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 (JUN 2012)
INSTALLATION - OPERATION - MAINTENANCE
File: SERVICE MANUAL - Section 070
Replaces: 070.750-IOM (APR 2011)
Dist: 3, 3a, 3b, 3c
HPSH
ROTARY SCREW COMPRESSOR
MODEL 1510
Please check www.johnsoncontrols.com/frick for the latest version of this publication.
THIS MANUAL CONTAINS RIGGING, ASSEMBLY, START-UP,
AND MAINTENANCE INSTRUCTIONS. READ THOROUGHLY
BEFORE BEGINNING INSTALLATION. FAILURE TO FOLLOW THESE
INSTRUCTIONS COULD RESULT IN DAMAGE OR IMPROPER
OPERATION OF THE UNIT.
HPSH ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
070.750-IOM (JUN 12)
Page 2
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.
NOTE: Indicates an operating procedure, practice, etc., or portion thereof which is essential to highlight.
Contents
GENERAL INFORMATION
 
 
 
 
 
 
 
 
 
 
 
 

 
 
 
 
 
INSTALLATION
 
 
 
 
 
 
 
 
 
 

 





OPERATION





MAINTENANCE






 
 
 

 










 
 
 

HPSH ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
070.750-IOM (JUN 12)
Page 3
THE INFORMATION CONTAINED IN THIS
DOCUMENT IS SUBJECT TO CHANGE
WITHOUT NOTICE
GENERAL INFORMATION
PREFACE

     
     

NOTE: Frick screw compressor repair must only be done
by skilled mechanics who have completed training at
Frick screw compressor school.
        

     




CORRECT INSTALLATION
PROPER OPERATION
REGULAR, SYSTEMATIC MAINTENANCE
       



         










HPSH compressors have small clearances and the com-
pressor package and system must be built with a very
high degree of cleanliness.
DESIGN LIMITATIONS
       
       

       


       

JOB INSPECTION
       

         

STANDARD BARE COMPRESSOR



TRANSIT DAMAGE CLAIMS



       
    

COMPRESSOR IDENTIFICATION



NOTE: When inquiring about the compressor or unit, or
ordering repair parts, provide the MODEL and SERIAL
NUMBERS from the data plate. See Figure 1.
Figure 1 - Identication Data Plate


EXAMPLE: 10240A90000015Z
GLOBAL ADDITIONAL
PLANT DECADE MONTH YEAR SEQ NO. REMARKS
  


       

       

HPSH ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
070.750-IOM (JUN 12)
Page 4
Figure 2 - Refrigerant Name Plates
Figure 3 - Name Plate and Vi Locations
       

rpm m3/h cfm
  
  
  
  
LONG TERM STORAGE



      




        






 








Compressor Long Term Storage Log
Model Serial No.




1½ Turn
Rotor
Housing
Charge
Charge
Added
Visual
Inspection
Per Qai-3 Charge Checked By Date
HPSH ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
070.750-IOM (JUN 12)
Page 5


PREPARING COMPRESSOR FOR STORAGE
 



 

          
     


  
 

MAINTAINING COMPRESSOR
 

 


         

 
        

Contact Johnson Controls-Frick Service with any ques-
tions regarding long term storage.
DESCRIPTION
HPSH COMPRESSOR
       


    

 





      



 



         

  








        





Compressor rotation is clockwise
when facing the compressor drive
shaft. The compressor should never
be operated in reverse rotation, as damage will result.



COMPRESSOR LUBRICATION SYSTEM








  



CAPACITY REGULATION AND FIXED VOLUME RATIO VI



        
  

         
 




HPSH ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
070.750-IOM (JUN 12)
Page 6
OIL PUMP (OPTIONAL)

(CoolWare will provide a warning when the
oil differential pressure is too low)
         




        

CONSTRUCTION DETAILS
HOUSING:


ROTORS: 
       
       
        

BEARINGS: 






BALANCE PISTON:
 
    


Shaft Seal:





UNLOADING VALVE:

        
      


MOTOR MOUNT:




DESIGN LIMITS

Please also use CoolWare™ to determine the limits for a
specic application.
       

NOTES:
1. The UNISAB and Quantum panels have several layers
of control functions to secure reliable operation. De-
pending on many operating conditions, they will unload
the plug valve and reduce or increase speed to keep the
compressor running in a safe way. Only as the last resort
will they initiate an alarm and ultimately stop the com-
pressor.
2. In CO2 application using miscible oil types POE and
PAG, it is extremely critical to keep water content to the
lowest possible - down to 10 PPM is the goal. The in-
stallation must have large lter dryers with replaceable
elements that can be effectively serviced and vacuum
dried before being put back in service.
3. Maximum discharge temperature depends on oil type
used. Please see Frick oil data for more detail.
Condition Min Max
  
  
  
  
  
  
  
  
 
  
  
  
 
  
  
 
  
  
DESIGN LIMITS (OPERATING)
HPSH ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
070.750-IOM (JUN 12)
Page 7
4. At lower CR, the plug valve will unload. UNISAB and
Quantum have further advanced logics and may unload
plug valve at higher CR to maintain optimum efciency.
Figure 4 - Requirement for Viscosity as function of speed
VIBRATION AND SOUND DATA






Male rotor, # of lobes 6 Main Exciting
Frequencies (Hz)
Female rotor, # of lobes 8
Driver Speed, rpm Typical
Exiting Member / Event 3000 3600 4200 6000
    
    
    
    
    
    





        




HPSH ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
070.750-IOM (JUN 12)
Page 8
INSTALLATION




        

         
      


Figure 5 - HPSH shown with motor mount (tunnel).
OUTLINE DIMENSIONS
      
     



HOLDING CHARGE AND STORAGE




          




Holding-charge shipping gauges (if
mounted) are rated for 2.1 bar (30
psig) and are for checking the ship-
ping 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.
RIGGING AND HANDLING




Figure 6 - Lifting Rings
FOUNDATION

          
    
Allow proper spacing for servicing
(see Dimensional Outline Drawing).

          


         
      


HPSH ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
070.750-IOM (JUN 12)
Page 9

        



       


        



          






    
CUSTOMER CONNECTIONS


 
 
 
  
      








COMPRESSOR OIL
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 will select a specic Frick oil for the refriger-
ant 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.
NOTE: 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 refrig-
erant, operating pressures, or temperatures, refer to
Frick Oil publication E160-802 SPC.
OIL PUMP






If oil pressure exceeds 55 PSI above
compressor discharge it could cause
catastrophic compressor failure due
to male axial bearing failure. See CoolWare for your ap-
plication’s requirements.
COMPRESSOR ROTATION IS CLOCKWISE WHEN FACING
THE END OF THE COMPRESSOR SHAFT.


MOTOR MOUNTING USING TUNNEL
 
 

         

ALLOWABLE FLANGE LOADS - METRIC
NOZ. MOMENTS (Nm) LOAD (N)
SIZE AXIAL VERT. LAT. AXIAL VERT. LAT.
ND (In.) MRMCMLP VCVL
1 34 34 34 222 222 222
1.25 34 34 34 222 222 222
1.5 68 54 54 445 334 334
2 136 95 95 667 556 556
3 339 237 237 1001 1112 1112
4 542 271 271 1334 1779 1779
5 576 542 542 1779 2002 2002
6 1356 1017 1017 2891 2891 2891
8 2034 1356 1356 6672 4003 4003
10 2034 1627 1627 6672 5338 5338
14 2712 2440 2440 7562 8896 8896
ALLOWABLE FLANGE LOADS - ENGLISH
NOZ. MOMENTS (ft-lbf) LOAD (lbf)
SIZE AXIAL VERT. LAT. AXIAL VERT. LAT.
NPS MRMCMLP VCVL
1 25 25 25 50 50 50
1.25 25 25 25 50 50 50
1.5 50 40 40 100 75 75
2 100 70 70 150 125 125
3 250 175 175 225 250 250
4 400 200 200 300 400 400
5 425 400 400 400 450 450
6 1000 750 750 650 650 650
8 1500 1000 1000 1500 900 900
10 1500 1200 1200 1500 1200 1200
14 2000 1800 1800 1700 2000 2000
HPSH ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
070.750-IOM (JUN 12)
Page 10
 


Figure 7 - Motor Mounting
 



 

  


 

Figure 8 - Welding to Motor Support Bracket
 

 






MOTOR MOUNTING (FOOT MOUNTED ONLY)
 


          

 


           
        

       

COMPRESSOR/MOTOR COUPLING REQUIREMENTS.













         

 
         

 


        
      


COUPLING ALIGNMENT REQUIREMENTS
(FOOT MOUNTED ONLY)
       
         





Maximum radial runout is .004” total indicator reading.
Maximum axial runout is .004” total indicator reading.


HPSH ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
070.750-IOM (JUN 12)
Page 11








OIL HEATER(S)



OIL FILTER(S)
       

         
b
       

OIL COOLING REQUIREMENTS








       





         
        
  










       
 

  

 

 








    

       

  




DEHYDRATION / EVACUATION TEST
 



       


ELECTRICAL INSTALLATION






Compressor Suction
B
P
A
T
Compressor Oil
(Discharge PSIG)
Compressor
Suction
b
Figure 8 - Schematic of unloader plug and solenoid
valve, shown loaded, solenoid “b” energized
HPSH ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
070.750-IOM (JUN 12)
Page 12
OPERATION
OPERATION AND START-UP INSTRUCTIONS


       




        

THE FOLLOWING SUBSECTIONS MUST BE READ AND
UNDERSTOOD BEFORE ATTEMPTING TO START OR OP-
ERATE THE UNIT.
LOW AMBIENT OPERATION







INITIAL START-UP


INITIAL START-UP PROCEDURE



        

 


       


 
          


      

NORMAL START-UP PROCEDURE
       

 
 




CONTROL SYSTEM
       



HPSH ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
070.750-IOM (JUN 12)
Page 13
MAINTENANCE
GENERAL INFORMATION

    

THIS SECTION MUST BE READ AND UNDERSTOOD BE-
FORE ATTEMPTING TO PERFORM ANY MAINTENANCE
OR SERVICE TO THE UNIT.
NORMAL MAINTENANCE OPERATIONS



     






GENERAL MAINTENANCE
        
      

  
       



      
        

 




 
        


         
 

 


         
        

        
         



     



CHANGING OIL
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.



 
 
 
      

 

 
         

 
 







RECOMMENDED MAINTENANCE PROGRAM


       
       
        



        

VIBRATION ANALYSIS




HPSH ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
070.750-IOM (JUN 12)
Page 14
   

 

 
         

        
         

OIL QUALITY AND ANALYSIS
   




 

      


 

OPERATING LOG

         

      





TROUBLESHOOTING GUIDE

         




ABNORMAL OPERATION
ANALYSIS AND CORRECTION
        

 
 
 
 




 
       

 
 
 
 

 
 
 







         


         








        

HPSH ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
070.750-IOM (JUN 12)
Page 15
MAINTENANCE SCHEDULE
This schedule should be followed to ensure trouble-free operation of the compressor unit.
FREQUENCY OR HOURS OF OPERATION (MAXIMUM)
MAINTENANCE
200
1000
5000
8000
10,000
15,000
20,000
25,000
30,000
35,000
40,000
45,000
50,000
55,000
60,000
65,000
70,000
75,000
80,000
85,000
90,000
95,000
Change Oil As Directed By Oil Analysis
Oil Analysis nEvery 6 Months
Replace Oil Filters 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
Vibration Analysis nEvery 6 Months, More Frequently If Levels Increase
Replace Shaft Seal When Leak Rate Exceeds 7 - 8 Drops Per Minute
TROUBLESHOOTING THE HPSH COMPRESSOR
 
NOTE: Unless the Service Technician has been certied
by Johnson Controls–Frick to rebuild our compressors,
troubleshooting the compressor is limited to identifying
the probable cause. If a mechanical problem is suspect-
ed, contact Johnson Controls–Frick Service. DO NOT AT-
TEMPT TO DISASSEMBLE COMPRESSOR.
BARE COMPRESSOR REPLACEMENT


 

 

 
 


    


 

 
 

 



SHUTDOWN DUE TO IMPROPER OIL PRESSURE (HIGH
STAGE AND BOOSTER)
The compressor must not operate with incorrect oil
pressure.

RECOMMENDED SPARE PARTS - CURRENT DESIGN
DESCRIPTION HPSH 1510
Complete Bearing Kit 534C2311G01
O-ring Kit 534B1335H01
Shaft Seal Kit 534C2310G01
Balance Piston Kit 534A1123G01
Compressor Tool Kit 534C2307G01
NOTE: Refer to the Service Parts List manual, 070.750-SPL1_HPSH, for detailed parts list.
HPSH ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
070.750-IOM (JUN 12)
Page 16
TROUBLESHOOTING THE OIL PUMP AND SYSTEM
 



Check that service valves are open.
Check PSID across lters.
Clean.
Readjust or repair.
Repair or replace.



            
Readjust both valves.
 Clean.
Repair or replace.


Set main oil injection and oil pressure for maximum head pressure
condition.


Replace.
Allow oil to warm up and check again.
Open valves fully.
HPSH ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
070.750-IOM (JUN 12)
Page 17
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
HPSH ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
070.750-IOM (JUN 12)
Page 18
Date:  
  
   



 




  



VIBRATION DATA SHEET
SUCTION DISCHARGE OIL SEPARATOR Slide Valve Position %
Press # Press # Press # Temp °F Vi Ratio
Temp °F Temp °F Temp °F F.L.A. %
Compressor Inboard
(Coupling End)
Vertical Direction
____.____ IPS Overall
Compressor Inboard
(Coupling End Male)
Axial Direction
____.____ IPS Overall
Motor Inboard (Coupled End)
Horizontal _______ . ______ IPS Overall
Vertical _______ . ______ IPS Overall
Axial _______ . ______ IPS Overall
Compressor Outboard
(Nondrive End)


Compressor Inboard
(Coupling End Female)


Motor Outboard (Noncoupled End)
  
 
 
 
 
Final Hot Alignment
Total Thickness of Shims Added
Face Rim
HPSH ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
070.750-IOM (JUN 12)
Page 19
PID EXAMPLE FOR A HEAT PUMP PACKAGE (PRELIMINARY)
HPSH ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
070.750-IOM (JUN 12)
Page 20
PID EXAMPLE FOR A CO2 CASCADE COMPRESSOR PACKAGE (PRELIMINARY)
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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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