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)
Page 3
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.
60
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.
60
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.
60
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
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
A
AB
B
SM-2
SM-1
SECTION A-A
SECTION B-B
A
AB
B
SM-2
SM-1
SECTION A-A
SECTION B-B
A
AB
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).
3.
Coupling must be able to take up any misalignment be-
tween motor and compressor. It is critical to the life of the
shaft seal that misalignment is kept to the minimum 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
B
P
A
T
Compressor Oil
(Discharge PSIG)
Compressor
Suction
b
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
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
A
A
SB-3
TRANSDUCER
MOUNTING
12.75 (.502)
12.70 (.500)
KEYWAY
Discharge Flange 3” Class 600
SD-2
SC-5
SB-2
SD-1
SL-0
BP-1
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
A
Ammonia heat pumps 10
asymmetric prole 6
axial load 9
axial runout 10
B
balance piston 5, 9
Balance piston 5
BALANCE PISTON 6
ball bearings 5
Bearings 6
C
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
D
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
E
Economizer port 5
electric drive motor 7
Evacuate 5
F
lter elements 10
foundation 7
Frick SuperFilters™ 6
G
gas bypassing 5
gas compression 7
gauge pressures 15
Grease 5
H
heat pumps 10
hot alignment 10
Housing 6
HPSH compressors 7
I
identication data plate 3
L
lifting rings 7
Long term storage 4
M
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
N
natural gas 10
nitrogen 5
O
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
P
plug valve 5
Port locations 7
pressurize 5
R
radial runout 10
regulating valve 10
rigging 7
roller bearings 5
Rotors 6
S
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
T
troubleshooting 13, 16
tunnel mount 7
U
UNLOADING VALVE 6
V
vacuum pump 11
Vacuum rise 11
variable speed 5
variable speed drive 5
vibration 6, 15
vibration analysis 15
W
warm oil 10
Warranty 4
ALPHABETICAL LISTING
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Frick HPSH Rotary Screw Compressor Installation Operation and Maintenance Guide

Brand
Frick
Model
HPSH Rotary Screw Compressor
Type
Installation Operation and Maintenance Guide
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