RETROFIT CONVERSION FRICK® QUANTUM™ HD CONTROL
Contents
1. WEN Fig 2c ICTD with 1 4 connection less thermowell 1 4 18 NPT 0 180 fi 4 5 3 375 eng 85 73 mm 0 62 lt lt 15 8 Figure 2 ICTD Sensor Options Note Fig 2c is an ICTD sensor only Typically used with Vilter packages the sensor threads into an existing thermowell FRICK QUANTUM HD VILTER RETROFIT INSTALLATION INSTRUCTIONS Page 3 090 040 102 NOV 2014 INTRODUCTION CONVERSION OF SCREW COMPRESSOR UNITS TO THE FRICK QUANTUM HD CONTROL PANEL These instructions are based on the installer having a fun damental knowledge of refrigeration design and installation Instructions are for conversion to the standard design unit Special package and or control modifications furnished on the existing unit will require deviation from these instructions Contact Fricke if you have any questions concerns or prob lems Fricke does not take responsibility for the suitability of these instructions for any nonstandard installation or for consequential damages resulting from the conversion NOTICE Do not initiate retrofit conversion until you have completely reviewed all instructions and checked material received for suitability and completeness Material supplied with this Fricke retrofit kit A A complete QUANTUM HD control panel2. _ __ Form 090 040 102 NOV 2014 K INSTALLATION LIIC SERVICE MANUAL Section 90 Replaces 090 040 102 AUG 2014 BY JOHNSON CONTROLS Dist 3 3a 3b 3c RETROFIT CONVERSION TO THE FRICK QUANTUM HD CONTROL VILTER SINGLE SCREW INSTALLATION INSTRUCTIONS Please check www jci com frick for the latest version of this publication 090 040 102 NOV 2014 FRICK QUANTUM HD RETROFIT PANELS The QUANTUM HD control panels sold under this program are designed to handle standard screw compressor package piping and instrument design Compressors are to be electric motor driven only Other drive lines can be accommodated through Frick Engineering Lubrication is accomplished by electric motor or shaft driven oil pumps or differential pressure lube systems If the compressor package does not meet these basic requirements contact Frick for engineering assistance Frick can make the proper changes for most applications Additional engineering and drawing charges will be quoted Examples of standard piping and instrument designs for both Frick and other manufacturer s designs are shown on page 3 In some cases even though the screw compressor package meets the basic requirements package modifications and or control panel modifications may be required non standard sensors modified piping additional solenoids and check valves and additional relays into the control circuits etc This is t
3. PLANT SUPPLY L B b 3 PHASE TRANS 4 E BUS ml I LI I GROUND BUS ELECTRONIC ELECTRONIC ELECTRONIC CONTROL CONTROL CONTROL CORRECT PLANT 3 PHASE BUS GROUND BUS INCORRECT c e IL ELECTRONIC ELECTRONIC ELECTRONIC CONTROL CONTROL CONTROL Figure 15 Electronic Control Panel Power Supplies 090 040 I02 M0V 2014 ES k NGGENENENGENT FRICK QUANTUM HD VILTER RETROFIT l Page 14 INSTALLATION INSTRUCTIONS Aea COMMUNICATIONS UPS POWER AND QUANTUM HD PANELS The use of communications such as serial and ethernet in industrial environments are commonplace The proper installation of these networks is as important to the proper operation of the communications as all of the preceding practices are to the equipment Serial communications cable needs to be of the proper gauge based on the total cable distance of the run Daisy chaining is the only acceptable style of running the communications cable While Star Networks may use less cable they more often than not cause problems and interruptions in communi cations due to varying impedances over the varying lengths of cable Ground or drain wires of the communications cable are to be tied together at each daisy chain connection and only taken to ground in the central control system panel It is important to carefully consider the type of cable to be used Just because a cable has the proper number of conduc tors and
4. B Operation Maintenance and Retrofit Conversion manuals C Four ICTD Temperature Probes 1 4 MPT less well D Three 0 500 PSIA Pressure Transducers 1 4 MPT E One 0 200 PSIA Pressure Transducer 1 4 MPT Each sensor comes with a 24 section of the proper shielded cable with DIN connector to plug onto the sensor A pressure transducer manifold block with mounting brack ets and service valves for four 4 pressure trans ducers is available as an option With this option the cables on the trans ducers are 8 NOTICE Older gear driven capacity and volume slide actuators must be replaced with the optical style actuators shown in Figure 3 before retrofitting Figure 3 Current Optical Actuator MATERIAL TO BE SUPPLIED BY INSTALLER AS REQUIRED Pressure tubing and fittings 1 4 inch stainless steel Pipe fittings and adaptors Electrical conduit fittings and solenoids Wire Current transformer in the compressor motor starter control transformer and any motor starter compo nents or modifications Labor and tools required to complete installation and start up 090 040 102 NOV 2014 SUCTION Bearing Main NO VALVE FRICK QUANTUM HD VILTER RETROFIT Page 4 INSTALLATION INSTRUCTIONS Oil Oil Injection Frick BY JOHNSON CONTROLS TYPICAL TRANSDUCER CONNECTION DIAGRAM FOR CONVERTING VILTER SINGLE SCREW UNITS TO OUANTUM HD CONTROL A TE 1 SUCTION TE
5. devices have revolutionized the way refrigeration plants operate today The earlier relay systems were virtually immune to radio frequency interference RFI electromagnetic interference EMI and ground loop currents Therefore installation and wiring were of little consequence and the wiring job con sisted of hooking up the point to point wiring and sizing the wire properly In an electronic system improper instal lation will cause problems that may outweigh the benefits of electronic control Electronic equipment is susceptible to RFI EMI and ground loop currents which can cause equip ment shutdowns processor memory and program loss as well as erratic behavior and false readings Manufacturers of industrial electronic equipment take into consideration the effects of RFI EMI and ground loop currents and incorpo rate protection of the electronics in their designs However these design considerations do not make the equipment immune so manufacturers require that certain installation precautions be taken to protect the electronics from these effects All electronic equipment must be viewed as sensitive instrumentation and therefore requires careful attention to installation procedures These procedures are well known to instrumentation networking and other professions but may not be followed by general electricians There are a few basic practices that if followed will minimize the potential for problems resulting from RFI EMI a
6. is shielded does not mean it is an acceptable cable Johnson Controls Frick recommends the use of Belden 9829 for RS 422 communications and Belden 9841 for RS 485 up to 2000 feet 600 Meters total cable length Refer to Frick drawing 649D4743 for more detail Comm Port Protection Surge suppression for the comm ports may not be the best method since suppression is re quired to divert excess voltage current to ground Therefore the success of these devices is dependent on a good ground covered earlier in this section This excess energy can be quite high and without a proper ground it will access the port and damage it Isolation or Optical Isolation is the preferred comm port protection method With optical isolation there is no con tinuity between the communications cable and the comm port There is no dependence on the quality of the ground Be sure to know what the voltage isolation value of the optical isolator is before selecting it These may range from 500 to 4000 Volts Fricke Optical Isolation Kits are offered under part number 639C0133G01 One kit is required per comm port Johnson Controls Inc does not advise nor support the use of uninterrupted power supply systems for use with the Quantum HD panel With a UPS system providing shutdown protection for a Frick Quantum panel the panel may not see the loss of the 3 phase voltage on the motor because the UPS may prevent the motor starter contactor from dropping out Wit
7. material by national or local codes conduits between a constant speed starter and the motor 3 phase may be PVC Any unshielded control voltage signal analog or com munication wiring that does not maintain 12 inches of separation from any 3 phase conductors for every 33 feet 10 meters of parallel run must be in metal conduit which will be grounded Separation 0 33 feet 0 10 meters 12 inches 3 meters 33 66 feet 10 20 meters 24 inches 6 meters Since PVC conduit does absolutely nothing to protect lower voltage lines from the magnetic field effects of higher voltage conductors running either the lower or the higher voltage lines in PVC does not reduce these requirements on separation Only running in metal conduit can relieve these requirements Due to the level of EMI that can be induced onto lower voltage lines when running multiple feeders in a trench control power communications analog or signal wiring cannot be run in trenches that house multiple conduits electrical ducts carrying 3 phase power to starters vfd or motors FRICK QUANTUM HD VILTER RETROFIT Page 12 INSTALLATION INSTRUCTIONS ES o Frick BY JOHNSON CONTROLS Control power communications analog or signal wir ing should be run overhead preferred or in a separate trench If these lines are not in threaded metallic or threaded PVC coated metallic abiding by the separation requirements noted above is necessary Though not re
8. of the proper sized insulated stranded conductor from the electronic control panel to the plant supply transformer See Figure 12 Driving a ground stake at the electronic control may also cause additional problems since other equipment in the plant on the same circuits may ground themselves to the ground stake causing large ground flow at the electronic control panel Also run ning multiple ground conductors into the electronic control panel from various locations can create multiple potentials resulting in ground loop currents A single ground wire 10 AWG or 8 AWG from the electronic control panel that is bonded to the control power neutral at the secondary side of the control power transformer in the starter and then to the 3 phase ground point will yield the best results 3 PHASE PLANT SUPPLY TRANSFORMER COPPER COPPER ELECTRONIC CONTROL Figure 12 Control Power Ground Circuit Structural grounding can also result in multiple ground potentials and is also a relatively poor conductor Therefore this is not an acceptable method for proper operation of electronic equipment There must be a ground for the three phase power wiring This must be sized in accordance to the NEC and any local codes relative to the highest rated circuit overload protec tion provided in the circuit The manufacturer may require a larger ground conductor than what Is required by the NEC for proper steering of EMI from sensitive circ
9. panels subjects the electronic equipment to noise generated by other devices connected to the breaker panel This noise is known as elec tromagnetic interference EMI EMI flows on the wires that are common to a circuit EMI cannot travel easily through transformers and therefore can be isolated from selected circuits Use a control power transformer of the proper VA rating usually provided in the compressor drive motor starter to isolate the electronic control panel from other equipment in the plant that generate EMI See Figure 11 CONTROL Ld TRANSFORMER ISOLATED CIRCUIT ELECTRONIC CONTROL CORRECT CONTROL TRANSFORMER NONISOLATED CIRCUIT INCORRECT Figure 11 Voltage Source Circuit To Prevent EMI S o Frick BY JOHNSON CONTROLS GROUNDING Grounding is the most important factor for successful opera tion and is typically the most overlooked The NEC states that control equipment may be grounded by using the rigid conduit as a conductor This worked for the earlier relay systems but IL is in no way acceptable for electronic control equipment Conduit is made of steel and is a poor conductor relative to an insulated stranded copper wire Electronic equipment reacts to very small currents and must have a proper ground in order to operate properly therefore stranded copper grounds are required for proper operation For proper operation the control power ground circuit must be a single continuous circuit
10. to the Capacity Volume calibration page on the Quantum HD controller Frick BY JOHNSON CONTROLS Capacity Slide Calibration 1 Press the Unload Capacity Slide button The photo chopper will spin at a high rate until the low end physical stop is reached and the photo chopper winds to a stop Quickly press the Unload Capacity Slide button again to turn of the unload output Press down on the Photo Chopper until the tension is relieved You may need to press down on the photo chopper a few times to fully relieve the tension Once the tension is relieved press the Blue Calibration Button on the capacity slide actuator to initiate capacity slide actuator calibration The red calibration LED will be flashing at a rapid rate multiple times per second Press the Blue calibration button again The red calibra tion LED is now flashing at a slower rate about once per second The minimum capacity position output is now set on the actuator On the Capacity Volume calibration page press the Set Low Capacity button to set the Capacity Low Value refer ence voltage on the Quantum HD controller To prevent the capacity slide from hitting the low end physical stop the reference voltage for Capacity Low Value is adjusted upward by 3 of the actuators output range of 0 5 VDC 15 volts The Quantum HD will not unload the capacity slide beyond the Capacity Low Value reference voltage With the red calibration LED flashing
11. Access Levels Basic 1 Operation 2 Service 3 25 Refer to the Operation manual 090 040 0 to ensure that all setpoints have been properly entered The main configu ration items for the Vilter single screw are Package Type Package Duty Oil Pump Type Refrigerant and Drive Type S o Frick BY JOHNSON CONTROLS Go to Menu Configuration Package to select Package Type Package Duty Refrigerant and Drive Type Select the Oil Pump Lubrication tab to select the oil pump type The default oil pump selection is Full Time If the pump operation is part time or on demand select Demand When Demand is selected additional setpoints used to run the Vilter lubrication logic are added to that page While these are adjustable it should not be necessary to do so 26 Before calibrating the analog devices sensors check the configuration of all utilized analog devices to ensure they are configured correctly with regard to sensor output and sensor range The analog board in the QUANTUM HD provides 24 vdc excitation for the sensors Sensor default configuration is as follows for the following sensors Any additional sensors will also need checked for proper configuration Pressure Transducers Location SensorOutput Sensor Range O to 200 PSIA Oil Oil Filter amp E Temperature Probes Location SensorOutput Sensor Range ICTD integrated Suction Oil Separator gt 459 3 to 463 1 F amp Dischar
12. MPERATURE AVALVE TE 2 DISCHARGE TEMPERATURE ATS TE 3 OIL TEMPERATURE LOCATION TE 4 SEPARATOR TEMPERATURE PE 1 OIL PRESSURE PE 2 OIL FILTER PRESSURE PE 3 DISCHARGE PRESSURE PE 4 SUCTION PRESSURE F 1 OIL FILTER DISCHARGE gt QUANTUM HD PANEL NO VALVE E AITUU Oom O mmou mo Figure 4 Transducer Connection Diagram Typ Conversion INSTRUCTIONS NOTICE Before proceeding read the instructions for Proper Installation of Electronic Equipment in an Industrial Environment on page 8 1 Push STOP key to shut down the unit Lockout and Tagout all sources of power to the compressor package 2 Close the discharge and liquid injection if applicable service valves 3 SLOWLY vent the separator to low side system pressure using the suction check valve bypass Close suction valve and suction check valve bypass NOTICE Recover or transfer all refrigerant vapor in accordance with local ordinances before opening to atmosphere Separator MUST be equalized to atmospheric pressure Refrigerant entrained in the oil may vaporize causing a separator pressure increase Repeat venting and recovery procedure if necessary 4 If an oil separator temperature probe well is to be installed drain the oil from the oil separator 5 Take digital photographs of all internal connecti
13. acity slide actuator is the one that is physically higher on the compressor To avoid any incidental damage disconnect the cables for control and signal at the optical actuators before wiring these devices to the digital and analog boards They will be reconnected later awe T WW T _ M 4 ih 5 WALL Ie I it ri PM LL M CT T L ORE E A Temperature B Pressure C Capacity amp Volume Figure 6 Analog I O cabling entry into the enclosure and routing to the analog board Typical 13 Refer to the Vilter specific drawings that come with the QUANTUM HD for instruction on properly landing the power signal and common wires of the signal cable for the capacity and volume slide position on the analog I O board These drawings also include connection information for the load unload and common wire for the control cable to the digital board 14 Before starting the AC control wiring the following items should be checked in the compressor starter Refer to the compressor motor starter diagrams A The compressor requires a minimum of 2 KVA trans former for 120 VAC control and heater power B The compressor starter must have a ground wire pulled from the three phase source The ground must be connected to the starter backplate and the neutral terminal 2 on the secondary side of the control transformer C Verify that the current transformer CT is placed as shown on the motor
14. and green GND Copper ground only Conduit ground is not acceptable The main power wiring to the QUANTUM HD panel line and neutral must be 10 AWG A separate ground wire is also required for each QUANTUM HD panel and must also be at least a number 10 insulated copper wire 16 Connect the remaining control wires between the starter and the control panel as shown on the drawings that come with the QUANTUM HD and or the compressor motor starter diagrams and the panel wiring diagrams These control wires are typically A Compressor start 18 B Compressor auxiliary 20 C Current transformer 3 amp 4 D Oil pump start if required 8 E Oil pump auxiliary if required 19 17 Connect the remaining package control wires including options to the control panel as shown on the panel wiring diagrams provided with the QUANTUM HD for Vilter retrofit 18 Before applying power to the QUANTUM HD control panel make the following checks A Check each terminal for loose connections or damage to the circuit boards or cables B Check for wire clippings or metal drill filings on the circuit board or in the panel Clean the QUANTUM HD control panel thoroughly before applying the control power FRICK QUANTUM HD VILTER RETROFIT Page 6 INSTALLATION INSTRUCTIONS Frick 19 Make sure that the circuit breakers CB1 and CB2 in the QUANTUM HD control panel are in the OFF position Engage the electrical dis
15. anels should never be used as a junction box These wires may be carrying large transients that will interfere with the operation of the control panel An extreme example of this would be to run 480 volts from the starter through the electronic control panel to an oil pump motor When running conduit to the electronic control panel use the access holes knockouts provided by the manufacturer These holes are strategically placed so that the field wiring does not interfere with the electronics in the panel Never allow field wiring to come in close proximity with the con troller boards since this will almost always cause problems S o Frick BY JOHNSON CONTROLS Do not drill into an electronic control panel to locate conduit connections You are probably not entering the panel where the manufacturer would like you to since most manufactur ers recommend or provide prepunched conduit connections You may also be negating the NEMA rating of the enclosure Drilling can cause metal filings to land on the electronics and create a short circuit when powered is applied If you must drill the panel take the following precautions First call the panel manufacturer before drilling into the panel to be sure you are entering the panel at the right place Take measures to avoid ESD electrostatic discharge to the electronics as you prep the inside of the Electronic control panel This can be done by employing an antistatic wrist band and mat co
16. ashers at the point of con nection at each end will maximize metal to metal contact STARTER Figure 13 Motor And Starter Grounding VFD APPLICATIONS The primary ground conductor that accompanies the three phase supply must be stranded copper insulated and two sizes larger than the minimum required by the NEC or any other applicable codes This is necessary due to the increased generation of EMI which is a characteristic of a VFD output to the motor when compared to a conventional starter For VFD applications isolation of the control power analog devices and communications ground from the 3 phase ground within the starter and the electronic control panel may be necessary This is due to the higher noise RFI EMI levels generated between the VFD output and the motor relative to a conventional starter II these grounds are left coupled by a common back plate in the starter drive this noise can be direct coupled to the control power analog device and communications grounding and may cause unexplained behavior and possible damage to components 090 040 I02 M0V 2014 To install correctly run a separate properly sized 10 or 8 AWG typically insulated ground along with and taken to ground with the 3 phase ground at the 3 phase supply transformer plant This will require that the 3 phase ground and the control power ground be electrically isolated except for the connection at the plant supply transformer This style of groun
17. at the slower rate press the Load Capacity Slide button The photo chopper Will spin at a high rate until the high end physical stop is reached and the photo chopper winds to a stop Quickly press the load Capacity Slide button again to turn of the load output Press down on the Photo Chopper until the tension is relieved You may need to press down on the photo chopper a few times to fully relieve the tension Press the Blue calibration button again The red calibration LED will go out The maximum capacity position output Is now set on the actuator On the Capacity Volume calibration page press the Set High Capacity button to set the Capacity High Value refer ence voltage on the Quantum HD controller To prevent the capacity slide from hitting the high end physical stop the reference voltage for Capacity High Value is adjusted downward by 3 of the actuators output range of 0 5 VDC 15 volts The Quantum HD will not load the capacity slide beyond the Capacity High Value reference voltage NOTICE FRICK QUANTUM HD VILTER RETROFIT INSTALLATION INSTRUCTIONS 090 040 102 NOV 2014 Page 9 Volume Slide Calibration 1 Press the Decrease Volume Slide button The photo chopper will spin at a high rate until the low end physical stop is reached and the photo chopper winds to a stop Quickly press the Decrease Volume Slide button again to turn of the decrease output Press down on the Photo Chopper until the te
18. ature sensors suction discharge oil and separator temperature Part 639A0361H01 4 24 2 wire shielded cables with integrated DIN connector 1 4 hole 3 4 strain relief Once each of the new temperature sensors are prop erly installed plug in the cables and route back to the QUANTUM HD where they will be gathered and ran through the 4 hole 3 4 strain relief provided in the kit Use one of the 4 holes provided at the bottom left side of the enclosure for the entry of these cables 8 Before making the final wiring connection for the tem perature sensors refer to the multipage drawing that is provided in the new controller or the panel wiring diagrams in the 090 040 M publication Temperature probe cabling Is grounded at the ground block in the panel Cut off the shield and drain wire at the probe end and use heat shrink or electrical tape to cover the bare wire preventing contact with ground 9 Connect the red or white and black wires to the analog I O board as shown on the on the panel wiring diagrams in the 090 040 M publication 10 If the output of the existing pressure transducers are NOT 4 20mA 0 20mA 1 5V 0 5 V 2 10V or 0 10V they must be replaced The signal from the older standard Vilter pressure transducer is not a standard sensor signal range The pressure transducer kit that comes with the QUANTUM HD retrofit includes the following 1 O 200psia 1 4 MPT Transducer suction pressure 3 O 500p
19. bration button again The red calibration LED will go out The maximum capacity position output Is now set on the actuator On the Capacity Volume calibration page press the Set High Volume button to set the Volume High Value refer ence voltage on the Quantum HD controller To prevent the volume slide from hitting the high end physical stop the reference voltage for Volume High Value is adjusted downward by 396 of the actuators output range of 0 5 VDC 15 volts The Quantum HD will not increase the volume slide beyond the Volume High Value reference voltage NOTICE If the signal from the actuator drops below the low If the signal from the actuator drops below the low end reference voltage or above the high end reference voltage for the volume slide a corresponding increase or decrease command will be issued end reference voltage or the above the high end reference voltage for the capacity slide a corresponding load or unload command will be issued 090 040 I02 M0V 2014 FRICK QUANTUM HD VILTER RETROFIT Page 10 INSTALLATION INSTRUCTIONS _ Frick BY JOHNSON CONTROLS PROPER INSTALLATION OF ELECTRONIC EQUIPMENT IN AN INDUSTRIAL ENVIRONMENT In today s refrigeration plants electronic controls have found their way into almost every aspect of refrigeration control Electronic controls have brought to the industry more precise control improved energy savings and operator conveniences Electronic control
20. ce valve Read the pressure on the test gauge and com pare this reading to the displayed value Adjust the displayed value if necessary 9 Step to the discharge pressure setting on the Pressure Calibration display 10 Repeat the calibration procedure using the value from the gauge 11 Step to the oil pressure setting on the Pressure Calibra tion display 12 Repeat the calibration procedure using the value from the gauge 13 Step to the pre oil filter pressure setting on the Pressure Calibration display CAPACITY amp VOLUME SLIDE CALIBRATION Go to Menu gt Calibration gt Capacity Volume Once on this screen with the capacity and volume slides in Manual mode you can attach the power and signal cables at the optical actuators for the capacity and volume slides NOTICE When looking at the compressor the Capacity Slide actuator will always be physically higher on the compressor than the Volume Slide actuator Figure 7 Calibration Capacity Volume Screen The optical actuators used for capacity and volume slide positioning provide a O 5vdc O 5000mvdc signal over the range of travel for these slides back to the QUANTUM HD analog board 1 channels 14 amp 15 respectively The rotation of the command shaft is critical for proper operation of loading and unloading for capacity control or increasing and decreasing for volume control The correct command shaft rotation for the capacity and volume slides by compress
21. commended if cable trays are used metal lic dividers must be used for separation of conductors of unlike voltages and types AC or DC NOTICE When in doubt contact the factory or use threaded metallic or threaded PVC coated metallic conduit WIRING PRACTICES Do not mix wires of different voltages in the same conduit An example of this would be the installation of a screw compressor package where the motor voltage is 480 volts and the electronic control panel power is 120 volts The 480 volt circuit must be run from the motor starter to the motor in its own conduit The 120 volt circuit must be run from the motor starter control transformer to the electronic control panel in its own separate conduit If the two circuits are run in the same conduit transients on the 480 volt circuit will be induced onto the 120 volt circuit causing functional problems with the electronic control panel Metallic dividers must be used in wire way systems conduit trays to separate unlike voltages The same rule applies for 120 volt wires and 220 volt wires Also never run low voltage wires for DC analog devices or serial communications in the same conduit with any AC wiring including 120 volt wires See Figure 14 480 VOLT 3 PHASE BUS GROUND BUS SEPARATE CONDUIT Figure 14 Separation Of Different Voltage Circuits Never run any wires through an electronic control panel that do not relate to the function of the panel Electronic control p
22. connect at the compressor starter 20 Using a DIGITAL VOLTMETER verify the AC line voltage in the QUANTUM HD control panel The AC line voltage should be between 100 VAC and 125 VAC or 185 VAC to 254 VAC 21 Check for AC volts in millivolts between AC neutral 2 and AC ground GND If the millivolt reading is greater than 500 millivolts pull the electrical disconnect at the motor starter and reverify ground and neutral circuits 22 If all is ok turn circuit breakers CB1 and CB2 to the ON position 23 POWER SUPPLY CALIBRATION QUANTUM There are three separate power supplies in the QUANTUM HD and are designated from left to right as 5 VDC 12 VDC and 24VDC UUUUUUUUUUUU LXIILIIILIIIIIILILIIIIIIIIIIII LI LI Adjustment Potentiometer Access o 00000 DC GNL 120 or 240 VAC Each power supply 5 12 amp 24 vdc is labeled with the part number and acceptable voltage output range The voltages for the 5 12 amp 24 vdc supplies are as follows 5vdcrange 5 10 5 20 vdc 12 vdc range 12 10 12 20 vdc 24 vdc range 24 2 24 5 vdc The power supplies accept both 120 or 220 VAC input range 100 240 VAC 24 At this point the operating display on the controller should be seen Log in to the controller using a default login code The default login codes for all access levels can be changed as part of the configuration process Quantum HD Default Login
23. ding should steer the noise EMI RFI to earth ground reducing the potential for it to affect the sensitive equipment which could occur if the grounds were left coupled NOTICE If all other recommendations for grounding are followed this process should not be necessary CONDUIT All national and local codes must be followed for conduit with regard to materials spacing and grounding In addition Johnson Controls Frick requirements must be followed where they exceed or match national or local codes Con versely there is no allowance for any practices that are substandard to what is required by national or local codes Johnson Controls Frick conduit requirements For variable frequency drives VFDs of any type threaded metallic or threaded PVC coated metallic is required for both the power feed line side from the source and between the VFD output and the motor load side PVC conduit is acceptable only when VFD rated cable of the proper conductor size and ground is used This applies to both the line side and load side of the drive When VFD rated cable is not used threaded metallic or threaded PVC coated metallic must be used When threaded metallic or threaded PVC coated metallic Is used it must be grounded at both ends When not required to be in metal or other material by national or local codes conduits for the power feed 3 phase of constant speed starters may be PVC When not required to be in metal or other
24. ge uin not adjustable Location SensorOutput Sensor Range CT 0 5 amp secondary 0 to 100 amps Note The CT Range is dependent upon the primary value of the CT ratio If the CT is a 500 5 the range would be O to 500 CALIBRATION OF TEMPERATURE amp PRESSURE SENSORS 1 Locate the associated temperature probe on the compres sor package and pull the temperature probe from the well Place the temperature probe in a concentrated ice water bath 80 20 ice to water along with a quality test thermometer Or sensor 2 Wait for approximately two minutes and compare the thermometer reading with the temperature probe reading Enter in the correction for temperature if required 3 Step to the next temperature to be calibrated locate the associated temperature probe on the unit and repeat the calibration process 4 After the temperature probe calibration is complete re insert the temperature probes into the wells 5 Open the suction and discharge stop valves If applicable open the side load stop valve the economizer stop valve and the liquid injection stop valve 6 CHECK FOR LEAKS FRICK QUANTUM HD VILTER RETROFIT INSTALLATION INSTRUCTIONS Page 7 090 040 102 NOV 2014 7 To calibrate the pressure transducers a quality test gauge Is required Go to the Pressure Calibration display and step to the suction pressure setting 8 If available attach the test gauge to the suction pressure servi
25. h the starter contactor still energized the compressor auxiliary will continue to feed an okay signal to the Quantum HD panel This may allow the motor to be subjected to the fault condition on the 3 phase bus A couple of fault scenarios are 1 The 3 phase bus has power on and off in a continuous cycle manner which may cause the motor to overheat due to repeated exces sive in rush current experiences 2 The motor cycling may damage the coupling or cause other mechanical damage due to the repeated high torque from rapid sequential motor bumps 3 Prolonged low voltage may cause the motor to stall and possibly overheat before the motor contactor is manually turned off Under normal conditions the loss of 3 phase power will shut down the Quantum HD panel and it will reboot upon proper power return If the panel was in Auto it will come back and return to running as programmed If the unit was in Remote the external controller will re initialize the panel and proceed to run as required If the panel was in Manual mode the compressor will have to be restarted manually after the 3 phase bus fault interruption has been cleared restored If the local power distribution system is unstable or prone to problems there are other recommendations to satisfy these problems If power spikes or low or high line voltages are the problem then a constant voltage CV transformer with a noise suppression feature is recommended Johnson Con
26. he case with most vertical separators screw chiller packages and other specific duty screw compressor packages Normally an experienced installer can handle these items in the field Contact Frick Engineering for assistance If a problem is encountered The QUANTUM HD control panel will be offered in a kit form which will supply the panel drawings and the current installation operation and maintenance manuals Standard pressure and temperature sensor kit includes four pressure and four temperature sensors Pressure sensor connections are 1 4 MPT SAFETY PRECAUTION DEFINITIONS FRICK QUANTUM HD VILTER RETROFIT Page 2 INSTALLATION INSTRUCTIONS Frick BY JOHNSON CONTROLS The standard temperature probe used with the Vilter Single Screw is 1 4 MPT and threads into the existing 1 4 x 1 2 thermowell A ICTD Temperature Sensor 4 MPT B Existing M x 2 Thermowell Figure 1 ICTD Temperature Sensor amp Thermowell Additional pressure transducers and temperature probes are available as optional items Temperature probes are available in 3 4 and 1 2 MPT with thermowells or 1 4 without the thermowell See page 3 of the Order Entry Data Sheet Publication 090 100A P to select these and other options Indicates an imminently hazardous situation which if not avoided will result in death or A DANGER d serious injury Indicates a potentially hazardous situation or practice which if not avoided
27. nd or ground loop currents The National Electric Code NEC is a guideline for safe wiring practices but it does not necessarily deal with procedures used for electronic control installation Use the following procedures for electronic equipment instal lation These procedures do not override any rules by the NEC but are to be used in conjunction with the NEC code and any other applicable codes With exclusion of the three phase wire sizing Frick drawing 649D4743 should be used as a reference for properly sizing control wires and other wiring specifications Throughout this document the term Electronic Control Panel Is used to refer to the microprocessor mounted on the com pressor package or a Central Control System panel NOTICE It is very important to read the installation instructions thoroughly before beginning the project Make sure you have drawings and instructions with your equipment If not call the manufacturer and request the proper instructions and drawings Every manufacturer of elec tronic equipment should have a knowledgeable staff willing to answer your questions or provide additional information Following correct wiring procedures will ensure proper installation and consequently proper operation of your electronic equipment WIRE SIZING Control power supply wires should be sized one size larger than required for amperage draw to reduce instantaneous voltage dips caused by large loads such as heaters con
28. nnected to ground Cover the electronics with plastic and secure it with masking or electrical tape Place masking tape or duct tape on the inside of the panel where you are going to drill The tape will catch most of the filings Clean all of the remaining filings from the panel before removing the protective plastic When routing conduit to the top of an electronic control panel condensation must be taken into consideration Water can condense in the conduit and run into the panel causing catastrophic failure Route the conduit to the sides or bottom of the panel and use a condutt drain If the conduit must be routed to the top of the panel use a sealable conduit fitting which is poured with a sealer after the wires have been pulled terminated and the control functions have been checked A conduit entering the top of the enclosure must have a NEMA 4 hub type fitting between the conduit and the enclosure so that if water gets on top of the enclosure it cannot run in between the conduit and the enclosure This Is extremely important in outdoor applications NOTICE It is simply NEVER a good practice to enter through the top of an electronic control panel or starter panel that does not already have knockouts provided If knockouts are not provided for this purpose it is obvious this is not recommended and could VOID WARRANTY Never add relays starters timers transformers etc in side an electronic control panel without fir
29. nsion is relieved You may need to press down on the photo chopper a few times to fully relieve the tension Once the tension is relieved press the Blue Calibration Button on the volume slide actuator to initiate volume slide actuator calibration The red calibration LED will be flashing at a rapid rate multiple times per second Press the Blue calibration button again The red calibra tion LED is now flashing at a slower rate about once per second The minimum volume position output is now set on the actuator On the Capacity Volume calibration page press the Set Low Volume button to set the Volume Low Value refer ence voltage on the Quantum HD controller To prevent the volume slide from hitting the low end physical stop the reference voltage for Volume Low Value is adjusted upward by 3 of the actuators output range of 0 5 VDC 15 volts The Quantum HD will not decrease the volume slide beyond the Volume Low Value reference voltage With the red calibration LED flashing at the slower rate press the Increase Volume Slide button The photo chop per will spin at a high rate until the high end physical stop is reached and the photo chopper winds to a stop Quickly press the Increase Volume Slide button again to turn of the increase output Press down on the Photo Chopper until the tension is relieved You may need to press down on the photo chopper a few times to fully relieve the tension Pressthe Blue cali
30. ons of the existing controller to use as a reference when making the connections on the replacement controller Remove the MD C in I STRAINER REGULATOR OR OIL PUMP BYPASS existing panel from the compressor package DO NOT CUT WIRES OR TUBING LINES They will be used to connect to the new panel Be sure that all wires are properly labeled by number and purpose 6 Mount the QUANTUM HD panel on the compressor package by bolting the panel to the existing panel mounting structure It may be necessary to weld new panel mounting brackets to the screw compressor package to accommodate the proper panel height If so DO NOT WELD TO THE PRESSURE VESSEL Weld only to existing mounts or other structural material DO NOT WELD WITH THE CONTROL PANEL IN PLACE Welding currents may damage the electronic components Refer to the PANEL MOUNTING HEIGHT diagram below PANEL MOUNTING HEIGHT BOLT OR WELD PANEL BRACKET TO EXISTING STRUCTURE CONTROL CABINET Typical Height 58 From Floor To Center of Display Figure 5 Panel Mounting Height Frick BY JOHNSON CONTROLS 7 II the existing temperature sensors are not ICTDs or the sensor s output is NOT 4 20mA 0 20mA O 5V 1 5V O 10V or 2 10V the temperature sensors must be replaced The temperature sensor kit that comes with the QUANTUM HD retrofit includes the following 4 ICTD 1 4 MPT temper
31. or model number is as follows Vilter Command Shaft Rotation ad Capacity Capacity Volume Volume oae Increase Decrease Increase Decrease CW CCW CW CCW 71 451 501 601 V5M 601 V55 701 3001 CW Clockwise CCW Counter Clockwise 090 040 I02 M0V 2014 Page 8 INSTALLATION INSTRUCTIONS Figure 8 Calibration Capacity Volume Screen Capacity Slide Actuator Volume Slide Actuator Figure 9 Capacity amp Volume Slide Actuator Orientation To check proper command shaft rotation for the capacity and volume actuators go to the calibration page for Capacity and volume See Figure 8 Press the load or unload capacity button for the capacity slide to check rotation If rotation is incorrect switch the brown and blue wire for load and unload at the digital board Use the increase or decrease volume button for the vol ume slide to check rotation If rotation is incorrect switch the brown and blue wire for increase and decrease at the digital board FRICK QUANTUM HD VILTER RETROFIT Frick BY JOHNSON CONTROLS Four components interact to display and calibrate the ca pacity and volume slides Command Shaft Photo Chopper Calibration Button amp Calibration LED C Calibration Button Blue D Calibration LED Red A Command Shaft B Photo Chopper Figure 10 Actuator Control Board Once the rotation of the capacity and volume command shafts are confirmed go
32. sia 1 4 MPT Transducer discharge oil amp pre filter pressure 4 24 3 wire shielded cables with integrated DIN connector 1 4 hole 3 4 strain relief Once each of the pressure transducers are properly installed plug in the cables and route back to the QUANTUM HD Gather the cables and run through the 4 hole 3 4 strain relief provided in the kit Use one of the 4 holes provided at the bottom left side of the enclosure for the entry of these cables 11 Refer to the panel wiring diagrams in the Maintenance manual 090 040 M or 090 020 M and connect the red black and white wires of the pressure transducers to the QUANTUM HD analog board The shield of the transducer cable is grounded inside the transducer and should not be grounded inside the cabinet NOTICE If the existing sensors are 4 20mA they can be used and need to be configured properly for signal type and range in Analog I O Configuration FRICK QUANTUM HD VILTER RETROFIT INSTALLATION INSTRUCTIONS Page 5 090 040 102 NOV 2014 12 The motors actuators for the capacity and volume slides need to be the current optical actuators If the existing motors are the old gear driven type these will need to be replaced with the optical actuators before proceeding The position feedback cable from the capacity and volume slide actuators will be routed back to the QUANTUM HD and through 2 of the 4 holes in the 3 4 strain relief that Is provided The cap
33. st contacting the manufacturer Contact arcing and EMI emitted from these devices can interfere with the electronics Relays and timers are routinely added to electronic control panels by the manufacturer but the manufacturer knows the acceptable device types and proper placement in the panel that will keep interference to a minimum If you need to add these devices contact the manufacturer for the proper device types and placement Never run refrigerant tubing inside an electronic control panel If the refrigerant is ammonia a leak will totally destroy the electronics FRICK QUANTUM HD VILTER RETROFIT INSTALLATION INSTRUCTIONS Page 13 090 040 102 NOV 2014 If the electronic control panel has a starter built into the same panel be sure to run the higher voltage wires where indicated by the manufacturer EMI from the wires can interfere with the electronics if run too close to the circuitry Never daisy chain or parallel connect power or ground wires to electronic control panels Each electronic control panel must have its own control power supply and ground wires back to the power source Plant Transformer Multiple electronic control panels on the same power wires create current surges in the supply wires which may cause control ler malfunctions Daisy chaining ground wires taking them to ground at each device allows ground loop currents to flow between electronic control panels which also causes malfunctions See Figure 15
34. starter diagram in the motor starter IOM and is sized according to the CT selection calculation 090 040 I02 M0V 2014 D Verify that auxiliary contacts are provided on the compressor and oil pump contactor E Verify that the compressor motor overloads are sized properly F If the compressor and oil pump starters do not have interposing relays already provided the relays must be mounted and wired as shown on the drawings NOTICE The most common electronic control panel problems are due to undersized AC power wiring poor grounds and control power supplied from lighting panels that have other devices tied to them that generate large amounts of AC line noise Please follow these directions carefully See p 8 for additional information on Installing Electronic Equipment in an Industrial Environment Metal oxide varistors MOV or surge suppressor are recom mended for the compressor starter coil oil pump starter coil if applicable and liquid injection solenoid coil if applicable The MOVs should be placed directly at the coils of these de vices Placement of the MOVs at the control panel terminal strip negates the surge suppression effect 15 Using 10 AWG wire connect the control transformer in the compressor starter panel to the proper terminals in the QUANTUM HD control panel as shown in the IOM on the compressor motor starter diagrams and the panel wiring diagrams These wires are black or red 1 white 2
35. tac tors and solenoids These sudden dips in voltage can cause the electronic control panel whether it is a microprocessor a computer or a PLC to malfunction momentarily or cause a complete reset of the control system If the wire is loaded to its maximum capacity the voltage dips are much larger and the potential of a malfunction is very high If the wire is sized one size larger than required the voltage dips are smaller than in a fully loaded supply wire and the potential for malfunction is much lower The NEC code book calls for specific wire sizes to be used based on current draw An example of this would be to use 14 gauge wire for circuits up to 15 amps or 12 gauge wire for circuits of up to 20 amps Therefore when connecting the power feed circuit to an electronic control panel use 12 gauge wire for a maximum current draw of 15 amp and 10 wire for a maximum current draw of 20 amp Use this rule of thumb to minimize voltage dips at the electronic control panel VOLTAGE SOURCE Selecting the voltage source is extremely important for proper operation of electronic equipment in an industrial environment Standard procedure for electronic instrumenta tion is to provide a clean isolated separate source voltage in order to prevent EMI from other equipment in the plant from interfering with the operation of the electronic equip ment Connecting electronic equipment to a breaker panel also known as lighting panels or utility
36. trols Inc can provide these types of transformers for this purpose Contact Johnson Controls for proper sizing VA Rating based on the requirement of the job If a phase loss occurs then you will typically get a high motor amp shut down If the problem continues an analysis of the facility s power supply quality may be necessary NOTICE It is very important to read the installation instructions thoroughly before beginning the project Make sure you have drawings and instructions for the equipment being installed If not call the manufacturer to receive the proper instructions and draw ings Every manufacturer of electronic equipment should have a knowledgeable staff willing to answer your questions or provide additional information Following correct wiring procedures will ensure proper installation and consequently proper operation of your electronic equipment Frick FRICK QUANTUM HD VILTER RETROFIT 090 040 102 NOV 2014 BY JOHNSON CONTROLS INSTALLATION INSTRUCTIONS Page 15 Notes Form 090 040 I02 2014 11 r JOHNSON CONTROLS Supersedes 090 040 I02 2014 08 j 100 CV Avenue Subject to change without notice Johnson A Waynesboro PA 17268 1206 USA a Published in USA 1114 PDF Phone 717 762 2121 FAX 717 762 8624 2014 Johnson Controls Inc ALL RIGHTS RESERVED Controls www jci com frick
37. uits This conduc tor must also be insulated to avoid inadvertent contact at multiple points to ground which could create Ground Loops In many installations that are having electronic control prob lems this essential wire is usually missing is not insulated or improperly sized FRICK QUANTUM HD VILTER RETROFIT INSTALLATION INSTRUCTIONS Page 11 090 040 102 NOV 2014 NEC size ratings are for safety purposes and not necessarily for adequate relaying of noise EMI to earth ground to avoid possible interference with sensitive equipment Therefore sizing this conductor 1 2 sizes larger than required by code will provide better transfer of this noise Johnson Controls Fricke requires that the ground conductor meet the following Stranded Copper Insulated One size larger than NEC requirements for conventional starters Two sizes larger than NEC requirements for VFD starters Conduit must be grounded at each end This circuit must be complete from the motor to the starter continuing in a seamless manner back to the plant supply transformer power source For Direct Coupled Package Mounted Starters the ground between the motor and the starter may need to be made externally See Figure 13 The connection on the starter end must be on the starter side of the vibration isolators Be certain the connection is metal to metal Paint may need to be removed to ensure a proper conductive circuit The use of counter sunk star w
38. will result in Indicates a potentially hazardous situation or practice which if not avoided will result in damage to equipment and or minor injury LA WARNING death or serious injury NOTICE Indicates an operating procedure practice etc or portion thereof which is essential to highlight Frick BY JOHNSON CONTROLS ORDERING PRESSURE AND TEMPERATURE SENSORS When ordering pressure and temperature sensors the following sensors and cables are provided Cables ARE NOT provided for additional sensors as the distance between those sensors and the panel is unknown Pressure Sensors 1 0 200psia A MPT suction 3 0 500psia 1 4 MPT discharge oil amp pre filter 4 24 3 wire Shielded Cables with DIN Connector Temperature Sensors 4 ICTD style temperature sensors 4 24 2 wire Shielded Cables with DIN Connector Available Temp Sensors specify size when ordering ICTD with 3 4 thermowell See Fig 2a ICTD with 1 2 thermowell See Fig 2b ICTD 1 4 MPT less thermowell See Fig 2c Typical for Vilter VSS retrofits Sensor threads into existing 1 4 x 1 2 thermowell NOTICE Cables ARE NOT provided for additional sensors as the distance between those sensors and the panel is unknown Fig 2a ICTD with 3 4 thermowell li NPT i i 14 Y 1 2
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