070.750-iom hpsh 1510 rotary screw compressor

Form 070.750-IOM (MAY 2018) INSTALLATION - OPERATION - MAINTENANCEFile: SERVICE MANUAL - Section 070Replaces: 070.750-IOM (MAY 2014)Dist: 3, 3a, 3b, 3c

HPSHROTARY SCREW COMPRESSOR

MODEL 1510

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.

Please check www.johnsoncontrols.com/frick for the latest version of this publication.

070.750-IOM (MAY 2018)

HPSH ROTARY SCREW COMPRESSORINSTALLATION - OPERATION - MAINTENANCE

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.Indicates a potentially hazardous situation or practice which, if not avoided, will result in death or serious injury.

SAFETY PRECAUTION DEFINITIONS

Indicates a potentially hazardous situation or practice which, if not avoided, will result in damage to equipment and/or minor injury.

Indicates an operating procedure, practice, etc., or portion thereof which is essential to highlight.

Contents

GENERAL INFORMATION

PREFACE .......................................................................... 3DESIGN LIMITATIONS ........................................................ 3JOB INSPECTION .............................................................. 3STANDARD BARE COMPRESSOR ...................................... 3TRANSIT DAMAGE CLAIMS .............................................. 3COMPRESSOR IDENTIFICATION ........................................ 3LONG TERM STORAGE ...................................................... 4

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

DESCRIPTION .................................................................... 5HPSH COMPRESSOR .................................................... 5COMPRESSOR LUBRICATION SYSTEM ......................... 5CAPACITY REGULATION AND FIXED VOLUME RATIO VI 5OIL PUMP (OPTIONAL) .................................................. 6

CONSTRUCTION DETAILS .................................................. 6DESIGN LIMITS .............................................................. 6

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

INSTALLATION

OUTLINE DIMENSIONS .................................................. 7HOLDING CHARGE AND STORAGE..................................... 7RIGGING AND HANDLING ................................................... 7FOUNDATION ................................................................... 7CUSTOMER CONNECTIONS ............................................... 8

VI AND EFFECTIVE ORIFICE SIZES: ................................ 8COMPRESSOR OIL ............................................................. 9OIL PUMP .......................................................................... 9MOTOR MOUNTING USING TUNNEL .................................. 9MOTOR MOUNTING (FOOT MOUNTED ONLY) ................... 9

COMPRESSOR/MOTOR COUPLING REQUIREMENTS ...... 9COUPLING ALIGNMENT REQUIREMENTS (FOOT MOUNTED ONLY) ............................................. 10

OIL HEATERS - HEATING WIRES ..................................... 10OIL FILTERS - HEAT WIRE - INSULATION ........................ 10OIL COOLING REQUIREMENTS......................................... 10DEHYDRATION / EVACUATION TEST .................................11ELECTRICAL INSTALLATION ..............................................11

OPERATION

OPERATION AND START-UP INSTRUCTIONS ...................12LOW AMBIENT OPERATION .............................................12INITIAL START-UP ...........................................................12

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

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

MAINTENANCE

GENERAL INFORMATION .................................................13NORMAL MAINTENANCE OPERATIONS ...........................13GENERAL MAINTENANCE ................................................13CHANGING OIL .................................................................13MAINTENANCE SCHEDULE .............................................. 14RECOMMENDED SPARE PARTS - CURRENT DESIGN ....... 14RECOMMENDED MAINTENANCE PROGRAM ....................15

VIBRATION ANALYSIS .................................................15OIL QUALITY AND ANALYSIS ......................................15OPERATING LOG .........................................................15

TROUBLESHOOTING GUIDE .............................................15ABNORMAL OPERATION ANALYSIS AND CORRECTION ..........................................15TROUBLESHOOTING THE HPSH COMPRESSOR ................16

BARE COMPRESSOR REPLACEMENT ...........................16SHUTDOWN DUE TO IMPROPER OIL PRESSURE (HIGH STAGE AND BOOSTER) ...............................................16

ALIGNMENT LOG – FOR ELECTRIC MOTOR DRIVER .........17COMPRESSOR PORT LOCATIONS - HPSH 1510 ................19

INDEX

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

WARNING

CAUTION

DANGER

NOTICE

070.750-IOM (MAY 2018)


THE INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO CHANGE

WITHOUT NOTICE

GENERAL INFORMATIONPREFACE

This manual has been prepared to acquaint the owner and serviceman with the INSTALLATION, OPERATION, and MAINTENANCE procedures as recommended by Johnson Controls-Frick for HPSH Rotary Screw Compressors.

NOTICEFrick screw compressor repair must only be done by skilled mechanics who have completed training at Frick screw compressor school.

It is most important that these compressors be properly applied to an adequately controlled refrigerant or gas sys-tem. Your authorized Johnson Controls-Frick representa-tive should be consulted for his expert guidance in this de-termination.

Proper performance and continued satisfaction with these units is dependent upon:

CORRECT INSTALLATION PROPER OPERATION REGULAR, SYSTEMATIC MAINTENANCE PROPER PACKAGE & SYSTEM ENGINEERING

To ensure correct installation and application, the equip-ment must be properly selected and connected to a prop-erly designed and installed system. The engineering plans, piping layouts, etc. must be detailed in accordance with the best practices and local codes, such as those outlined in ASHRAE, ASME and EN codes.

A screw compressor is a VAPOR PUMP. To be certain that it is not being subjected to pumping liquid it is necessary that controls are carefully selected and in good operating condi-tion; the piping is properly sized and traps, if necessary, are correctly arranged; the suction line has an accumulator or slugging protection; that load surges are known and provi-sions are made for control; operating cycles and stand still periods are reasonable; and that high side components are sized within system and compressor design limits.

HPSH compressors have small clearances and the com-pressor package and system must be built with a very high degree of cleanliness.

DESIGN LIMITATIONS

HPSH compressors are designed for operation within the pressure and temperature limits, which are specified by Johnson Controls-Frick and the Johnson Controls-Frick se-lection software COOLWARE. They are primarily used for compressing refrigerant gas and most hydrocarbon gasses.

If your application is for sour gas, there are special require-ments to protect the compressor. A main requirement is that discharge temperature or superheat must be met at any speed. Contact Johnson Controls-Frick Compressor En-gineering for application details.

JOB INSPECTION Immediately upon delivery examine all crates, boxes and exposed compressor and component surfaces for damage. Unpack all items and check against shipping lists for any discrepancy. Examine all items for damage in transit.

STANDARD BARE COMPRESSOR Items not included with bare compressor that are available as sales order options: Motor Mount, Connection Fittings, Coupling, Solenoid Valve for Plug Valve.

TRANSIT DAMAGE CLAIMS All claims must be made by consignee. This is an ICC re-quirement. Request immediate inspection by the agent of the carrier and be sure the proper claim forms are execut-ed. Report damage or shortage claims immediately to Johnson Controls-Frick Sales Administration Department, in Waynesboro, PA.

COMPRESSOR IDENTIFICATION Each compressor has an identification data plate, contain-ing compressor model and serial number mounted on the compressor body.

NOTICEWhen inquiring about the compressor or unit, or or-dering repair parts, provide the MODEL and SERIAL NUMBERS from the data plate. See Figure 1.

534B2722

COMPRESSOR SHAFT

CLOCKWISE ROTATION

534B2721

534B2720

534B2719

R22

COMPRESSOR OPERATES ON AND ISCOMPATIBLE WITH THE FOLLOWINGREFRIGERANTS

R290, R1270, NATURAL GAS


R50, R134a, R170, R290, R404A, R410A, R507,R513A, R600, R600A, R717, R728, R729, R744,R1150, NATURAL GAS


534C2934H01

SGXB2 4021

US2430125370500010

10241A89999999R

3600 600 41

USA

REFERENCE MATERIAL FIELD ONSHEET 1 OF PRODUCTION ORDER

REFERENCE TABLE ONSHEET 2 AND NOTE 3

REFERENCE TABLEON SHEET 2

REFERENCE TABLE ONSHEET 2 AND NOTE 2GENERATED BY SAP

ASSEMBLY PLANT LOCATION

534C2933H01

USA

US2430129999900010

10241A89999999R

100 CUMBERLAND VALLEY AVENUEWAYNESBORO, PA 17268

ROTARY SCREW COMPRESSORMODEL NO.

MAX DRIVER SPEED MAX ALLOWABLE PRESSURE

PART NO.

RPM PSIG BARG

ASSEMBLED IN

FROM FOREIGN AND DOMESTIC MATERIALS

SERIAL NO.

608706000

HPSH 1510

Figure 1 - Identification Data Plate

Rotary screw compressor serial numbers are defined by the following information:

EXAMPLE: 10240A90000015Z

PLANT DECADE MONTH YEAR GLOBAL ADDITIONALSEQ 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 configuration.

070.750-IOM (MAY 2018)


The name plates in Figure 2 show which refrigerants are compatible with the compressor as manufactured.

534B2722

COMPRESSOR SHAFT

CLOCKWISE ROTATION

534B2721

534B2720

534B2719

R22






534C2934H01

SGXB2 4021

US2430125370500010

10241A89999999R

3600 600 41

USA






534C2933H01

USA

US2430129999900010

10241A89999999R




PART NO.

RPM PSIG BARG

ASSEMBLED IN


SERIAL NO.

608706000

HPSH 1510

534B2722

COMPRESSOR SHAFT

CLOCKWISE ROTATION

534B2721

534B2720

534B2719

R22






534C2934H01

SGXB2 4021

US2430125370500010

10241A89999999R

3600 600 41

USA






534C2933H01

USA

US2430129999900010

10241A89999999R




PART NO.

RPM PSIG BARG

ASSEMBLED IN


SERIAL NO.

608706000

HPSH 1510

Figure 2 - Refrigerant Name Plates

HPSH 1510 Geometrical Swept Volume

RPM m3/h cfm2950 292.8 172.23550 352.4 207.54200 416.9 245.56000 595.6 350.8

Figure 3 - Name Plate and Vi Locations

LONG TERM STORAGE

Long term storage (6 months to 5 years) provisions are re-quired, regardless of storage environment, if start-up and/or useful operation does not occur within six (6) months of equipment shipment. Special provisions may be required for storage of less than six (6) months if the storage area is subject to unusual environment such as high humidity, large changes in temperature, dusty atmosphere, etc.

The standard Johnson Controls-Frick Warranty for an HPSH screw compressor covers 12 months from start-up or 18 months from shipment, whichever comes first. It is recom-mended that arrangements be made with the local Johnson Controls-Frick service organization (arranged through fac-tory service) regarding surveillance and maintenance dur-ing the storage period. It will be the customer’s responsibil-ity to submit a monthly report showing the condition of the unit and noting any discrepancies to the guidelines listed herein. Failure to comply with this Long Term Storage Rec-ommendation may void the warranty.

Long term storage of equipment may lead to the deteriora-tion of components over the period of time. Synthetic com-ponents in the compressor may deteriorate over time even

Compressor Long Term Storage Log

Model Serial No.Compressor, Motor Oil Pump & Refrigerant Pump Shaft Rotation

1½ Turn

RotorHousingCharge

ChargeAdded

VisualInspection

ChargeChecked

ByDate

070.750-IOM (MAY 2018)


if they are kept flooded with oil. A warm and dry environ-ment is essential to minimize environmental and corrosion damage.

The following guidelines must be followed to maintain the SCREW COMPRESSOR WARRANTY.

PREPARING COMPRESSOR FOR STORAGE

1. Evacuate compressor to remove moisture. An evacua-tion line is to be connected to the one Schrader valve provided with the compressor. The valve is connected to the SD-1 port on the rotor housing.

2. Break vacuum with dry nitrogen and bring pressure to zero psig.

3. Pump oil into the same ports mentioned in step 1. Johnson Controls-Frick recommends break-in oil P/N 111Q0831809 for storage purposes. The amounts of oil needed per compressor are:

157 mm – 2.8 Gal

4. After compressor is oil charged, pressurize compressor to 1.0 bar (15 psig) with nitrogen.

MAINTAINING COMPRESSOR (IN STORAGE)

1. Ensure that the 0.3 – 1.0 bar (5-15 psig) nitrogen charge is maintained with 1.0 bar (15 psig ) preferred.

2. Rotate the male rotor shaft every two weeks. Mark the shaft to ensure the rotor does not return to the original position.

3. The compressor must be stored inside a dry building environment.

4. Grease the male rotor shaft to prevent rust.

5. Record all information in a “Compressor Long Term Storage Log.”

Contact Johnson Controls-Frick Service with any ques-tions regarding long term storage.

DESCRIPTIONHPSH COMPRESSOR

The Frick HPSH rotary screw compressor utilizes mating asymmetrical profile helical rotors to provide a continuous flow of vapor and is designed for high-pressure applica-tions. The compressor incorporates the following features:

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

2. No slide valve for capacity regulation - just a simple ro-bust capacity control plug valve to reduce starting torque requirement and provide overload protection. Plug valve is operated with a 2-position solenoid valve. See Fig. 9.

3. Fixed volume Vi ratio: 1.4, 1.7, 2.2, 2.9 and 4.0 are avail-able as standard. No moveable slide stop valve.

4. High capacity roller bearings to carry radial loads at both the inlet and outlet ends of the compressor.

5. Heavy duty angular contact ball bearings to carry axial loads on the rotors.

6. Balance piston located in the inlet end of the male rotor reduces axial loads on the male axial bearings.

7. Housings are designed for 67 bar (970 psig) working pres-sure when flanges are made from the higher quality steel. Standard flange design allows for 60 bar (870 psig).

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

9. Liquid injection port at 1.30 Vi.

10. Two main oil injection ports: Use SM-2 for Vi 1.4, 1.7 and 2.2 and use SM-1 for Vi 2.9 and 4.0 to meet application requirements. (SM-2 at Vi = 1.05 & SM-1 at Vi = 1.3)

11. All bearing and control oil vented to lower pressure lo-cations inside compressor allowing operation without an oil pump for some applications.

12. Shaft seal with a seal ring made of silicon carbide mated against a similar material, where carbon and graphite add-ed to the matrix provide long life.

Shaft seal housing designed to maintain operating pressure on seal well below discharge pressure for increased seal life.

13. Oil injected into the rotor threads to maintain good vol-umetric and adiabatic efficiency.

14. Shaft rotation clockwise facing compressor drive end, suitable for all types of drives. SEE WARNING.

WARNINGCompressor rotation is clockwise when facing the compressor drive shaft. The compressor should never be operated in reverse rotation, as damage will result.

15. Suction flange is ANSI B16.1 Class 400. Discharge flange is ANSI B16.1 Class 600.

16. Integral suction strainer.

COMPRESSOR LUBRICATION SYSTEM

The lubrication system on a HPSH screw compressor unit performs several functions:

1. Provides lubrication to bearings, seal and rotors.

2. Provides a cushion between the rotors to minimize noise and vibrations.

3. Helps keep the compressor at the proper temperature and prevents overheating.

4. Provides oil supply to hydraulically operate the plug valve on and off.

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

6. Provides an oil seal between the rotors to prevent rotor contact or gas bypassing.

7. Oil flow will often need to be regulated by an automatic control valve.

CAPACITY REGULATION AND FIXED VOLUME RATIO VI

The design without a moveable slide valve under the rotors provides a very robust design. However, the fixed volume ratio must be selected close to the ideal value to provide reliable and efficient operation. The plug valve is provided to allow start-up and safe operation at low differential.

Capacity regulation is all with variable speed - the plug valve can be used, but the effect is limited to between 10% and 15%.

070.750-IOM (MAY 2018)


OIL PUMP (OPTIONAL)

A demand oil pump is required for low differential pressure applications (CoolWare will provide a warning when the oil differential pressure is too low). Oil being supplied to the compressor from the oil separator is at system dis-charge pressure. Within the compressor, oil porting to all parts of the compressor is vented back to a location in the compressor’s body that is at a lower pressure than com-pressor discharge pressure. All oil entering the compressor is moved by the compressor rotors, out the compressor outlet, and back to the system oil separator.

CONSTRUCTION DETAILSHOUSING: 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 profile. The six-lobed male rotor is directly connected to the driver. The eight-lobed female ro-tor is driven by the male on a thin oil film.

BEARINGS: Antifriction bearings with L10 rated life in excess of 50,000 hours (using Frick SuperFilters™) at design condi-tions are used for reduced frictional horsepower and supe-rior rotor positioning, resulting in reduced power consump-tion. Cylindrical roller bearings are provided to handle the radial loads and the thrust loads are absorbed by preloaded angular contact ball bearings (ACBB).

BALANCE PISTON: The male rotor is equipped with a bal-ance piston to reduce load on the male axial bearing. Oil pressure provides the force and therefore shall be within limits of discharge pressure, 1.5 bar (22 psi) below and 3.3 bar (50 psi) above discharge pressure.

Shaft Seal: The compressor shaft seal is a single-face bal-anced type with a spring-loaded, silicon carbide stationary hardened surface riding against a rotating seat. Carbon and graphite added provide self lubrication. During operation it is vented to low pressure to provide extended life.

UNLOADING VALVE: Reduced current (power) requirement at start-up is achieved by use of a plug valve. The plug valve reduces torque by approximately 10%. Also, the plug valve provides overload protection in more situations: power overload, low oil pressure, low compression ratio, and high internal compression.

MOTOR MOUNT: The HPSH series is designed with a drive-end flange that mates with a cast iron motor mount (avail-able as a sales order option). The motor mount is precision machined so that it ensures proper alignment of the com-pressor and motor coupling.

DESIGN LIMITS

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

NOTES FOR DESIGN LIMITS:

(1) The HPSH 1510 compressor has minimum viscosity requirements as shown in Fig. 4 to maintain proper bearing lubrication. Consideration must be given to viscosity changes due to refrigerant or gas dilution.

Figure 4 - Requirement for Viscosity as function of speed

(2) Maximum discharge temperature depends on oil type used - normally 150°C (300°F). Please see Frick oil data for more detail.

(3) In applications using miscible oil types POE and PAG, it is extremely critical to keep water content to the lowest possible to avoid corrosion and formation of acids. The installation must have large filter dryers with replaceable elements that can be effectively serviced and vacuum dried before being put back in service.

(4) If the temperature difference becomes greater than or equal to 140°C (250°F) between suction and discharge - the plug valve must be unloaded immediately.

(5) For heat pumps, it is often practical to select an oil temperature that equals condensing temperature.

VIBRATION AND SOUND DATA

The rotors balance grade is G 2.5 according to ISO 1940. The male rotor drive end has a keyway and has been bal-anced with a half key in the keyway, to be considered as a round, full body shaft.

Reference Frick publication 070.902-IB for vibration sever-ity limits.

Male rotor, # of lobes 6 Main Exciting Frequencies (Hz)Female rotor, # of lobes 8

Driver Speed, rpm TypicalExiting Member / Event 3000 3600 4200 6000Male rotor, rotational, 1st order 50 60 72 100Male rotor, rotational, 2nd order 100 120 144 200Female rotor, rotational, 1st 37.5 45 54 75Female rotor, rotational, 2nd 75 90 108 150Discharge gas pulsation, 1st 300 360 432 600Discharge gas pulsation, 2nd 600 720 864 1200

Vibration level on the package can be higher, especially on piping elements and when the natural frequency of an ele-ment falls together with one of the exciting frequencies. If the vibration level gets too high, a skip frequency function in the control system shall be activated. When activated, the motor will run through the critical speed very fast, not causing any continuously high vibration.

070.750-IOM (MAY 2018)


INSTALLATION

CAUTIONTHIS EQUIPMENT HAS BEEN PRESSURIZED WITH NITROGEN GAS. TEMPORARY VALVES & GAUGES

HAVE BEEN INSTALLED.

1. RELIEVE PRESSURE PRIOR TO OPENING LINES OR MAKING FIELD CONNECTIONS.

2. REMOVE CHARGING VALVES OR GAUGES PRIOR TO PRESSURIZING SYSTEM.

3. REFER TO INSTALLATION OPERATION AND MAIN-TENANCE MANUAL FOR ADDITIONAL INFORMA-TION.

ESCAPING GAS MAY CAUSE INJURY

RIGGING AND HANDLING

The compressor can be moved with rigging, using a crane or forklift, by hooking into the two lifting rings at each end of the main housings. The compressor lifting rings shall only be used to lift the compressor itself.

Figure 6 - Lifting Rings

FOUNDATION

Each HPSH Rotary Screw Compressor is shipped mounted on a wooden skid, which must be removed prior to unit installation.

CAUTIONAllow proper spacing for servicing (see Dimensional Outline Drawing).

The first requirement of the compressor foundation is that it must be able to support the weight. The HPSH 1510 weighs approximately 367 kg (810 lb).

Screw compressors are capable of converting large quanti-ties of shaft power into gas compression in a relatively small space. The compression process creates relatively high frequency vibrations that require sufficient mass in the base to effectively dampen them.

HPSH compressors are primarily designed for connecting to an electric drive motor using a tunnel mount. If the applica-tion requires it, the compressor can also be driven with a foot mounted motor. The tunnel mount (see Figure 5) en-sures proper alignment of the compressor and motor so that the shaft seal and coupling will operate properly.

The rotor and bearing design set limitations must not be exceeded (See CoolWare). Refer to Johnson Controls-Frick Compressor Control Panel instruction 090.040-O for addi-tional information on setpoint limits and CES 1400 for prop-er engineering.

Figure 5 - HPSH shown with motor mount (tunnel).

OUTLINE DIMENSIONS

Complete dimensions and connection information can be found on the outline drawing which can be requested by contacting Johnson Controls-Frick Sales. Port locations are shown on the drawings at the back of this manual. See Ta-ble of Contents.

HOLDING CHARGE AND STORAGE

Every HPSH compressor is pressure and leak tested at the Johnson Controls – Frick Factory and then thoroughly evac-uated and charged with dry nitrogen to ensure its integrity during shipping and short term storage prior to installation.

All compressors must be kept in a clean, dry location to prevent corrosion damage. Compressors that will be stored for more than two months must have their nitrogen charge checked periodically (see pages in GENERAL INFORMATION for complete instructions).

WARNINGHolding-charge shipping gauges (if mounted) are rated for 2.1 bar (30 psig) and are for checking the shipping charge only. They must be removed before pressure testing and operating the system. Failure to remove these gauges may result in catastrophic failure of the gauge resulting in serious injury or death.

Access valves are bronze and they must be replaced with steel plugs when package is assembled.

070.750-IOM (MAY 2018)


The best insurance for a trouble-free installation is to firm-ly anchor the compressor to a suitable foundation using proper bolting and by preventing piping stress from being imposed on the compressor. Once the compressor is rigged into place, its feet must be shimmed to level it. There must be absolutely no stresse transferred to the compressor body due to bolting of the feet and flanges.

The compressor motor mount is not designed to carry the unsupported weight of the motor. The full motor weight must be supported using the motor lifting point during the motor installation process. After the necessary bracket to support the motor has been welded into place on the pack-age and the rear motor feet and the motor mount have been bolted into place, the weight of the motor can rest on the support bracket and the motor mount.

In any screw compressor installation, suction and discharge lines should be supported in pipe hangers (preferably with-in 2 ft. of vertical pipe run) so that the lines won’t move if disconnected from the compressor. See table for Allowable Flange Loads.

CUSTOMER CONNECTIONSAs a minimum you must connect to the following locations in addition to suction and discharge.

SB-2 Inlet Bearings and Balance Piston

SB-3 Shaft seal, outlet end bearings, and unloader plug

SM-2 or SM-1 Main oil injection (See CoolWare for port required by operating conditions)

VI AND EFFECTIVE ORIFICE SIZES:

SM-2: Vi = 1.4, 1.7 and 2.2.402”, 1/2” x 14 NPTF, No orifice installed, Max orifice .386”

SM-1: Vi = 2.9 and 4.0.437”, 1/4” x 18 NPTF, No orifice installed, Max. orifice .25”

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

Other connections are available for instrumentation and service as noted on the Dimensional Outline drawing. The electrical connections for the unloader plug solenoid valve coils must be connected to your control system.

SECTION A-A SECTION B-B

A

A B

B

SM-2SM-1SECTION A-A SECTION B-B

A

A B

B

SM-2SM-1

SECTION A-A SECTION B-B

A

A B

B

SM-2SM-1

Figure 7 - SM-2 and SM-1 Port Cutaways

070.750-IOM (MAY 2018)


The oil supply system for the compressor must be designed for a total pressure drop of no more than 1 bar (15 psi) with a new oil filter element. This is critical for the proper op-eration of the balance piston which is used to ensure the life of the male axial bearing.

A regulating valve must be installed in the main oil injection line and at start-up be tuned in to the desired discharge temperature. Some applications may use a manual valve, others will require a motor-operated valve.

COMPRESSOR OIL

WARNINGDO NOT MIX OILS of different brands, manufacturers, or types. Mixing of oils can cause excessive oil foam-ing, nuisance oil level cutouts, oil pressure loss, gas or oil leakage and catastrophic compressor failure. Cool-Ware will select a specific Frick oil for the refrigerant being used. Depending on the application, a different oil can be selected provided it is of the proper viscos-ity and is compatible with the refrigerant and com-pressor elastomers.

NOTICEThe Frick oil charge shipped with the unit is the best suited lubricant for the conditions specified at the time of purchase. If there is any doubt due to the re-frigerant, operating pressures, or temperatures, refer to Frick Oil publication 160.802-SPC.

OIL PUMPIf your HPSH compressor application requires an oil pump, it is recommended that a strainer be mounted upstream to protect it. Frick supplied pumps are a positive displacement gear type that must have a safety relief valve to ensure the oil pressure will not be more than 50 psi above compressor discharge pressure for all models.

CAUTIONIf oil pressure exceeds 55 PSI above compressor dis-charge it could cause catastrophic compressor failure due to male axial bearing failure. See CoolWare for your application’s requirements.

MOTOR MOUNTING USING TUNNEL

For specific instruction about motor mounting using a tun-nel use publication 070.660-SM - Bare Rotary Screw Com-pressor Replacement.

NOTICERefer to the Bare Rotary Screw Compressor Replac-ment manual, Frick publication 070.660-SM for motor mounting instructions.

MOTOR MOUNTING (FOOT MOUNTED ONLY)

1. Thoroughly clean the motor feet and mounting pads of grease, burrs, and other foreign matter to ensure firm seat-ing of the motor.

2. Attach the motor to the base using bolts and motor raising blocks, if required.

3. After the motor has been set, check to see that the shafts are properly spaced for the coupling being used. Check the appropriate Dimensional Outline drawing for the minimum clearance required between the shaft ends to change the shaft seal.

COMPRESSOR/MOTOR COUPLING REQUIREMENTS

HPSH compressors are arranged for direct motor drive and require a flexible drive coupling to connect the compressor to the motor. Coupling must be suitable for variable speed.

Compressor drive shaft end has a keyway and is balanced with a half key mounted. That means the coupling must also be balanced with a half key mounted in the keyway.

If you are using the Johnson Controls–Frick motor mount, the mount is machined to ensure that motor-to-compres-sor alignment is within specification (see the section “MO-TOR MOUNTING USING TUNNEL” for mounting details).

If you are using a foot mounted motor, it is essential that the coupling be properly aligned to ensure proper bearing and seal performance.

1. Coupling must be selected and installed so that it doesn’t transmit any axial load to the compressor shaft.

ALLOWABLE FLANGE LOADS

NOZ. SIZENPS

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

AXIAL - MR VERT. - MC LAT. - ML AXIAL - P VERT. - VC LAT. - VL

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

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

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

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

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

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

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

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

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

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

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

070.750-IOM (MAY 2018)


2. Set up the minimum distance between compressor shaft and motor shaft to allow for seal removal (see Outline drawings).

3. Coupling must be able to take up any misalignment be-tween motor and compressor. It is critical to the life of the shaft seal that misalignment is kept to the minimum possible value. Be sure to follow the coupling manufacturer’s guide-lines for checking and correcting any misalignment. See the next section for Johnson Control–Frick’s requirements.

COUPLING ALIGNMENT REQUIREMENTS (FOOT MOUNTED ONLY)

Coupling alignment must be performed prior to start-up. After the compressor has been installed on the job site, alignment must be checked again and if necessary correct-ed prior to start-up. After a few hours operation, the align-ment must be checked while the package is still hot. Cor-rect hot alignment is critical to ensure the life of the shaft seal and compressor bearings.

Maximum radial runout is .004” total indicator reading.Maximum axial runout is .004” total indicator reading.

A dial indicator or another appropriate measuring device is to be used to determine the Total Indicator Runout.

Indicator bracket sag must be checked as all brackets have some flexibility. The best way to measure this is to attach the dial indicator and bracket on a pipe at the coupling span distance. Zero the indicator in the 12:00 position, and ro-tate the pipe so the indicator is in the 6:00 position. The reading on the indicator in the 6:00 position is the bracket sag. This value must be included in the dial indicator read-ings when affixed to the coupling for an accurate alignment.

OIL HEATERS - HEATING WIRES Your package must be equipped with oil heaters that provide sufficient heat to prevent condensation from occurring dur-ing startup and shutdown cycles. Also, sufficient heat must be provided to ensure proper oil viscosity at compressor start-up.

OIL FILTERS - HEAT WIRE - INSULATIONUse of filter elements other than Johnson Controls-Frick must be approved in writing by Johnson Controls-Frick En-gineering or a warranty claim may be denied. Typical oil filter specification b5 = 75 according to ISO 4572 is required to obtain the recommended oil cleanliness class 16/14/11 according to ISO 4406.

OIL COOLING REQUIREMENTSCompressor oil needs to be cooled to control the discharge temperature, maintain proper oil viscosity, and to preserve the life of the oil. The discharge temperature depends on application and operation condition (see CoolWare). For a CO2 compressor, it is typically about 60°C (140°F). For an ammonia heat pump, it can be 120°C (250°F) or higher.

There are applications that it is normal to have discharge temperatures as high as 120°C (250°F). An ammonia heat pump is one example. The higher discharge temperature permits higher process fluid temperatures to be achieved.

Another application that typically requires higher discharge temperatures as high as 120°C (250°F) is natural gas gath-ering at the wellhead. Moisture is normally present in the gas and it is imperative that the discharge temperature be at least 17°C (30°F) higher than the discharge dew point temperature for the gas.

NOTICEThe discharge temperature requirement is at any loading and capacity - ANY SPEED, NOT ONLY AT FULL LOAD.

Run CoolWare with the “Water Saturated” block checked to get the discharge dew point temperature for your applica-tion. Oil temperatures as high as 130°C (266°F) can be used to achieve the necessary discharge temperature to prevent moisture from condensing in the oil separator. Contact Johnson Controls–Frick for additional information for natu-ral gas compression.

The main oil injection line that is connected to port SM-1 or SM-2 must have a regulating valve to permit adjustment of the oil flow to maintain the desired discharge temperature at all times. If a 130°C (266°F) temperature is required, you must adjust to that at maximum load and speed. At lower speed you may have a motor-operated valve to maintain the temperature. A nonreturn valve may also be needed in order to prevent gas from flowing backward into the oil system under start-up and transition of operating condi-tions.

The regulating valve may need to have a motor so the ac-tual opening/flow can be controlled by the control panel. This is often a needed for heat pumps where a certain ca-pacity, water temperature, and efficiency is expected. It may also be a requirement when the speed turndown is significant e.g. from 6000 rpm to 1000 rpm as the relative oil flow may get too high at the lower speed range. Consult Coolware and the factory.

When considering minimum supply oil temperature, the use of a thermostatic three-way bypass mixing valve is not rec-ommended.

WARNINGFor high temperature applications, consult factory. Some of the 3-way thermostatic valves will not work at high temperatures and damage to thermostatic mixing valves can occur.

The valve will provide warm oil to the compressor quickly, reducing the pressure drop caused by cold, viscous oil. This ensures proper oil flow and temperature over the full range of operating conditions.

070.750-IOM (MAY 2018)


DEHYDRATION / EVACUATION TEST

Evacuate the system to 1000 microns. Valve off the vacuum pump and hold vacuum for one hour.

Pass – Vacuum cannot rise more than 500 microns during one hour hold period.

Fail – Vacuum rise is more than 500 microns during one hour hold period. Identify and repair any system leaks. Re-peat vacuum test until requirements are met.

ELECTRICAL INSTALLATION

The only electrical connection to be made to the compres-sor is for the 2-position hydraulic valve controlling the un-loader plug. (Solenoid valve not included)

Solenoid “b” must be electrically connected.

To load, energize solenoid “b”

To unload, de-energize solenoid “b”

Compressor Suction

B

P

A

T

Compressor Oil(Discharge PSIG)

CompressorSuction

b

Figure 9 - Schematic of unloader plug and solenoid valve, shown loaded, solenoid “b” energized

070.750-IOM (MAY 2018)


OPERATIONINITIAL START-UP

Prior to the start-up, the prestart check must be accom-plished. Refer to the compressor package IOM.

INITIAL START-UP PROCEDURE

Having performed the prestart check, the compressor unit is ready for start-up. In low ambient conditions, have oil heaters and heating wires on for 24 hours prior to start-up. It is important that an adequate gas load be available to load test the unit at normal operating conditions. The fol-lowing points should be kept in mind during initial start-up.

1. For proper and safe operation, the compressor must be run at the proper speed and discharge pressure. At any speed, exceeding design conditions creates a potential haz-ard.

2. Immediately after start-up, adjust oil cooling system and again after 1 to 3 hours when operating condition are within expected parameters.

3. Pull and clean suction strainer after 24 hours of opera-tion. If it is excessively dirty, repeat every 24 hours until system is clean. Otherwise, follow the normal maintenance schedule.

4. Perform vibration analysis if preventive maintenance desired.

NORMAL START-UP PROCEDURE

1. Confirm system conditions permit starting the com-pressor.

NOTICEAmbient temperatures need to be high enough to pre-vent excessive condensing; otherwise, initiate oil heaters and heat tracing 24 hours before start-up.

2. Start.

3. Observe the compressor unit for mechanical tightness of the external piping, bolts and valves. Ensure that the ma-chine has no oil and vapor leaks. If any of these occur, shut down the compressor and correct the problem as neces-sary using good safety precautions.

CONTROL SYSTEM

The HPSH compressor and package requires a dedicated control system For details on operation of Johnson Controls control systems, refer to the respective IOM manuals.

OPERATION AND START-UP INSTRUCTIONS

The Frick HPSH Rotary Screw Compressor will be a compo-nent in an integrated system. As such, the compressor re-quires some specific operation and conditions to ensure trouble-free running.

The information in this section of the manual provides logi-cal instructions to properly start up and operate the HPSH Rotary Screw Compressor in your unit. Only matters which may influence the proper operation of the Frick HPSH com-pressor are included.

LOW AMBIENT OPERATION

WARNINGAvoid condensation of refrigerant, gases or water in the compressor. Ambient conditions may require heat tracing and insulation of the compressor package components and piping.

Catastrophic failure may occur if condensation is present.

It is recommended that package oil separators, the oil pip-ing and the oil filler be insulated as a minimum requirement to preserve the heat generated by the oil heaters, to pre-vent condensation, and to secure lubrication at start-up.

Heat pumps and fuel gas compression must always have the oil separator insulated. Heat pumps will often require the complete suction line to be insulated in order to prevent condensation and possible slugging. In these cases, heat tracing is required.

With an automated valve, regulate oil flow to the main oil ports SM-2/SM-1 in order to continuously achieve the high-est possible discharge temperature needed.

070.750-IOM (MAY 2018)


MAINTENANCE4. Avoid slugging the compressor with liquids (refrigerant and/or oil). While screw compressors are probably the most tolerant (of any compressor type available today) about in-gestion of some liquid, they are not liquid pumps. Make certain a properly sized suction accumulator is used to avoid dumping liquid into compressor suction.

5. Protect the compressor during long periods of shut-down. If the compressor will be sitting for long periods without running, it is advisable to evacuate to low pressure and charge with dry nitrogen or oil. This is particularly true on systems known to contain water vapor.

6. Preventive maintenance is recommended including measuring of vibration and performing oil analyses. Inspec-tion is recommended any time a compressor exhibits a no-ticeable change in vibration level, noise or performance.

CHANGING OIL

WARNINGDO NOT MIX OILS of different brands, manufacturers, or types. Mixing of oils may cause excessive oil foam-ing, nuisance oil level cutouts, oil pressure loss, gas or oil leakage and catastrophic compressor failure.

Shut down the unit when changing oil. At the same time, all oil filter cartridges must be changed and all oil strainer ele-ments removed and cleaned. The procedure is as follows:

1. Stop the compressor unit.

2. Lock out the motor starter.

3. Close the suction and discharge service valves

4. Using appropriate equipment, lower the compressor pressure to -15 mm (-.59 in.) of mercury.

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

6. Drain the oil filter(s) and the oil coolers.

7. Remove the old filter cartridges, and then install new ones.

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

9. Evacuate the unit.

10. Open the suction service valve and pressurize the unit to system suction pressure. Close the suction valve and leak test.

11. Add oil.

12. Open the suction and discharge service valves

13. Remove the lockout from the motor starter.

14. Start the unit

GENERAL INFORMATION

This section provides instructions for normal maintenance, a recommended maintenance program, troubleshooting and correction guides, and typical P and I diagrams.

WARNINGTHIS SECTION MUST BE READ AND UNDERSTOOD BE-FORE ATTEMPTING 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:

1. IF UNIT IS RUNNING, PRESS [STOP] KEY.

2. STOP MOTOR AND LOCK OUT STARTER BEFORE PER-FORMING ANY MAINTENANCE.

3. WEAR PROPER SAFETY EQUIPMENT WHEN COMPRES-SOR UNIT IS OPENED TO ATMOSPHERE.

4. ENSURE ADEQUATE VENTILATION.

5. TAKE NECESSARY SAFETY PRECAUTIONS REQUIRED FOR THE GAS BEING USED.

GENERAL MAINTENANCE

Proper maintenance is important in order to assure long and trouble-free service from your screw compressor. Some areas critical to good compressor operation are:

1. Keep oil clean and dry, avoid moisture contamination. After servicing any portion of the refrigeration system, evacuate to remove moisture before returning to service. Water vapor condensing in the compressor while running or more likely while shut down, can cause breakdown of oil and refrigerant, which can generate corrosive agents breaking down bearings and other vital components in a short time.

2. Keep suction strainer clean. Check periodically, particu-larly on new systems where welding slag or pipe scale could find its way to the compressor suction. Excessive dirt in the suction strainer could cause it to collapse, dumping parti-cles into the compressor.

3. Keep oil filters clean. If filters show increasing pressure drop, indicating dirt or water, stop the compressor and change filters. Running a compressor for long periods with high filter pressure drop can starve the compressor of oil and lead to premature bearing failure. Dual oil filters are recommended so that the filters can be changed without shutting down the package.

070.750-IOM (MAY 2018)


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

DESCRIPTION HPSH 1510

Complete Bearing Kit 534C2311G01

O-ring Kit 534B1335H01

Shaft Seal Kit 534C2707G01

Balance Piston Kit 534A1123G01

Compressor Tool Kit 534C2307G01

NOTICERefer 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 flanges. See table below for torque requirements.c. Units with variable speed drives - check for excess vibration and skip frequencies anytime unit operating conditions change. d. Check and torque all terminals in the processor and starter panel per the specification posted in the enclosure.e. Check calibration of Slide Valve, Slide Stop, pressures and temperatures. Calibration should be conducted with NIST certified 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

10,0

00

15,0

00

20,0

00

25,0

00

30,0

00

35,0

00

40,0

00

45,0

00

50,0

00

55,0

00

60,0

00

65,0

00

70,0

00

75,0

00

80,0

00

85,0

00

90,0

00

95,0

00

Change Oil As Directed By Oil AnalysisOil Analysis n Every 6 Months Replace Filters n n n n n n n n n n n Clean Oil Strainers n n n n n n n n n n n Clean Liquid Strainers n n n n n n n n n n n Replace Coalescers n n n Check and Clean Suction Strainer n n n n n n n n n n n Check Coupling (a) n Annually Regardless of Operating HoursSuction & Disch Flange Bolts (b) n n n n n n n n n n n n n n n n n n n n n n

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

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

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

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

Vibration Analysis (g) n Every 6 Months, More Frequently If Levels Increase Replace Shaft Seal When Leak Rate Exceeds 7 - 8 Drops Per Minute (600 ml in 24 hours)

CompressorModel

Discharge Flange to Separator Flange3" Class 600

Suction Flange4" Class 400

Bolt Size Torque* (ft-lb) Bolt Size (in.) Torque* (ft-lb)HPSH 1510 M20 X 2.5 160 M20 X 2.5 160

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

RECOMMENDED SPARE PARTS - CURRENT DESIGN

070.750-IOM (MAY 2018)


RECOMMENDED MAINTENANCE PROGRAM

In order to obtain maximum compressor performance and ensure reliable operation, a regular maintenance program should be followed. The compressor should be checked regularly for leaks, abnormal vibration, noise, and proper operation. A log should also be maintained. Oil analysis should be performed on a regular basis. It is a valuable tool that can identify the presence of moisture, acid, metallics and other contaminants that will shorten compressor life if not corrected. In addition, an analysis of the compressor vibration should be made regularly.

VIBRATION ANALYSIS

Periodic vibration analysis can be useful in detecting bear-ing wear and other mechanical failures. If vibration analysis is used as a part of your preventive maintenance program, take the following guidelines into consideration.

1. Always take vibration readings from exactly the same places and at exactly the same percentage of load.

2. Use vibration readings taken from the new unit at start-up as the base line reference.

3. Evaluate vibration readings carefully as the instrument range and function used can vary. Findings can be easily misinterpreted.

4. Vibration readings can be influenced by other equip-ment operating in the vicinity or connected to the same piping as the unit.

OIL QUALITY AND ANALYSIS

High quality and suitable oil is necessary to ensure com-pressor longevity and reliability. Oil quality will rapidly dete-riorate in systems containing moisture and air or other con-taminants. In order to ensure the quality of the oil in the compressor unit:

1. Only use Frick oil or high quality oils approved by John-son Controls-Frick for your application.

2. Only use Frick SuperFilter™ elements. Substitutions must be approved in writing by Johnson Controls-Frick En-gineering or warranty claim may be denied.

3. Participate in a regular, periodic oil analysis program to maintain oil and system integrity.

OPERATING LOG

The use of an OPERATING LOG (See Table of Contents) per-mits thorough analysis of the operation of a system by those responsible for its maintenance and servicing. Con-tinual recording of gauge pressures, temperatures, and other pertinent information, enables the observer and ser-viceman to be constantly familiar with the operation of the system and to recognize immediately any deviations from normal operating conditions. It is recommended that read-ings be taken at least daily.

TROUBLESHOOTING GUIDE

Successful problem solving requires an organized approach to define the problem, identify the cause, and make the proper correction. Sometimes it is possible that two rela-tively obvious problems combine to provide a set of symp-toms that can mislead the troubleshooter. Be aware of this possibility and avoid solving the “wrong problem”.

WARNINGAvoid condensation of refrigerant, gases or water in the compressor. Ambient conditions may require heat tracing and insulation of the compressor package components and piping.

Catastrophic failure may occur if condensation is present.

ABNORMAL OPERATION ANALYSIS AND CORRECTION

Four logical steps are required to analyze an operational problem effectively and make the necessary corrections:

1. Define the problem and its limits. 2. Identify all possible causes. 3. Test each cause until the source of the problem is found. 4. Make the necessary corrections.

The following list of abnormal system conditions can cause abnormal operation of the HPSH compressor:

1. Oil flow too high at low speed.2. Discharge temperature too close to condensing tem-

perature.3. Insufficient or excessive gas load. 4. Excessively high suction pressure. 5. Excessively high discharge pressure. 6. Excessively high or low temperature coolant to the oil

cooler. 7. Excessive liquid entering the compressor (slugging). 8. Insufficient oil cooling.9. Excessive oil cooling10. Incorrect gas line sizing. 11. Improper system piping. 12. Wrong operation of hydraulic operated plug valve.13. Problems in electrical service to compressor. 14. Moisture present in the system.

Make a list of all deviations from normal compressor opera-tion. Delete any items, which do not relate to the symptom and separately list those items that might relate to the symptom. Use the list as a guide to further investigate the problem.

The second step in problem solving is to decide which items on the list are possible causes and which items are additional symptoms. High discharge temperature and high oil temperature readings on a display may both be symp-toms of a problem and not causally related.

070.750-IOM (MAY 2018)


The third step is to identify the most likely cause and take action to correct the problem. If the symptoms are not re-lieved, move on to the next item on the list and repeat the procedure until you have identified the cause of the prob-lem. Once the cause has been identified and confirmed, make the necessary corrections.

TROUBLESHOOTING THE HPSH COMPRESSOR

NOTICEUnless the Service Technician has been certified by Johnson Controls–Frick to rebuild our compressors, troubleshooting the compressor is limited to identify-ing the probable cause. If a mechanical problem is sus-pected, contact Johnson Controls–Frick Service. DO NOT ATTEMPT TO DISASSEMBLE COMPRESSOR.

BARE COMPRESSOR REPLACEMENT

The following procedure is required only when a bare com-pressor is replaced in the field.

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 firm seating of the compressor.

6. Thoroughly clean the new compressor and remove all cover plates and protection etc.

7. Install new gaskets and sealing in all connections.

8. Set the new compressor in place and shim feet where required.

9. Reattach the drive coupling.

10. The shaft alignment must be checked if a factory pro-vided motor mount is not used.

11. Complete tubing, piping and wiring.

SHUTDOWN DUE TO IMPROPER OIL PRESSURE (HIGH STAGE AND BOOSTER)

The compressor must not operate with incorrect oil pressure.

Refer to CONTROL SETUP.

070.750-IOM (MAY 2018)


ALIGNMENT LOG – FOR ELECTRIC MOTOR DRIVER

DRIVE TRAIN ALIGNMENTAmbient 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 CompressorIndicator Readings Facing Compressor Motor Magnetic Center Checked Marked N/ACompressor 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


Face Rim


070.750-IOM (MAY 2018)


Date: __________________________________________ Sales Order Number: ________________________________

End User: _______________________________________ Installing Contractor: ________________________________

Address: __________________________________________ Service Technician: __________________________________

Equipment ID (As in Microlog): ____________________Compressor Serial Number: __________________________Unit Serial Number: _________________________________National Board Number: _____________________________Running Hours: _____________________________________Manufacturer and Size of Coupling: ____________________Motor Manufacturer: ________________________________Motor Serial Number: ________________________________RPM: ________ Frame Size: ___________ H.P. __________Refrigerant:Ambient Room Temperature: ____________°FOperating Conditions:

VIBRATION DATA SHEET

SUCTION DISCHARGE OIL SEPARATOR Slide Valve Position %Press # Press # Press # Temp °F Vi Ratio

Temp °F Temp °F Temp °F F.L.A. %

Compressor Inboard(Coupling End)

Vertical Direction____.____ IPS Overall

Compressor Inboard(Coupling End Male)

Axial Direction____.____ IPS Overall

Motor Inboard (Coupled End) Horizontal _______ . ______ IPS Overall Vertical _______ . ______ IPS Overall Axial _______ . ______ IPS Overall

Compressor Outboard(Nondrive End)

Vertical Direction____.____ IPS Overall

Compressor Inboard(Coupling End Female)

Axial Direction____.____ IPS Overall

Motor Outboard (Noncoupled End) Horizontal _______ . ______ IPS Overall Vertical _______ . ______ IPS Overall Axial _______ . ______ IPS Overall

Soft Foot Soft Foot

Soft Foot Soft Foot

Final Hot Alignment

Total Thickness of Shims Added

Face Rim

070.750-IOM (MAY 2018)


SC-7

SC-6

SV-1

SM-1

SC-8

SM-2

4” Class 400 Suction Flange

COMPRESSOR OPERATES ON AND ISCOMPATIBLE WITH THE FOLLOWINGREFRIGERANTS:

COMPRESSOR OPERATES ON AND ISCOMPATIBLE WITH THE FOLLOWINGREFRIGERANTS:

R22, R23, R32, R50, R123, R125, R134a,R142b, R170, R218, R236fa, R245fa,R290, R40A, R407C, R410A, R507,R508, R508B, R600, R600A, R717, R728,R729, R744, R1150, AMMONIA,NATURAL GAS

R22, R23, R32, R50, R123, R125, R134a,R142b, R170, R218, R236fa, R245fa,R290, R40A, R407C, R410A, R507,R508, R508B, R600, R600A, R717, R728,R729, R744, R1150, AMMONIA,NATURAL GAS


SERIAL NO.

MAX ALLOWABLEPRESSURE - PSIG

MAX DRIVERSPEED - RPM

WAYNESBORO PA 17268

XXX

A

A

SB-3

TRANSDUCERMOUNTING

12.75 (.502)12.70 (.500)KEYWAY

Discharge Flange 3” Class 600

SD-2SC-5

SB-2

SD-1

SL-0BP-1

VIEW A-A

Vi ratio

CONNECTION LEGEND

PORT LABEL DESCRIPTION CONNECTION

SIZE

SB-2 Balance Piston and Inlet Bearing Oil Feed 3/4-16UNF-2B

SB-3 Discharge Bearings, Shaft Seal, and Unloader Plug Oil Feed 3/4-16UNF-2B

SC-5 Inlet Pressure 9/16-18UNF-2BSC-6 Discharge Pressure 9/16-18UNF-2BSC-7 Seal Weepage 1/8-27 NPTFSC-8 Clased Thread Drain 3/4-16UNF-2BSD-1 Coalescer Bleed 9/16-18UNF-2BSD-2 Liquid Injection Bleed 9/16-18UNF-2BSL-0 Liquid Injection Bleed 3/4-16UNF-2BSM-1 Main Oil Injection, Vi = 1.3 1Z\zn -12UN-2BSM-2 Main Oil Injection, Vi = 1.05 3/4-16UNF-2BSV-1 Economizer 1B\, -12UN-2BBP-1 Discharge Bypass 1½ Sq Flange

COMPRESSOR PORT LOCATIONS - HPSH 1510

070.750-IOM (MAY 2018)


May 2018 Form Revisions

p.3 – Updated nameplate image to current stylep.4 – Updated refrigerant plates to current stylep.5 – Updated to current Vi ratios throughout pagep.6 – Updated design limit notes and removed limits tablep.8 – Added SM port cutaway figure – Updated Vi and SM port connection informationp.9 – Added 070.660-SM reference Notice box

IndexSymbols4-way hydraulic valve 11

AAmmonia heat pumps 10asymmetric profile 6axial load 9axial runout 10

Bbalance piston 5, 9Balance piston 5BALANCE PISTON 6ball bearings 5Bearings 6

Ccapacity regulation 5Capacity regulation 5compressor 12Compressor oil 10Compressor rotation 5compressor shaft 9compressor suction 13contaminants 15CoolWare 7corrosion 5coupling 10, 16Coupling 9Coupling alignment 10

Ddemand oil pump 6dial indicator 10direct motor drive 9Discharge gas pulsation 6discharge pressure 5, 6discharge temperature 6, 10Drive Train Alignment 17

EEconomizer port 5electric drive motor 7Evacuate 5

Ffilter elements 10foundation 7Frick SuperFilters™ 6

Ggas bypassing 5gas compression 7gauge pressures 15Grease 5

Hheat pumps 10hot alignment 10Housing 6HPSH compressors 7

Iidentification data plate 3

Llifting rings 7Long term storage 4

Mmaintenance 13

Maintenance Schedule 14misalignment 10mixing valve 10moisture 5moisture contamination 13motor 7Motor 17motor coupling 6MOTOR MOUNT 6motor shaft 16

Nnatural gas 10nitrogen 5

Ooil analyses 13oil charge 9oil cooling system 12oil differential pressure 6oil filter cartridges 13oil filters 13Oil flow 15oil heaters 10oil pressure 9Oil pressure 6oil pump 5, 9oil separator 6

oil strainer elements 13oil supply system 9Operating Log Sheet 17

Pplug valve 5Port locations 7pressurize 5

Rradial runout 10regulating valve 10rigging 7roller bearings 5Rotors 6

Sserial number 3setpoint 7shaft alignment 16Shaft rotation 5Shaft Seal 6shipping gauge 7slugging 15start-up 10, 12storage 5Suction flange 5suction strainer 5, 13SuperFilter™ 15

Ttroubleshooting 13, 16tunnel mount 7

UUNLOADING VALVE 6

Vvacuum pump 11Vacuum rise 11variable speed 5variable speed drive 5vibration 6, 15vibration analysis 15

Wwarm oil 10Warranty 4

ALPHABETICAL LISTING

JOHNSON CONTROLS100 Cumberland Valley AvenueWaynesboro, PA 17268-1206 USAPhone: 717-762-2121 • FAX: 717-762-8624www.johnsoncontrols.com/frick

Form 070.750 IOM (2018-05)Supersedes: 070.750 IOM (2014-05)

Subject to change without noticePublished in USA • 08/18 • PDF

© 2018 Johnson Controls Int’l. PLC - ALL RIGHTS RESERVED

p.10 – Added discharge temp. Notice boxp.12 – Added condensation Warning box & ambient temp. Noticep.14 – Added condensation Warning boxp.15 – Added additional line items to Maintenance Schedule Table – Added compressor flange bolt torque table – Removed engineering-specific PID diagrams – Updated Frick IR logo throughout document

070.750-iom hpsh 1510 rotary screw compressor

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