Frick HPSH Rotary Screw Compressor Installation Operation and Maintenance Guide

Brand: Frick

Model: HPSH Rotary Screw Compressor

Type: Installation Operation and Maintenance Guide

Form 070.750-IOM (MAY 2018)

Installation - Operation - Maintenance

File: Service ManuaL - Section 070

Replaces: 070.750-IOM (MAY 2014)

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

Revised: October 28, 2022

HPSH

Rotary Screw Compressor

Model 1510

This manual contains installation, operation, 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 incorrect operation.

Check www.FrickCold.com for the latest version of this publication.

070.750-IOM (MAY 2018)

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

PREFACE .......................................................................... 3

DESIGN LIMITATIONS ........................................................ 3

JOB INSPECTION .............................................................. 3

STANDARD BARE COMPRESSOR ...................................... 3

TRANSIT DAMAGE CLAIMS .............................................. 3

COMPRESSOR IDENTIFICATION ........................................ 3

LONG TERM STORAGE ...................................................... 4

PREPARING COMPRESSOR FOR STORAGE .................... 5

MAINTAINING COMPRESSOR (IN STORAGE) .................. 5

DESCRIPTION .................................................................... 5

HPSH COMPRESSOR .................................................... 5

COMPRESSOR LUBRICATION SYSTEM ......................... 5

CAPACITY REGULATION AND FIXED VOLUME RATIO VI 5

OIL PUMP (OPTIONAL) .................................................. 6

CONSTRUCTION DETAILS .................................................. 6

DESIGN LIMITS .............................................................. 6

VIBRATION AND SOUND DATA .......................................... 6

INSTALLATION

OUTLINE DIMENSIONS .................................................. 7

HOLDING CHARGE AND STORAGE..................................... 7

RIGGING AND HANDLING ................................................... 7

FOUNDATION ................................................................... 7

CUSTOMER CONNECTIONS ............................................... 8

VI AND EFFECTIVE ORIFICE SIZES: ................................ 8

COMPRESSOR OIL ............................................................. 9

OIL PUMP .......................................................................... 9

MOTOR MOUNTING USING TUNNEL .................................. 9

MOTOR MOUNTING (FOOT MOUNTED ONLY) ................... 9

COMPRESSOR/MOTOR COUPLING REQUIREMENTS ...... 9

COUPLING ALIGNMENT REQUIREMENTS

(FOOT MOUNTED ONLY) ............................................. 10

OIL HEATERS - HEATING WIRES ..................................... 10

OIL FILTERS - HEAT WIRE - INSULATION ........................ 10

OIL COOLING REQUIREMENTS......................................... 10

DEHYDRATION / EVACUATION TEST .................................11

ELECTRICAL INSTALLATION .............................................. 11

OPERATION

OPERATION AND START-UP INSTRUCTIONS ................... 12

LOW AMBIENT OPERATION ............................................. 12

INITIAL START-UP ...........................................................12

INITIAL START-UP PROCEDURE ..................................12

NORMAL START-UP PROCEDURE ...............................12

CONTROL SYSTEM ...........................................................12

MAINTENANCE

GENERAL INFORMATION .................................................13

NORMAL MAINTENANCE OPERATIONS ...........................13

GENERAL MAINTENANCE ................................................13

CHANGING OIL .................................................................13

MAINTENANCE SCHEDULE .............................................. 14

RECOMMENDED SPARE PARTS - CURRENT DESIGN ....... 14

RECOMMENDED MAINTENANCE PROGRAM ....................15

VIBRATION ANALYSIS .................................................15

OIL QUALITY AND ANALYSIS ......................................15

OPERATING LOG .........................................................15

TROUBLESHOOTING GUIDE .............................................15

ABNORMAL OPERATION

ANALYSIS AND CORRECTION ..........................................15

TROUBLESHOOTING THE HPSH COMPRESSOR ................16

BARE COMPRESSOR REPLACEMENT ...........................16

SHUTDOWN DUE TO IMPROPER OIL PRESSURE (HIGH

STAGE AND BOOSTER) ...............................................16

ALIGNMENT LOG – FOR ELECTRIC MOTOR DRIVER .........17

COMPRESSOR PORT LOCATIONS - HPSH 1510 ................19

INDEX

ALPHABETICAL LISTING ................................................. 20

WARNING

CAUTION

DANGER

NOTICE

070.750-IOM (MAY 2018)

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HPSH Rotary Screw Compressor

Installation - Operation - Maintenance

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.

NOTICE

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

PROPER PACKAGE & SYSTEM ENGINEERING

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, ASME 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 specied 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. A main requirement is

that discharge temperature or superheat must be met at

any speed. Contact Johnson Controls-Frick Compressor En-

gineering 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 identication data plate, contain-

ing compressor model and serial number mounted on the

compressor body.

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.

534B2722

COMPRESSOR SHAFT

CLOCKWISE ROTATION

534B2721

534B2720

534B2719

R22

COMPRESSOR OPERATES ON AND IS

COMPATIBLE WITH THE FOLLOWING

REFRIGERANTS

R290, R1270, NATURAL GAS

COMPRESSOR OPERATES ON AND IS

COMPATIBLE WITH THE FOLLOWING

REFRIGERANTS

R50, R134a, R170, R290, R404A, R410A, R507,

R513A, R600, R600A, R717, R728, R729, R744,

R1150, NATURAL GAS

COMPRESSOR OPERATES ON AND IS

COMPATIBLE WITH THE FOLLOWING

REFRIGERANTS

534C2934H01

SGXB2 4021

US2430125370500010

10241A89999999R

3600 600 41

USA

REFERENCE MATERIAL FIELD ON

SHEET 1 OF PRODUCTION ORDER

REFERENCE TABLE ON

SHEET 2 AND NOTE 3

REFERENCE TABLE

ON SHEET 2

REFERENCE TABLE ON

SHEET 2 AND NOTE 2

GENERATED BY SAP

ASSEMBLY PLANT LOCATION

534C2933H01

USA

US2430129999900010

10241A89999999R

100 CUMBERLAND VALLEY AVENUE

WAYNESBORO, PA 17268

ROTARY SCREW COMPRESSOR

MODEL NO.

MAX DRIVER SPEED MAX ALLOWABLE PRESSURE

PART NO.

RPM PSIG BARG

ASSEMBLED IN

FROM FOREIGN AND DOMESTIC MATERIALS

SERIAL NO.

870

6000

HPSH 1510

Figure 1 - Identication Data Plate

Rotary screw compressor serial numbers are dened by the

following information:

EXAMPLE: 10240A90000015Z

PLANT DECADE MONTH YEAR GLOBAL ADDITIONAL

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; R1 = Rebuild;

R2 = Rebuild Plus; Z = Deviation from base conguration.

070.750-IOM (MAY 2018)

Page 4

HPSH Rotary Screw Compressor

Installation - Operation - Maintenance

The name plates in Figure 2 show which refrigerants are

compatible with the compressor as manufactured.

534B2722

COMPRESSOR SHAFT

CLOCKWISE ROTATION

534B2721

534B2720

534B2719

R22

COMPRESSOR OPERATES ON AND IS

COMPATIBLE WITH THE FOLLOWING

REFRIGERANTS

R290, R1270, NATURAL GAS

COMPRESSOR OPERATES ON AND IS

COMPATIBLE WITH THE FOLLOWING

REFRIGERANTS

R50, R134a, R170, R290, R404A, R410A, R507,

R513A, R600, R600A, R717, R728, R729, R744,

R1150, NATURAL GAS

COMPRESSOR OPERATES ON AND IS

COMPATIBLE WITH THE FOLLOWING

REFRIGERANTS

534C2934H01

SGXB2 4021

US2430125370500010

10241A89999999R

3600 600 41

USA

REFERENCE MATERIAL FIELD ON

SHEET 1 OF PRODUCTION ORDER

REFERENCE TABLE ON

SHEET 2 AND NOTE 3

REFERENCE TABLE

ON SHEET 2

REFERENCE TABLE ON

SHEET 2 AND NOTE 2

GENERATED BY SAP

ASSEMBLY PLANT LOCATION

534C2933H01

USA

US2430129999900010

10241A89999999R

100 CUMBERLAND VALLEY AVENUE

WAYNESBORO, PA 17268

ROTARY SCREW COMPRESSOR

MODEL NO.

MAX DRIVER SPEED MAX ALLOWABLE PRESSURE

PART NO.

RPM PSIG BARG

ASSEMBLED IN

FROM FOREIGN AND DOMESTIC MATERIALS

SERIAL NO.

870

6000

HPSH 1510

534B2722

COMPRESSOR SHAFT

CLOCKWISE ROTATION

534B2721

534B2720

534B2719

R22

COMPRESSOR OPERATES ON AND IS

COMPATIBLE WITH THE FOLLOWING

REFRIGERANTS

R290, R1270, NATURAL GAS

COMPRESSOR OPERATES ON AND IS

COMPATIBLE WITH THE FOLLOWING

REFRIGERANTS

R50, R134a, R170, R290, R404A, R410A, R507,

R513A, R600, R600A, R717, R728, R729, R744,

R1150, NATURAL GAS

COMPRESSOR OPERATES ON AND IS

COMPATIBLE WITH THE FOLLOWING

REFRIGERANTS

534C2934H01

SGXB2 4021

US2430125370500010

10241A89999999R

3600 600 41

USA

REFERENCE MATERIAL FIELD ON

SHEET 1 OF PRODUCTION ORDER

REFERENCE TABLE ON

SHEET 2 AND NOTE 3

REFERENCE TABLE

ON SHEET 2

REFERENCE TABLE ON

SHEET 2 AND NOTE 2

GENERATED BY SAP

ASSEMBLY PLANT LOCATION

534C2933H01

USA

US2430129999900010

10241A89999999R

100 CUMBERLAND VALLEY AVENUE

WAYNESBORO, PA 17268

ROTARY SCREW COMPRESSOR

MODEL NO.

MAX DRIVER SPEED MAX ALLOWABLE PRESSURE

PART NO.

RPM PSIG BARG

ASSEMBLED IN

FROM FOREIGN AND DOMESTIC MATERIALS

SERIAL NO.

870

6000

HPSH 1510

Figure 2 - Refrigerant Name Plates

HPSH 1510 Geometrical Swept Volume

RPM m3/h cfm

2950 292.8 172.2

3550 352.4 207.5

4200 416.9 245.5

6000 595.6 350.8

Figure 3 - Name Plate and Vi Locations

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 rst. 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

Compressor Long Term Storage Log

Model Serial No.

Compressor, Motor Oil Pump &

Refrigerant Pump Shaft Rotation

1½ Turn

Rotor

Housing

Charge

Added

Visual

Inspection Charge Checked

By Date

070.750-IOM (MAY 2018)

Page 5

HPSH Rotary Screw Compressor

Installation - Operation - Maintenance

if they are kept ooded with oil. A warm and dry environ-

ment is essential to minimize environmental and corrosion

damage.

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 (IN STORAGE)

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 prole helical rotors to provide a continuous

ow of vapor and is designed for high-pressure applica-

tions. The compressor incorporates the following features:

1. Designed for variable speed drive, 1000 to 6,000 rpm.

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 2-position solenoid valve. See Fig. 9.

3. Fixed volume Vi ratio: 1.4, 1.7, 2.2, 2.9 and 4.0 are avail-

able as standard. No moveable slide stop valve.

4. High capacity roller bearings to carry radial loads at both

the inlet and outlet ends of the compressor.

5. Heavy duty angular contact ball bearings to carry axial

loads on the rotors.

6. Balance piston located in the inlet end of the male rotor

reduces axial loads on the male axial bearings.

7. Housings are designed for 67 bar (970 psig) working pres-

sure when anges are made from the higher quality steel.

Standard ange design allows for 60 bar (870 psig).

8. Economizer port at 1.05 Vi, optimized for CO2 applications.

9. Liquid injection port at 1.30 Vi.

10. Two main oil injection ports: Use SM-2 for Vi 1.4, 1.7 and

2.2 and use SM-1 for Vi 2.9 and 4.0 to meet application

requirements. (SM-2 at Vi = 1.05 & SM-1 at Vi = 1.3)

11. All bearing and control oil vented to lower pressure lo-

cations inside compressor allowing operation without an oil

pump for some applications.

12. Shaft seal with a seal ring made of silicon carbide mated

against a similar material, where carbon and graphite add-

ed to the matrix provide long life.

Shaft seal housing designed to maintain operating pressure

on seal well below discharge pressure for increased seal

life.

13. Oil injected into the rotor threads to maintain good vol-

umetric and adiabatic efciency.

14. Shaft rotation clockwise facing compressor drive end,

suitable for all types of drives. SEE WARNING.

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 ange is ANSI B16.1 Class 400. Discharge ange

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, seal and rotors.

2. Provides a cushion between the rotors to minimize noise

and vibrations.

3. Helps keep the compressor at the proper temperature

and prevents overheating.

4. Provides oil supply to hydraulically operate the plug valve

on and off.

5. Provides oil pressure to the balance piston to help in-

crease bearing life.

6. Provides an oil seal between the rotors to prevent rotor

contact or gas bypassing.

7. Oil ow will often need to be regulated by an automatic

control valve.

CAPACITY REGULATION AND FIXED VOLUME RATIO VI

The design without a moveable slide valve under the rotors

provides a very robust design. However, the xed volume

ratio must be selected close to the ideal value to provide

reliable and efcient operation. The plug valve is provided

to allow start-up and safe operation at low differential.

Capacity regulation is all with variable speed - the plug

valve can be used, but the effect is limited to between 10%

and 15%.

070.750-IOM (MAY 2018)

Page 6

HPSH Rotary Screw Compressor

Installation - Operation - Maintenance

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 lower pressure than com-

pressor discharge pressure. All oil entering the compressor

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 made from quality, wear-resistant

rolled steel to the exacting tolerances of the latest industry

standard asymmetric prole. The six-lobed male rotor is

directly connected to the driver. The eight-lobed female ro-

tor is driven by the male on a thin oil lm.

BEARINGS: Antifriction bearings with L10 rated 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 preloaded

angular contact ball bearings (ACBB).

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, silicon carbide stationary

hardened surface riding against a rotating seat. Carbon and

graphite added provide self lubrication. During operation it

is vented to low pressure to provide extended life.

UNLOADING VALVE: Reduced current (power) requirement

at start-up is achieved by use of a plug valve. The plug valve

reduces 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 ange 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

Please use CoolWare™ to determine the limits for a spe-

cic application.

NOTES FOR DESIGN LIMITS:

(1) The HPSH 1510 compressor has minimum viscosity

requirements as shown in Fig. 4 to maintain proper

bearing lubrication. Consideration must be given to

viscosity changes due to refrigerant or gas dilution.

Figure 4 - Requirement for Viscosity as function of speed

(2) Maximum discharge temperature depends on oil type

used - normally 150°C (300°F). Please see Frick oil

data for more detail.

(3) In applications using miscible oil types POE and PAG,

it is extremely critical to keep water content to the

lowest possible to avoid corrosion and formation of

acids. The installation must have large lter dryers

with replaceable elements that can be effectively

serviced and vacuum dried before being put back in

service.

(4)

If the temperature difference becomes greater than or

equal to 140°C (250°F) between suction and discharge

- the plug valve must be unloaded immediately.

(5) For heat pumps, it is often practical to select an oil

temperature that equals condensing temperature.

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.

Reference Frick publication 070.902-IB for vibration sever-

ity limits.

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, a skip frequency function

in the control system shall be activated. When activated,

the motor will run through the critical speed very fast, not

causing any continuously high vibration.

070.750-IOM (MAY 2018)

Page 7

HPSH Rotary Screw Compressor

Installation - Operation - Maintenance

INSTALLATION

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

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

LIFTING INSTRUCTIONS

Lifting rings are located to facilitate the rigging and lifting

of the bare compressor. See Figure 7. Ensure only a quali-

ed operator performs the lifting and that they follow the

necessary precautions.

• Lift rings are intended for lifting the bare compressor

only.

• Examine the lift rings for damage before lifting the

compressor. Replace any damaged rings

• Fully screw in the lift rings and seat them rmly against

the contact surface before lifting.

• Load the lift rings in the vertical direction only; that

is, ensure the load is parallel to the threaded portion

of the lift ring. See Figure 7. This may require the use

of a spreader beam. Loading the lift rings at an angle

reduces their load capacity.

• Ensure that the load is level and stable before lifting

more than a few inches.

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

exceeded (See CoolWare). Refer to Johnson Controls-Frick

Compressor Control Panel instruction 090.040-O for addi-

tional information on setpoint limits and CES 1400 for prop-

er engineering.

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).

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.

070.750-IOM (MAY 2018)

Page 8

HPSH Rotary Screw Compressor

Installation - Operation - Maintenance

• Lift the compressor slowly.

• Remove the lift rings from the compressor before

operation. The vibration of a running compressor can

cause the lift rings to loosen and become damaged.

Figure 7 - Lifting rings orientation

FOUNDATION

Each HPSH Rotary Screw Compressor is shipped mounted

on a wooden skid, which must be removed prior to unit

installation.

CAUTION

Allow proper spacing for servicing (see Dimensional

Outline Drawing).

The rst requirement of the compressor foundation is that

it must be able to support the weight. The HPSH 1510

weighs approximately 367 kg (810 lb).

Screw compressors are capable of converting large quanti-

ties of shaft power into gas compression in a relatively

small space. The compression process creates relatively

high frequency vibrations that require sufcient mass in the

base to effectively dampen them.

SECTION A-A SECTION B-B

SM-2

SM-1

SECTION A-A

SECTION B-B

SM-2

SM-1

SECTION A-A

SECTION B-B

SM-2

SM-1

Figure 8 - SM-2 and SM-1 Port Cutaways

070.750-IOM (MAY 2018)

Page 9

HPSH Rotary Screw Compressor

Installation - Operation - Maintenance

The best insurance for a trouble-free installation is to rm-

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 anges.

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 lines 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-2 or SM-1 Main oil injection (See CoolWare for port

required by operating conditions)

VI AND EFFECTIVE ORIFICE SIZES:

SM-2: Vi = 1.4, 1.7 and 2.2

.402”, 1/2” x 14 NPTF, No orice installed, Max orice .386”

SM-1: Vi = 2.9 and 4.0

.437”, 1/4” x 18 NPTF, No orice installed, Max. orice .25”

*SM-2 is low Vi (1.05), and SM-1 is high Vi (1.3). If you’re

unsure, connect main oil to SM-2.

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 lter 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.

A regulating valve must be installed in the main oil injection

line and at start-up be tuned in to the desired discharge

temperature. Some applications may use a manual valve,

others will require a motor-operated valve.

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 160.802-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.

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.

ALLOWABLE FLANGE LOADS

NOZ. SIZE

NPS

MOMENTS -- ft-lbf (Nm) LOAD -- lbf (N)

AXIAL - MRVERT. - MCLAT. - MLAXIAL - P VERT. - VCLAT. - VL

1 25 (34) 25 (34) 25 (34) 50 (222) 50 (222) 50 (222)

1.25 25 (34) 25 (34) 25 (34) 50 (222) 50 (222) 50 (222)

1.5 50 (68) 40 (54) 40 (54) 100 (445) 75 (334) 75 (334)

2 100 (136) 70 (95) 70 (95) 150 (667) 125 (556) 125 (556)

3 250 (339) 175 (237) 175 (237) 225 (1001) 250 (1112) 250 (1112)

4 400 (542) 200 (271) 200 (271) 300 (1334) 400 (1779) 400 (1779)

5 425 (576) 400 (542) 400 (542) 400 (1779) 450 (2002) 450 (2002)

6 1,000 (1356) 750 (1017) 750 (1017) 650 (2891) 650 (2891) 650 (2891)

8 1,500 (2034) 1,000 (1356) 1,000 (1356) 1,500 (6672) 900 (4003) 900 (4003)

10 1,500 (2034) 1,200 (1627) 1,200 (1627) 1,500 (6672) 1,200 (5338) 1,200 (5338)

14 2,000 (2712) 1,800 (2440) 1,800 (2440) 1,700 (7562) 2,000 (8896) 2,000 (8896)

070.750-IOM (MAY 2018)

Page 10

HPSH Rotary Screw Compressor

Installation - Operation - Maintenance

MOTOR MOUNTING USING TUNNEL

For specic instruction about motor mounting using a tun-

nel use publication 070.660-SM - Bare Rotary Screw Com-

pressor Replacement.

NOTICE

Refer to the Bare Rotary Screw Compressor Replac-

ment manual, Frick publication 070.660-SM for motor

mounting instructions.

MOTOR MOUNTING (FOOT MOUNTED ONLY)

1. Thoroughly clean the motor feet and mounting pads of

grease, burrs, and other foreign matter to ensure rm seat-

ing of the motor.

2. Attach the motor to the base using bolts and motor

raising blocks, if required.

3. 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 exible 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 specication (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).

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 possible

value. Be sure to follow the coupling manufacturer’s guide-

lines for checking and correcting any misalignment. See the

next section for Johnson Control–Frick’s requirements.

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.

A dial indicator or another appropriate measuring device is

to be used to determine the Total Indicator Runout.

Indicator bracket sag must be checked as all brackets have

some exibility. 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 afxed to the coupling for an accurate alignment.

OIL HEATERS - HEATING WIRES

Your package must be equipped with oil heaters that provide

sufcient heat to prevent condensation from occurring dur-

ing startup and shutdown cycles. Also, sufcient heat must

be provided to ensure proper oil viscosity at compressor

start-up.

OIL FILTERS - HEAT WIRE - INSULATION

Use of lter 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

lter specication 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) or higher.

There are applications that it is normal to have discharge

temperatures as high as 120°C (250°F). An ammonia heat

pump is one example. The higher discharge temperature

permits higher process uid temperatures to be achieved.

Another application that typically requires higher discharge

temperatures as high as 120°C (250°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.

070.750-IOM (MAY 2018)

Page 11

HPSH Rotary Screw Compressor

Installation - Operation - Maintenance

NOTICE

The discharge temperature requirement is at any loading

and capacity - ANY SPEED, NOT ONLY AT FULL LOAD.

Run CoolWare with the “Water Saturated” block checked to

get the discharge dew point temperature for your applica-

tion. Oil temperatures as high as 130°C (266°F) can be used

to achieve the necessary discharge temperature to prevent

moisture from condensing in the oil separator. Contact

Johnson Controls–Frick for additional information for natu-

ral gas compression.

The main oil injection line that is connected to port SM-1 or

SM-2 must have a regulating valve to permit adjustment of

the oil ow to maintain the desired discharge temperature

at all times. If a 130°C (266°F) temperature is required, you

must adjust to that at maximum load and speed. At lower

speed you may have a motor-operated valve to maintain

the temperature. A nonreturn valve may also be needed in

order to prevent gas from owing backward into the oil

system under start-up and transition of operating condi-

tions.

The regulating valve may need to have a motor so the ac-

tual opening/ow can be controlled by the control panel.

This is often a needed for heat pumps where a certain ca-

pacity, water temperature, and efciency is expected. It

may also be a requirement when the speed turndown is

signicant e.g. from 6000 rpm to 1000 rpm as the relative

oil ow may get too high at the lower speed range. Consult

Coolware and the factory.

When considering minimum supply oil temperature, the use

of a

thermostatic three-way bypass mixing valve is not rec-

ommended.

WARNING

For high temperature applications, consult factory.

Some of the 3-way thermostatic valves will not work

at high temperatures and damage to thermostatic

mixing valves can occur.

The valve will provide warm oil to the compressor quickly,

reducing the pressure drop caused by cold, viscous oil. This

ensures proper oil ow and temperature over the full range of

operating conditions.

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 2-position hydraulic valve controlling the un-

loader plug. (Solenoid valve not included)

Solenoid “b” must be electrically connected.

To load, energize solenoid “b”

To unload, de-energize solenoid “b”

Compressor Suction

Compressor Oil

(Discharge PSIG)

Compressor

Suction

Figure 9 - Schematic of unloader plug and solenoid

valve, shown loaded, solenoid “b” energized

070.750-IOM (MAY 2018)

Page 12

HPSH Rotary Screw Compressor

Installation - Operation - Maintenance

OPERATION

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. In low ambient conditions, have oil

heaters and heating wires on for 24 hours prior to start-up.

It is important that an adequate gas load be available to

load test the unit at normal operating conditions. The fol-

lowing 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. At any

speed, exceeding design conditions creates a potential haz-

ard.

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. Conrm system conditions permit starting the com-

pressor.

NOTICE

Ambient temperatures need to be high enough to pre-

vent excessive condensing; otherwise, initiate oil

heaters and heat tracing 24 hours before start-up.

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

The HPSH compressor and package requires a dedicated

control system For details on operation of Johnson Controls

control systems, refer to the respective IOM manuals.

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 specic operation and conditions to ensure

trouble-free running.

The information in this section of the manual provides logi-

cal instructions to properly start up and operate the HPSH

Rotary Screw Compressor in your unit. Only matters which

may inuence the proper operation of the Frick HPSH com-

pressor are included.

WARNING

The compression process creates noise and operating

screw compressors are loud. Wear the correct hearing

protection when near the compressor during operation.

If people are expected to be in the vicinity of the

running compressor for extended time periods, provide

warnings.

LOW AMBIENT OPERATION

WARNING

Avoid condensation of refrigerant, gases or water in

the compressor. Ambient conditions may require heat

tracing and insulation of the compressor package

components and piping.

Catastrophic failure may occur if condensation is present.

It is recommended that package oil separators, the oil pip-

ing and the oil ller be insulated as a minimum requirement

to preserve the heat generated by the oil heaters, to pre-

vent condensation, and to secure lubrication at start-up.

Heat pumps and fuel gas compression must always have the

oil separator insulated. Heat pumps will often require the

complete suction line to be insulated in order to prevent

condensation and possible slugging. In these cases, heat

tracing is required.

With an automated valve, regulate oil ow to the main oil

ports SM-2/SM-1 in order to continuously achieve the high-

est possible discharge temperature needed.

070.750-IOM (MAY 2018)

Page 13

HPSH Rotary Screw Compressor

Installation - Operation - Maintenance

MAINTENANCE

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

nd 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 lters clean. If lters show increasing pressure

drop, indicating dirt or water, stop the compressor and

change lters. Running a compressor for long periods with

high lter pressure drop can starve the compressor of oil

and lead to premature bearing failure. Dual oil lters are

recommended so that the lters 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.

GENERAL INFORMATION

This section provides instructions for normal maintenance,

a recommended maintenance program, troubleshooting

and correction guides, and typical P and I diagrams.

WARNING

This section must be read and understood before at-

tempting to perform any maintenance or service to

the unit.

WARNING

Compressor surfaces, especially those on the discharge

housing, may become hot during operation.

Additionally, surfaces near the suction ange may be

cold. Contact with compressor surfaces during or soon

after operation may cause burns. If it is likely that

anyone may touch the compressor during operation

and the conditions are such that burns may occur, the

packager must implement protection measures. For

compressors that must comply with the Machinery

Directive, refer to the requirements of EN ISO 13732-1.

WARNING

Opening any part of the compressor unit to atmosphere

while under pressure may cause injury. Ensure that the

compressor pressure is at 0 psig before removing any

pressure containing part.

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.

070.750-IOM (MAY 2018)

Page 14

HPSH Rotary Screw Compressor

Installation - Operation - Maintenance

MAINTENANCE SCHEDULE

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

DESCRIPTION HPSH 1510

Complete Bearing Kit 534C2311G01

O-ring Kit 534B1335H01

Shaft Seal Kit 534C2707G01

Balance Piston Kit 534A1123G01

Compressor Tool Kit 534C2307G01

NOTICE

Refer to the Service Parts List manual, 070.750-SPL1_

HPSH, for detailed parts list.

a. Check bolts, shim packs, center inserts, keys, and all bolt torques.

b. Verify tightness of bolts on suction and discharge anges. See table below for torque requirements.

c. Units with variable speed drives - check for excess vibration and skip frequencies anytime unit operating conditions change.

d. Check and torque all terminals in the processor and starter panel per the specication posted in the enclosure.

e. Check calibration of Slide Valve, Slide Stop, pressures and temperatures. Calibration should be conducted with NIST certied devices.

f. BPR - Balance Piston Regulation

g. Vibration measurement must be carried out continuously to obtain optimum preventive control on bearings. If not continuously controlled,

then every 6 months, more frequently if levels increase.

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 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

Check Coupling (a) nAnnually Regardless of Operating Hours

Suction & Disch Flange Bolts (b) n n n n n n n n n n n n n n n n n n n n n n

VFD Units Check Skip Frequency (c) n n n n n n n n n n n n n n n n n n n n n n

Check Electrical Connections (d) n n n n n n n n n n n n n n n n n n n n

Check Sensor Calibration (e) n n n n n n n n n n n n n n n n n n n n n

Check BPR Function (f) n n n n n n n n n n n n n n n n n n n n n n

Vibration Analysis (g) nEvery 6 Months, More Frequently If Levels Increase

Replace Shaft Seal When Leak Rate Exceeds 7 - 8 Drops Per Minute (600 ml in 24 hours)

Compressor

Model

Discharge Flange to Separator Flange

3" Class 600

Suction Flange

4" Class 400

Bolt Size Torque* (ft-lb) Bolt Size (in.) Torque* (ft-lb)

HPSH 1510 M20 X 2.5 160 M20 X 2.5 160

* Based on: Gaskets-Garlock® Blue-Gard® 3300; Bolts-class 8.8 or stronger hex head bolts, lightly oiled and clean

RECOMMENDED SPARE PARTS - CURRENT DESIGN

070.750-IOM (MAY 2018)

Page 15

HPSH Rotary Screw Compressor

Installation - Operation - 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.

Shut down the unit when changing oil. At the same time, all

oil lter 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 lter(s) and the oil coolers.

7. Remove the old lter 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

Note: Allow time for oil to cool before opening the drain

plugs.

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

Periodic vibration analysis can be useful in detecting bear-

ing wear and other mechanical failures. If vibration analysis

is used as a part of your preventive maintenance program,

take the following guidelines into consideration.

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 inuenced 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 dene 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”.

WARNING

Avoid condensation of refrigerant, gases or water in

the compressor. Ambient conditions may require heat

tracing and insulation of the compressor package

components and piping.

Catastrophic failure may occur if condensation is present.

070.750-IOM (MAY 2018)

Page 16

HPSH Rotary Screw Compressor

Installation - Operation - Maintenance

ABNORMAL OPERATION

ANALYSIS AND CORRECTION

Four logical steps are required to analyze an operational

problem effectively and make the necessary corrections:

1. Dene 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 following list of abnormal system conditions can cause

abnormal operation of the HPSH compressor:

1. Oil ow too high at low speed.

2. Discharge temperature too close to condensing tem-

perature.

3. Insufcient 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. Insufcient 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.

The third step is to identify the most likely cause and take

action to correct the problem. If the symptoms are not re-

lieved, move on to the next item on the list and repeat the

procedure until you have identied the cause of the prob-

lem. Once the cause has been identied and conrmed,

make the necessary corrections.

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

The following procedure is required only when a bare com-

pressor is replaced in the eld.

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

rm 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.

070.750-IOM (MAY 2018)

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 2018)

Page 18

HPSH Rotary Screw Compressor

Installation - Operation - Maintenance

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

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)

Vertical Direction

____.____ IPS Overall

Compressor Inboard

(Coupling End Female)

Axial Direction

____.____ IPS Overall

Motor Outboard (Noncoupled End)

Horizontal _______ . ______ IPS Overall

Vertical _______ . ______ IPS Overall

Axial _______ . ______ IPS Overall

Soft Foot Soft Foot

Final Hot Alignment

Total Thickness of Shims Added

Face Rim

070.750-IOM (MAY 2018)

Page 19

HPSH Rotary Screw Compressor

Installation - Operation - Maintenance

SC-7

SC-6

SV-1

SM-1

SC-8

SM-2

4” Class 400 Suction Flange

COMPRESSOR OPERATES ON AND IS

COMPATIBLE WITH THE FOLLOWING

REFRIGERANTS:

COMPRESSOR OPERATES ON AND IS

COMPATIBLE WITH THE FOLLOWING

REFRIGERANTS:

R22, R23, R32, R50, R123, R125, R134a,

R142b, R170, R218, R236fa, R245fa,

R290, R40A, R407C, R410A, R507,

R508, R508B, R600, R600A, R717, R728,

R729, R744, R1150, AMMONIA,

NATURAL GAS

R22, R23, R32, R50, R123, R125, R134a,

R142b, R170, R218, R236fa, R245fa,

R290, R40A, R407C, R410A, R507,

R508, R508B, R600, R600A, R717, R728,

R729, R744, R1150, AMMONIA,

NATURAL GAS

ROTARY SCREW COMPRESSOR

MODEL NO.

SERIAL NO.

MAX ALLOWABLE

PRESSURE - PSIG

MAX DRIVER

SPEED - RPM

WAYNESBORO PA 17268

XXX

SB-3

TRANSDUCER

MOUNTING

12.75 (.502)

12.70 (.500)

KEYWAY

Discharge Flange 3” Class 600

SD-2

SC-5

SB-2

SD-1

SL-0

BP-1

VIEW A-A

Vi ratio

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, Vi = 1.3 1Z\zn -12UN-2B

SM-2 Main Oil Injection, Vi = 1.05 3/4-16UNF-2B

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

BP-1 Discharge Bypass 1½ Sq Flange

COMPRESSOR PORT LOCATIONS - HPSH 1510

070.750-IOM (MAY 2018)

Page 20

HPSH Rotary Screw Compressor

Installation - Operation - Maintenance

Index

Symbols

4-way hydraulic valve 11

Ammonia heat pumps 10

asymmetric prole 6

axial load 9

axial runout 10

balance piston 5, 9

Balance piston 5

BALANCE PISTON 6

ball bearings 5

Bearings 6

capacity regulation 5

Capacity regulation 5

compressor 12

Compressor oil 10

Compressor rotation 5

compressor shaft 9

compressor suction 13

contaminants 15

CoolWare 7

corrosion 5

coupling 10, 16

Coupling 9

Coupling alignment 10

demand oil pump 6

dial indicator 10

direct motor drive 9

Discharge gas pulsation 6

discharge pressure 5, 6

discharge temperature 6, 10

Drive Train Alignment 17

Economizer port 5

electric drive motor 7

Evacuate 5

lter elements 10

foundation 7

Frick SuperFilters™ 6

gas bypassing 5

gas compression 7

gauge pressures 15

Grease 5

heat pumps 10

hot alignment 10

Housing 6

HPSH compressors 7

identication data plate 3

lifting rings 7

Long term storage 4

maintenance 13

Maintenance Schedule 14

misalignment 10

mixing valve 10

moisture 5

moisture contamination 13

motor 7

Motor 17

motor coupling 6

MOTOR MOUNT 6

motor shaft 16

natural gas 10

nitrogen 5

oil analyses 13

oil charge 9

oil cooling system 12

oil differential pressure 6

oil lter cartridges 13

oil lters 13

Oil ow 15

oil heaters 10

oil pressure 9

Oil pressure 6

oil pump 5, 9

oil separator 6

oil strainer elements 13

oil supply system 9

Operating Log Sheet 17

plug valve 5

Port locations 7

pressurize 5

radial runout 10

regulating valve 10

rigging 7

roller bearings 5

Rotors 6

serial number 3

setpoint 7

shaft alignment 16

Shaft rotation 5

Shaft Seal 6

shipping gauge 7

slugging 15

start-up 10, 12

storage 5

Suction ange 5

suction strainer 5, 13

SuperFilter™ 15

troubleshooting 13, 16

tunnel mount 7

UNLOADING VALVE 6

vacuum pump 11

Vacuum rise 11

variable speed 5

variable speed drive 5

vibration 6, 15

vibration analysis 15

warm oil 10

Warranty 4

ALPHABETICAL LISTING

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Frick HPSH Rotary Screw Compressor Installation Operation and Maintenance Guide

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