Frick HPSH Rotary Screw Compressor Installation Operation and Maintenance Guide

Brand: Frick

Model: HPSH Rotary Screw Compressor

Type: Installation Operation and Maintenance Guide

This manual contains rigging, assembly, start-up, and maintenance

instructions. Read thoroughly before beginning installation. Failure

to follow these instructions may result in personal injury or death,

damage to the unit, or improper operation.

ROTARY SCREW COMPRESSOR

HPSH 2709/2712

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

Form 070.750-IOM2 (SEP 2019)

INSTALLATION–OPERATION–MAINTENANCE

File: SERVICE MANUAL–Section 070

Replaces: NOTHING

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

070.750-IOM2 (SEP 19)

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 Denitions

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 identication ................................................ 3

Long-term storage ............................................................ 5

Preparing compressor for storage ................................ 5

Maintaining compressor (in storage) ............................ 5

Description ........................................................................5

HPSH compressor ........................................................ 5

Compressor lubrication system ................................... 6

Oil pump (optional) .......................................................6

Construction details ..........................................................6

Design limits .................................................................7

Vibration and sound data .................................................. 7

Installation

Outline dimensions ...........................................................9

Holding charge and storage .............................................. 9

Rigging and handling .........................................................9

Foundation ....................................................................... 9

Customer connections ....................................................10

Vi and effective orice sizes ....................................... 10

Compressor oil ................................................................ 10

Oil pump .........................................................................11

Motor mounting (foot mounted only) .............................. 11

Compressor/Motor coupling requirements .................11

Coupling alignment requirements

(foot mounted only) ....................................................11

Oil heaters - Heating wires and insulation ..................... 12

Oil lters .........................................................................12

Oil cooling requirements ................................................. 12

Dehydration / evacuation test .........................................12

Electrical installation .......................................................12

Operation

Operation and start-up instructions ............................... 13

Low ambient operation .................................................. 13

Initial start-up ................................................................13

Initial start-up procedure ..........................................13

Normal start-up procedure ........................................13

Control system ................................................................ 13

Maintenance

General information .......................................................15

Normal maintenance operations ....................................15

General maintenance .....................................................15

Changing oil ....................................................................15

Recommended maintenance program .......................15

Maintenance schedule .....................................................16

Recommended spare parts ............................................. 16

Vibration analysis ......................................................17

Oil quality and analysis ..............................................17

Operating log ............................................................17

Troubleshooting guide ....................................................17

Abnormal operation analysis and correction .................. 17

Troubleshooting the hpsh compressor ............................ 18

Bare compressor replacement ...................................18

Shutdown due to improper oil pressure ..................... 18

Forms

Compressor prestart checklist .........................................19

Alignment log ..................................................................20

Drive train alignment ....................................................... 20

Operating log sheet ........................................................20

Vibration data sheet ........................................................21

Compressor port locations .............................................. 22

Warning

Caution

Danger

Notice

070.750-IOM2 (SEP 19)

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 describes the installation, operation, and main-

tenance procedures of 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

system. Consult your authorized Johnson Controls-FRICK

representative for expert guidance in this determination.

Proper performance and continued satisfaction with these

units is dependent upon:

• Correct Installation

• Proper Operation

• Regular, Systematic Maintenance

• Proper Package and System Engineering

To ensure correct installation and application, the equip-

ment must be properly selected and connected to a

properly designed and installed system. The engineering

plans, piping layouts, for example, must be detailed in ac-

cordance with the best practices and local codes, such as

those outlined in ASHRAE and EN codes.

A screw compressor is a vapor pump. To ensure that

working uid in the liquid state is not being ingested, per-

form the following steps:

• Select controls carefully. Make sure they are in good

operating condition.

• Properly size piping and correctly arrange traps, if they

are necessary.

• Check that the suction line has an accumulator or slug-

ging protection.

• Know the load surges and make provisions for control.

• Check that operating cycles and stand still periods are

reasonable.

• Size high side components within system and compres-

sor 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

selection software CoolWare. They are primarily used for

compressing refrigerant gas and most hydrocarbon gasses.

If your application is for sour gas, there are special require-

ments to protect the compressor. Contact Johnson Con-

trols-FRICK Compressor Engineering for application details.

JOB INSPECTION

Immediately upon delivery examine all crates, boxes, and

exposed compressor and component surfaces for damage.

Unpack all items and check against shipping lists for any

discrepancy. Examine all items for damage in transit.

STANDARD BARE COMPRESSOR

Items not included with bare compressor that are available

as sales order options:

• Motor mount

• Connection ttings

• Coupling

• Solenoid valve manifold block assembly

TRANSIT DAMAGE CLAIMS

All claims must be made by consignee. This is an ICC

requirement. Request immediate inspection by the agent

of the carrier and be sure the proper claim forms are ex-

ecuted. 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 order-

ing repair parts, provide the model and serial numbers

from the data plate. See Figure 1.

Figure 1: Identication data plate

COMPRESSOR SHAFT

CLOCKWISE ROTATION

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

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.

89.6

1300

3800

HPSH 2709A

070.750-IOM2 (SEP 19)

Page 4

HPSH ROTARY SCREW COMPRESSOR

INSTALLATION - OPERATION - MAINTENANCE

The compressor model number designates the size of the

compressor and its Vi conguration.

Example: HPSH 2709 A

Rotary screw compressor serial numbers identify the

factory that the compressor was manufactured in and its

build date. They are dened by the following information:

HPSH 27 09 A

MODEL / SERIES

HPSH = High Pressure Screw

ROTOR DIAMETER

27 = 273 mm

ROTOR LENGTH DESIGNATION

Vi CONFIGURATION

A = 2.2 – 5.0

B = 1.7 – 3.0

C = 1.3 – 1.96

Rotor Length ÷ Diameter x 10

Example: 1024 0 A 9 0000015 Z

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.

The name plates in Figure 2 show which refrigerants are

compatible with the compressor as manufactured.

Figure 2: Refrigerant nameplates

COMPRESSOR SHAFT

CLOCKWISE ROTATION

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

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.

89.6

1300

3800

HPSH 2709A

Table 1: Geometrical swept volume

HPS

rpm

HPSH 2709 HPSH 2712 2%*

2709/2712

m3/h (cfm) m3/h (cfm) Lpm

1450 398 (676) 530 (901) 133/177

1750 480 (816) 640 (1088) 160/213

2950 809 (1,375) 1079 (1833) 270/360

3550 974 (1655) 1298 (2206) 325/433

* Oil ow as a % of swept volume.

Table 2: Compressor Long Term Storage Log

Model Serial no.

Compressor, motor oil

pump & refrigerant pump

shaft rotation 1½ turn

Rotor

housing

charge Charge

added

Visual

inspec-

tion Charge Checked

by Date

070.750-IOM2 (SEP 19)

Page 5

HPSH ROTARY SCREW COMPRESSOR

INSTALLATION - OPERATION - MAINTENANCE

Figure 3: Nameplate and Vi locations

LONG-TERM STORAGE

Long-term storage (6 months to 5 years) provisions are

required, regardless of storage environment, if start-up

and useful operation does not occur within six (6) months

of equipment shipment. Special provisions may be re-

quired for storage of less than six (6) months if the storage

area is subject to environments with high humidity, large

changes in temperature, dusty atmosphere, or other un-

usual environmental conditions.

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

recommended that arrangements be made with the local

Johnson Controls-FRICK service organization (arranged

through factory service) regarding surveillance and main-

tenance during the storage period. It is the customer’s

responsibility 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 Recommendation may void the warranty.

Long term storage of equipment may lead to the deterio-

ration of components over the period of time. Synthetic

components in the compressor may deteriorate over time

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

environment 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.

2. Connect the evacuation line to the one Schrader valve

provided with the compressor which is connected to

the SD-1 port on the rotor housing.

2. Break vacuum with dry nitrogen and bring pressure to

0 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 for each compressor are:

• HPSH 2709/2712 – 25 gal

4. After the compressor is oil charged, pressurize

compressor 0.3 bar to 1.0 bar (5 psig to 15 psig) with

nitrogen.

MAINTAINING COMPRESSOR (IN STORAGE)

1. Ensure that the 0.3 bar to 1.0 bar (5 psig to 15 psig)

nitrogen charge is maintained with 1.0 bar (15 psig)

preferred.

2. Rotate the male rotor shaft monthly. Mark the shaft to

ensure the rotor does not return to the original posi-

tion.

3. Store the compressor inside a dry building environ-

ment.

4. Grease the male rotor shaft to prevent rust.

5. Record all information in a Compressor Long Term

Storage Log (see Table 2).

Contact Johnson Controls-FRICK Service with any ques-

tions regarding long term storage.

DESCRIPTION

HPSH COMPRESSOR

The FRICK HPSH rotary screw compressor uses 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:

• Designed for variable speed drive with a range of 600

rpm to 4200 rpm; but can also be operated with a xed

speed motor drive at 2950 rpm and 3550 rpm or a xed

speed engine drive at 1200 rpm.

• The HPSH 273 compressor models uses stepless capac-

ity control providing innite unloading capacity down to

about 20% of full load capacity.

• The HPSH 273 compressor models have a moveable

slide stop with three Vi ranges offered as standard:

- 2.2 to 5.0

- 1.7 to 3.0

- 1.3 to 1.96

• High capacity roller bearings to carry radial loads are

used at both inlet and outlet ends of the compressor.

• The High pressure compressor models use heavy duty

four point ball bearings to carry the axial loads on the

rotor for the HPSH 273 compressor models.

• The high pressure compressor models uses balance

piston assemblies to limit the axial bearing loads. HPSH

273 compressor models use one at the male and female

inlet ends that require pressure regulation on the oil

supply.

• The housings for the HPSH 273 compressor models are

designed for 89 bar (1300 psig) working pressure.

• The HPSH 273 compressor models are designed with

multiple ports, including:

– Economizer port located at 1.34 Vi.

– Liquid injection port located at 1.27 Vi.

– Two main oil injection ports - SM2 (1.05 Vi ) for the

two lower Vi ranges (1.3 to 1.96 and 1.7 to 3.0) and

SM1 (1.3 Vi) for the 2.2 Vi to 5.0 Vi range.

• All bearing and control oil is vented to lower pressure

locations inside the compressor allowing operation

without an oil pump for most applications.

NAMPLATE

COMPRESSOR

VOLUME RATIO Vi,

STAMPED

070.750-IOM2 (SEP 19)

Page 6

HPSH ROTARY SCREW COMPRESSOR

INSTALLATION - OPERATION - MAINTENANCE

• The shaft seal is designed with a seal ring made of

silicon carbide mated against a similar material, with

carbon and graphite added to the matrix to provide

self-lubrication, especially for startups.

The shaft seal housing is designed to maintain operat-

ing pressure on the seal much lower than discharge

pressure for increased seal life.

• Oil injected into the compressor is directed between

the rotor threads to maintain good volumetric and

adiabatic efciency.

• The shaft rotation is clockwise when facing the com-

pressor drive end and is suitable for all types of drives.

Warning

Compressor rotation is clockwise when facing the com-

pressor drive shaft. Never operate the compressor in

reverse rotation as this can result in damage.

• The suction and discharge anges are ANSI B16.1 Class

600 type for the HPSH 273 compressor models.

• Suction strainers for the HPSH 273 compressor models

are external to the compressor. The strainer specied

must meet the following requirements as a minimum:

– Filter Cloth: SS 304, 30 x 150 Mesh, plain Dutch

Weave with 0.009 in. WARP diameter and 0.007 in.

WEFT diameter

– Filter Cloth Support: 6 mesh with 0.035 in. wire

diameter, 0.132 in. openings with 62.7% open area

COMPRESSOR LUBRICATION SYSTEM

The lubrication system on a HPSH screw compressor unit

performs several functions:

• Provides lubrication to bearings, seal, and rotors.

• Provides a cushion between the rotors to minimize

noise and vibrations.

• Helps keep the compressor at the proper temperature

and prevents overheating.

• Provides oil supply to hydraulically operate the slide

valve and slide stop for the HPSH 273 to provide capac-

ity and volume control.

• Provides oil pressure to the balance piston assemblies

to help increase bearing life.

• Provides an oil seal between the rotors to prevent rotor

contact or gas bypassing.

Volumizer variable volume ratio control

The FRICK compressor includes a method of varying the

internal volume ratio to match the system pressure ratio.

Control of the internal volume ratio eliminates the power

penalty associated with over- or under-compression. Vol-

ume ratio control is achieved by the use of a slide stop, a

movable portion of the rotor housing assembly that moves

axially with the rotors to control discharge port location.

Stepless capacity control

Capacity control is achieved by use of a movable slide

valve. The slide valve moves axially under the rotors to

provide fully modulated capacity control from 100% to ap-

proximately 20% minimum load capacity.

Approximate minimum load capacity varies slightly with

compressor model, pressure ratio, discharge pressure

level, and rotor speed.

The slide valve is positioned by hydraulic movement of its

control piston. When in the unloaded position, gas is by-

passed back to suction through a recirculation slot before

compression begins and any work is expended, providing

the most efcient unloading method available for part-

load operation of a screw compressor.

OIL PUMP (OPTIONAL)

A demand oil pump is required for low differential pressure

applications (CoolWare provide a warning when the oil

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

compressor from the oil separator is at system discharge

pressure. Within the compressor, oil porting to all parts of

the compressor is vented back to a location in the com-

pressor’s body that is at a lower pressure than compres-

sor 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

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

Bearings

Antifriction bearings with L10 rated life in excess of 10,000

hours (using FRICK SuperFilters™) at design conditions are

used for reduced frictional horsepower and superior ro-

tor positioning, resulting in reduced power consumption.

Cylindrical roller bearings are provided to handle the radial

loads and the thrust loads are absorbed by preloaded

angular contact ball bearings or four point ball bearings

depending on the compressor model.

Balance piston

The high pressure compressors are equipped with balance

piston assemblies to reduce load on the axial bearings. Oil

pressure is regulated by a modulating pressure regulating

valve and provides the force, and therefore, must remain

as specied by Coolware for specic operating conditions.

Shaft seal

The compressor shaft seal is a single-face balanced type

with a spring-loaded, silicon carbide stationary hardened

surface riding against a rotating seat. Carbon and graph-

ite are added to both surfaces to provide self-lubrication.

During operation it is vented to low pressure to provide

extended life. The compressor can be tted with either

shaft seals as an option.

need to update (table)

070.750-IOM2 (SEP 19)

Page 7

HPSH ROTARY SCREW COMPRESSOR

INSTALLATION - OPERATION - MAINTENANCE

Motor mount

The HPSH 273 series compressor is a foot mounted, open

drive model which can be paired with an electric, engine,

or turbine drive.

DESIGN LIMITS

Use CoolWare™ to determine the limits for a specic

application.

Notes for design limits:

1. CR = Compression Ratio. Absolute discharge pressure

divided by absolute suction pressure.

Figure 4: HPSH 273 Viscosity Requirement as function

of speed

2. Maximum discharge temperature depends on oil type

used - normally 150°C (300°F). Refer to FRICK oil data

for more detail.

3. If oil ow is more than 1.5% of swept volume and the

turndown is more than 3, regulation of the main oil

ow must be used. Turndown is the actual maximum

speed/minimum speed. Coolware calculates the oil ow

in Lpm. See Table 1.

The UNISAB and Quantum panels have several lay-

ers of control functions to secure reliable operation.

Depending on many operating conditions, they unload

the slide valve and reduce or increase speed to keep

the compressor running in a safe way. Only as the last

resort do they initiate an alarm and ultimately stop the

compressor.

This is particularly true for the HPSH 273 compressor

models on applications with high suction pressure, like

fuel gas boosting. The concern is that the high internal

thread pressure may lead to excessive rotor deection

and unwanted contact with the rotor housing. For this

reason, proper calibration of the slide valve and slide

stop is essential.

Note: For 1.3 to 1.96 and 1.7 to 3.0 Vi range machines, the

main oil injection occurs at lower Vi port locations than

compressors operating with the 2.2 to 5.0 Vi range. This

means the UNISAB and Quantum use lower values for

the safeties.

5. In CO2 applications using miscible oil types POE and

PAG, it is extremely critical to keep water content to

the lowest possible - down to 10 ppm is the goal. The

installation must have large lter dryers with replace-

able elements that can be effectively serviced and

vacuum dried before being put back in service.

6. If the temperature difference becomes greater than or

equal to 180°F (355 K) between suction and discharge

the slide valve must be unloaded immediately.

7. The minimum discharge temperature must be a mini-

mum 30°F difference above the maximum dewpoint of

the discharge gases. This applies to part load condi-

tions as well as full load operation.

VIBRATION AND SOUND DATA

The rotors balance grade is G 2.5 according to ISO 1940.

The male rotor drive end of the HPSH 273 compressor is

keyless.

Effective vibration velocity must not exceed 8 mm/s RMS

(0.32 in./s) anywhere on the compressor. Alarm level is 12

mm/s RMS.

Table 3: Critical frequencies

Male rotor, # of lobes 6 Main exciting

frequencies (Hz)

Female rotor, # of lobes 8

Driver speed, rpm typical

Exiting member/event 3000 3600 4200

Male rotor, rotational, 1st order 50 60 72

Male rotor, rotational, 2nd order 100 120 144

Female rotor, rotational, 1st 37.5 45 54

Female rotor, rotational, 2nd 75 90 108

Discharge gas pulsation, 1st 300 360 432

Discharge gas pulsation, 2nd 600 720 864

Vibration level on the package can be higher, especially

on piping elements, and when the natural frequency of an

element falls together with one of the exciting frequen-

cies. If the vibration level gets too high, a skip frequency

function in the control system is activated. When acti-

vated, the motor runs through the critical speed very fast,

not causing any continuously high vibration.

Shaft speed, rpm

1000

002000 3000 4000 5000

Viscosity Min., cst

070.750-IOM2 (SEP 19)

Page 8

HPSH ROTARY SCREW COMPRESSOR

INSTALLATION - OPERATION - MAINTENANCE

070.750-IOM2 (SEP 19)

Page 9

HPSH ROTARY SCREW COMPRESSOR

INSTALLATION

Installation

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. Only use the compressor lifting rings

to lift the compressor itself.

Figure 5: Lifting Rings

FOUNDATION

Each HPSH Rotary Screw Compressor is shipped mounted

on a wooden skid. Remove before installing the unit.

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 weights of the

HPSH 2709 and HPSH 2712 assemblies respectively, are

2132 kg (4700 lb) and 2241 kg (4940 lb).

Screw compressors are capable of converting large quan-

tities 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. Refer to FRICK

070.210-1B Screw Compressor Foundations.

The best insurance for a trouble-free installation is to

rmly anchor the compressor to a suitable foundation

using proper bolting and by preventing piping stress from

being imposed on the compressor. After the compressor

is rigged into place, its feet must be shimmed to level it.

There must be absolutely no stresses transferred to the

compressor body due to bolting of the feet and anges.

In any screw compressor installation, support suction and

discharge lines in pipe hangers, preferably within 2 ft of

vertical pipe run, so that the lines won’t move if discon-

nected from the compressor. See Table 4 for Allowable

ange loads.

HPSH 273 compressors are designed to be driven with an

open drive, foot mounted motor. The rotor and bearing

design set limitations must not be exceeded (See Cool-

Ware). Refer to Johnson Controls-FRICK Compressor Con-

trol Panel instruction 090.040-O for additional information

on setpoint limits.

OUTLINE DIMENSIONS

Complete dimensions and connection information can be

found on the outline drawing which can be requested by

contacting Johnson Controls-FRICK Sales. See Compressor

Port Locations.

HOLDING CHARGE AND STORAGE

Every HPSH compressor is pressure and leak tested at the

Johnson Controls–FRICK Factory and thoroughly evacuated

and charged with dry nitrogen to ensure its integrity dur-

ing shipping and short term storage before installation.

Keep all compressors in a clean, dry location to prevent

corrosion damage. For compressors stored for more than

two months, check their nitrogen charge periodically. See

General Information for complete instructions and refer

to FRICK Form 020.050-W 2012 Screw Compressor Long

Term Storage for FRICK Bare Screw Compressors.

Warning

Holding-charge shipping gauges (if mounted) are rated

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

charge only. They must be removed before pressure

testing and operating the system. Failure to remove

these gauges may result in catastrophic failure of the

gauge resulting in serious injury or death.

Access valves are bronze and they must be replaced

with steel plugs when package is assembled.

Caution

This equipment has been pressurized with

nitrogen gas. Temporary valves and gauges have been

installed.

1. Relieve pressure before opening lines or making

eld connections.

2. Remove charging valves or gauges be pressurizing

system.

3. Refer to installation operation and maintenance

manual for additional information.

Escaping gas may cause injury

LIFTING RINGS

070.750-IOM2 (SEP 19)

Page 10

HPSH ROTARY SCREW COMPRESSOR

INSTALLATION

CUSTOMER CONNECTIONS

In addition to the suction and discharge connections, the

following ports require piping for operation of the com-

pressor.

SB-2 and SB-2a Inlet Bearings and Balance Piston

SB-3 Shaft seal, outlet end bearings, and

unloader plug

SM-1 or SM-2 Main oil injection. SM-1 is only used for

2.2-5.0 Vi)

Vi AND EFFECTIVE ORIFICE SIZES

SM-2 is low Vi (1.05), and SM-1 is high Vi (1.3). If unsure,

connect main oil to SM-2. The HPSH 2709 and HPSH 2712

both have factory installed orice plugs (0.469 in. diam-

eter).

Other connections are available for instrumentation and

service as noted on the Dimensional Outline drawing.

The oil supply system for the compressor must be de-

signed 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 operation of the balance piston which is used to

ensure the life of the male and female axial bearing.

If the speed turndown is more than 3, then automated

regulation of the main oil ow is required (in order to keep

a high discharge temperature at any speed and prevent oil

slugging at slow speeds).

COMPRESSOR OIL

Warning

DO NOT MIX OILS of different brands, manufacturers,

or types. Mixing of oils can cause excessive oil foaming,

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

leakage and catastrophic compressor failure. CoolWare

selects 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 viscosity and

is compatible with the refrigerant and compressor

elastomers.

Figure 6: SM-1 and SM-2 Port Cutaways

SM-1

(Port SM-1 Orice Plug)

SM-2

(Port SM-2 Orice Plug)

070.750-IOM2 (SEP 19)

Page 11

HPSH ROTARY SCREW COMPRESSOR

INSTALLATION

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 refrigerant,

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 displace-

ment gear type that must have a safety relief valve to en-

sure the oil pressure does not go above 50 psi 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 axial bearing failure. See CoolWare for your

application’s requirements.

MOTOR MOUNTING (FOOT MOUNTED ONLY)

1. Thoroughly clean the motor feet and mounting pads of

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

seating of the motor.

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

raising blocks, if required.

3. Weld the four kick bolts (not included with compres-

sor) into place so that they are positioned to allow

movement of the motor feet.

4. After the motor has been set, check to see that the

shafts are properly spaced for the coupling being used.

Check the appropriate dimensional outline drawing for

the minimum clearance required between the shaft

ends to change the shaft seal.

COMPRESSOR/MOTOR COUPLING REQUIREMENTS

HPSH compressors are arranged for direct motor drive and

require a exible drive coupling to connect the compressor

to the motor. Coupling must be suitable for variable speed.

The HPSH 273 models use a keyless drive shaft.

For a foot mounted motor, it is essential to properly align

the coupling to ensure proper bearing and seal perfor-

mance:

1. Select and install coupling 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

between 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 guidelines for checking and correcting

any misalignment. See the next section for Johnson

Control–FRICK’s requirements.

COUPLING ALIGNMENT REQUIREMENTS

(FOOT MOUNTED ONLY)

Perform coupling alignment before start-up. After the

compressor has been installed on the job site, check align-

ment again and if necessary, correct before start-up. After

a few hours operation, the alignment must be checked

while the package is still hot. Correct hot alignment is

critical to ensure the life of the shaft seal and compressor

bearings.

Maximum radial runout is 0.004 in. total indicator

reading.

Maximum axial runout is 0.004 in. total indicator

reading.

Use a dial indicator or another appropriate measuring

device to determine the Total Indicator Runout.

Check indicator bracket sag as all brackets have some

exibility.

Table 4: Allowable ange 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-IOM2 (SEP 19)

Page 12

HPSH ROTARY SCREW COMPRESSOR

INSTALLATION

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 rotate 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 readings when af-

xed to the coupling for an accurate alignment.

OIL HEATERS - HEATING WIRES AND

INSULATION

Your package must be equipped with oil heaters that pro-

vide sufcient heat to prevent condensation from occurring

during startup and shutdown cycles. Insulate the whole

system.

OIL FILTERS

Use of lter elements other than Johnson Controls-FRICK

must be approved in writing by Johnson Controls-FRICK

Engineering 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 dis-

charge 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 150°C (300°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 150°C (300°F) is natural gas gath-

ering at the wellhead. Moisture is normally present in the

gas and it is imperative that the discharge temperature be

at least 17°C (30°F) higher than the discharge dew point

temperature for the gas.

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 ap-

plication. 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 natural gas compression.

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

or SM-2 must have a regulating valve to permit adjust-

ment of the oil ow to maintain the desired discharge

temperature at all times. A non-return valve is also

required in order to prevent gas from owing backward

into the oil system under start-up and transition of

operating conditions

The regulating valve may need to have a motor so the

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

This is often needed for heat pumps where a certain

capacity, water temperature, and efciency is expected.

It may also be a requirement when the speed turndown is

signicant (from 4200 rpm to 1000 rpm, for example) as

the relative oil ow may get too high at the lower speed

range. Turndown above 3 requires an automatic valve.

Consult Coolware and the factory.

When considering minimum supply oil temperature, the

use of a thermostatic three-way bypass mixing valve is not

recommended. For alternate methods consult FRICK

Engineering.

Warning

For high temperature applications, consult factory.

Some of the 3-way thermostatic valves do not work at

high temperatures and damage to thermostatic mixing

valves can occur.

A three-way mixing valve, or one of the alternate meth-

ods, provides 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 oper-

ating conditions. For some applications this valve needs to

be a motor-operated valve controlled by the control panel.

This is needed for a heat pump where the oil is cooled to a

lower temperature than the condensing temperature.

An ideal oil temperature is the same as the condensing tem-

perature, for example 80°C (176°F).

In a heat pump application there is a risk the discharge

temperature gets too low at low speed, therefore some hot

oil must bypass the oil cooler. Discharge temperature must

be a minimum of 10°C (18°F) above condensing tempera-

ture. Consult Coolware and factory, also study PID diagram

examples (see Table of Contents).

DEHYDRATION / EVACUATION TEST

Evacuate the system to 1500 microns. Valve off the

vacuum pump and hold vacuum for one hour.

Pass: Vacuum cannot rise above the 2000 micron level

during a one hour hold period.

Fail: Vacuum reading goes above the 2000 micron

level during a one hour hold period. Identify and

repair any system leaks. Repeat vacuum test until

requirements are met.

ELECTRICAL INSTALLATION

The only electrical connection to be made to the com-

pressor is for the solenoid operated capacity control valve.

070.750-IOM2 (SEP 19)

Page 13

HPSH ROTARY SCREW COMPRESSOR

OPERATION

Operation

INITIAL START-UP

Before the start-up, the prestart check must be accom-

plished. See Forms section for Prestart Checklist.

INITIAL START-UP PROCEDURE

After performing 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 before start-up.

It is important that an adequate gas load be available to

load test the unit at normal operating conditions. Keep the

following points 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

hazard.

2. Immediately after start-up, adjust the oil cooling sys-

tem. Adjust it 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 the system is clean. Otherwise, follow the normal

maintenance schedule.

4. Perform vibration analysis if preventive maintenance is

required. If performing a vibration analysis, it is neces-

sary to establish a baseline when the system is running

at normal conditions.

NORMAL START-UP PROCEDURE

1. Conrm system conditions permit starting the com-

pressor.

Notice

Ambient temperatures need to be high enough to

prevent excessive condensing; otherwise, initiate oil

heaters and heat tracing 24 hours before start-up.

2. Start the unit.

3. Observe the compressor unit for mechanical tight-

ness of the external piping, bolts, and valves. Ensure

that the machine has no oil and vapor leaks. If any of

these occur, shut down the compressor and correct the

problem as necessary using good safety precautions.

CONTROL SYSTEM

The HPSH compressor and package requires a dedicated

control system, either Quantum or UNISAB. For details on

operation of these control systems, refer to the respective

IOM manuals.

OPERATION AND START-UP INSTRUCTIONS

The FRICK HPSH Rotary Screw Compressor is a compo-

nent in an integrated system. As such, the compressor

operation requires some specic conditions to ensure

trouble-free running.

The information in this section of the manual provides the

logical step by step instructions to properly start up and

operate the HPSH Rotary Screw Compressor in your unit.

Only matters which may inuence the proper operation of

the FRICK HPSH compressor are included.

The following subsections must be read and understood

before attempting to start or operate the unit.

LOW AMBIENT OPERATION

Warning

Everything must be heat traced and insulated - even the

compressor.

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

ing, and the oil lter be insulated as a minimum require-

ment to preserve the heat generated by the oil heaters,

to prevent condensation, and to secure lubrication at

start-up.

Heat pump and fuel gas compression applications must

always have the oil separator insulated. Heat pumps often

require the complete suction line to be insulated in order

to prevent condensation and possible slugging. In these

cases, heating wires are required.

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

oil port being used (SM-2 or SM-1) in order to continu-

ously achieve the highest possible discharge temperature

needed.

070.750-IOM2 (SEP 19)

Page 14

HPSH ROTARY SCREW COMPRESSOR

OPERATION

070.750-IOM2 (SEP 19)

Page 15

HPSH ROTARY SCREW COMPRESSOR

MAINTENANCE

Maintenance

nitrogen or oil. It is also necessary to rotate the shaft

monthly to keep the seal faces lubricated. This is par-

ticularly true on systems known to contain water vapor.

• Preventive maintenance is recommended including

measuring of vibration and performing oil analyses.

Inspection is recommended any time a compressor

exhibits a noticeable change in vibration level, noise, or

performance.

CHANGING OIL

Warning

Do not mix oils of different brands, manufacturers, or

types. Mixing of oils may cause excessive oil foaming,

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

leakage and catastrophic compressor failure.

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

all oil lter cartridges must be changed and all oil strainer

elements removed and cleaned. The procedure is as fol-

lows:

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 0 psig.

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

container.

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

7. Remove the old lter cartridges, and install new ones.

8. Remove, clean, and reinstall elements in the strainers.

9. Evacuate the unit.

10. Open the suction service valve and pressurize the unit

to system suction pressure. Close the suction valve and

leak test.

11. Add oil.

12. Open the suction and discharge service valves.

13. Remove the lockout from the motor starter.

14. Start the unit.

RECOMMENDED MAINTENANCE PROGRAM

In order to obtain maximum compressor performance

and ensure reliable operation, follow a regular mainte-

nance program. Check the compressor regularly for leaks,

abnormal vibration, noise, and proper operation as well

as maintaining a log. Perform an oil analysis on a regular

basis. It is a valuable tool that can identify the presence

of moisture, acid, metallics, and other contaminants that

shorten compressor life if not corrected. In addition, peri-

odic vibration analysis can be useful in detecting bearing

wear and other mechanical failures.

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.

NORMAL MAINTENANCE OPERATIONS

When performing maintenance you must take several pre-

cautions to ensure your safety:

• If the unit is running, press the STOP key.

• Stop the motor and lock out starter before performing

any maintenance.

• Wear proper safety equipment when the compressor

unit is opened to the atmosphere.

• Ensure there is adequate ventilation.

• Take necessary safety precautions required for the gas

being used.

GENERAL MAINTENANCE

Proper maintenance is important in order to ensure long

and trouble-free service from your screw compressor.

Some areas critical to good compressor operation are as

follows:

• Keep oil clean and dry, and avoid moisture contamina-

tion. After servicing any portion of the refrigeration

system, evacuate to remove moisture before returning

to service. Water vapor condensing in the compres-

sor while running or more likely while shut down, can

cause breakdown of the oil and refrigerant, which can

generate corrosive agents. This can lead to the break-

ing down of bearings and other vital components in a

short time.

• Keep the suction strainer clean. Check periodically,

particularly 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 particles into the compressor.

• 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 compres-

sor 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.

• Avoid slugging the compressor with liquids (refrigerant

and/or oil). While screw compressors are probably the

most tolerant (of any compressor type available today)

of the ingestion of some liquid, they are not liquid

pumps. Make certain a properly sized suction accumu-

lator is used to avoid dumping liquid into compressor

suction.

• Protect the compressor during long periods of shut-

down. If the compressor sits for long periods without

running, evacuate to low pressure and charge with dry

070.750-IOM2 (SEP 19)

Page 16

HPSH ROTARY SCREW COMPRESSOR

MAINTENANCE

MAINTENANCE SCHEDULE

Follow this schedule to ensure trouble-free operation of the compressor unit.

Description HPSH 2709/2712

Complete Bearing Kit 534B2853G01

O-ring Kit, HBNR 534B2822H01

Shaft Seal Kit 534A1363G01

Seal Replacement Tool 534C2772G01

Balance Piston Kit 534A1364G01 (Male)

534A1365G01 (Female)

Compressor Tool Kit 534C2844G01

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 5 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 as stated in the specication posted in the enclosure.

e. Check calibration of Slide Valve, Slide Stop, pressures and temperatures. Conduct calibration 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 lters 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 and disch ange 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) nn n n n n n n n n n n n n n n n n n n

Check sensor calibration (e) nn 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 a Minute (600 ml in 24 hours)

Compressor

model

Discharge ange to separator ange

6 in. Class 600 Suction ange

8 in. Class 400

Bolt size Torque* (ft-lb) Bolt size Torque* (ft-lb)

HPSH 2709/2712 1 in. 406 1 1/8 in. 647

* 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

Table 5: Bolt sizes and torque

070.750-IOM2 (SEP 19)

Page 17

HPSH ROTARY SCREW COMPRESSOR

MAINTENANCE

VIBRATION ANALYSIS

Periodic vibration analysis can be useful in detecting

bearing wear and other mechanical failures. If vibration

analysis is used as a part of your preventive maintenance

program, take the following guidelines into consideration:

• Always take vibration readings from exactly the same

places and at exactly the same percentage of load.

• Use vibration readings taken from the new unit at start-

up as the base line reference.

• Evaluate vibration readings carefully as the instrument

range and function used can vary. Findings can be eas-

ily misinterpreted.

• 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 rapidly dete-

riorates in systems containing moisture and air or other

contaminants. In order to ensure the quality of the oil in

the compressor unit:

• Only use FRICK oil or high quality oils approved by

Johnson Controls-FRICK for your application.

• Only use FRICK SuperFilter™ elements. Substitutions

must be approved in writing by Johnson Controls-FRICK

Engineering or warranty claim may be denied.

• Participate in a regular, periodic oil analysis program to

maintain oil and system integrity.

OPERATING LOG

The use of an Operating Log permits thorough analysis

of the operation of a system by those responsible for its

maintenance and servicing. Continual recording of gauge

pressures, temperatures, and other pertinent information,

enables the observer and serviceman to be constantly

familiar with the operation of the system and to recognize

immediately any deviations from normal operating condi-

tions. It is recommended that readings 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

relatively obvious problems combine to provide a set of

symptoms 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 com-

ponents and piping.

Catastrophic failure may occur if condensation is present.

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:

• Oil ow too high at low speed.

• Discharge temperature too close to condensing tem-

perature.

• Insufcient or excessive gas load.

• Excessively high suction pressure.

• Excessively high discharge pressure.

• Excessively high or low temperature coolant to the oil

cooler.

• Excessive liquid entering the compressor (slugging).

• Insufcient oil cooling.

• Excessive oil cooling.

• Incorrect gas line sizing.

• Improper system piping.

• Wrong operation of hydraulic operated plug valve.

• Problems in electrical service to compressor.

• Moisture present in the system.

Make a list of all deviations from normal compressor

operation. Delete any items that 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 investi-

gate 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

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

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

problem. Once the cause has been identied and con-

rmed, make the necessary corrections.

070.750-IOM2 (SEP 19)

Page 18

HPSH ROTARY SCREW COMPRESSOR

MAINTENANCE

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 identi-

fying the probable cause. If a mechanical problem is

suspected, 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.

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.

Note: Refer to 070.660-SM - Bare Rotary Screw Compressor

Replacement when a motor tunnel is installed.

SHUTDOWN DUE TO IMPROPER OIL PRESSURE (HIGH

STAGE AND BOOSTER)

The compressor must not operate with incorrect oil

pressure.

Refer to relevant Control Setup.

070.750-IOM2 (SEP 19)

Page 19

HPSH ROTARY SCREW COMPRESSOR

FORMS

READ THIS FIRST: COMPRESSOR PRESTART CHECKLIST

The installer must check and complete the following items before the arrival of the FRICK Field Service

Supervisor. Details on the checklist can be found in this manual. Certain items on this checklist are reveried

by the FRICK Field Service Supervisor before the actual start-up.

Mechanical Checks

__ Package installed according to FRICK publication

070.210-IB, Screw Compressor Foundations.

__ Conrm that motor disconnect is open

__ Isolate suction pressure transducer

__ Pressure test and leak check unit

__ Evacuate unit

__ Remove compressor drive coupling guard

__ Remove coupling center and do not reinstall

(motor rotation must be checked without center)

__ Check for correct position of all hand, stop, and check

valves before charging unit with oil or refrigerant

__ Charge unit with correct type and quantity of oil

__ Lubricate electric drive motor bearings before

checking motor rotation

__ Check oil pump alignment (if applicable)

__ Check for correct economizer piping (if applicable)

__ Check separate source of liquid refrigerant supply (if

applicable, liquid injection oil cooling)

__ Check water supply for water-cooled oil cooler (if ap-

plicable, water cooled oil cooling)

__ Check thermosyphon receiver refrigerant level (if ap-

plicable, thermosyphon oil cooling)

Check for proper pipe supports and correct foundation

__ Check to ensure all piping including relief valves is

completed

After the above items have been checked and veried:

__ Close the main disconnect from the main power supply to the motor starter

__ Close the motor starter disconnect to energize the micro

__ Manually energize oil pump and check oil pump motor rotation

__ Leave micro energized to ensure oil heaters are on and oil temperature is correct for start-up

__ Do not energize compressor drive motor. Only authorized Factory Field Service Technicians are to perform this.

Summary:

Ensure the above items are completed before the FRICK Field Service Supervisor arrives

Ensure there is an

uncoupled compressor drive unit (to verify motor rotation and alignment) and energized oil heaters with the oil at the

proper standby temperatures

. Full compliance with the above items contributes to a quick, efcient, and smooth start-up.

The Start-up Supervisor:

1. Veries position of all valves

2. Veries all wiring connections

3. Veries compressor motor rotation

4. Veries oil pump motor rotation

5. Veries the percentage of FLA on the micro display

6. Veries and nalizes alignment (if applicable)

7. Calibrates slide valve and slide stop

8. Calibrates temperature and pressure readings

9. Corrects any problem in the package

10. Instructes operation personnel

Note: Customer connections are to be made as illustarated in the electrical diagram for the motor starter

listed under the installation section and the wiring diagram listed under the maintenance section of the IOM.

Complete and sign this form and fax to 717-762-8624 as conrmation of completion.

FRICK Sales Order Number: _____________________

Compressor Model Number: _____________________

Unit Serial Number: ____________________________

End User Name: _______________________________

Address of Facility: _____________________________

City, State, Zip: ________________________________

Print Name: ___________________________________

Company: _____________________________________

Job Site Contact: _______________________________

Contact Phone Number:_________________________

Signed: ______________________________________

Forms

070.750-IOM2 (SEP 19)

Page 20

HPSH ROTARY SCREW COMPRESSOR

FORMS

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

Equipment room temp.

Suction pressure

Suction temperature

Suction superheat

Discharge pressure

Discharge temperature

Corresponding temperature

Oil pressure

Oil temperature

Oil lter 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

Page is loading ...

Frick HPSH Rotary Screw Compressor Installation Operation and Maintenance Guide

Brand: Frick

Model: HPSH Rotary Screw Compressor

Type: Installation Operation and Maintenance Guide

Download PDF

report

Frick HPSH Rotary Screw Compressor Installation Operation and Maintenance Guide

Frick HPSH Rotary Screw Compressor Installation Operation and Maintenance Guide

Related papers

Other documents