZ-Cal High Pressure Cut-Out Test Block and Calibration Kit Operating instructions

Frick EZ-Cal High Pressure Cut-Out Test Block and Calibration Kit Operating instructions

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