PowerPac™ - Johnson Controls Inc.
Contents
1. Form 170 600 JUN 2011 Frick INSTALLATION OPERATION MAINTENANCE File SERVICE MANUAL Section 170 Replaces 5170 600 IOM JUN 08 BY JOHNSON CONTROLS Dist 3 3a 3b 3c PowerPac PACKAGED CHILLER UNITS 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 170 600 1OM JUN 11 FRICK POWERPAC Frick Page 2 INSTALLATION OPERATION MAINTENANCE SY JOHNSON CONTROLS Contents UI aS OE D sl Ec LAU SEGRE 3 JOBIINSPEGTION X d hec ate hie M Na sco dr de 3 TRANSIT DAMAGE GEAIMS i232 2223452223 2 0 x 0 keaton AL Lo Bt Ne a e 3 CHILLER AND UNIT IDENTIFICATION he eoe cet ecce resi eerte tec ec c dE eter 3 PACKAGED AMMONIA CHIEEER UNITS uias CD ceo cese Poet etd 4 COMPRES SO Re see Av 4 COMPRESSOR CAPACITY 2 4 EUBRICATION SYSTEM deb Meo In um Mame he ntu Mu iere cs M cU dE De e MR CN ELSE et cea Ee i 4 OIL SEPARATOR RESERVOIR cccccccccceeeececeeccccueeeececececenueeecececece2. Prestart Checks Compressor PHD Setup Motor PHD Setup Coolant Installed 4 20 Coolant Loop Pump Setup Installation Foundation Position of all valves Proper oil charge All wiring connections Starter Cleanliness All micro settings 4 20 CT Channel 16 Setup Capacity Mode 1 Mode 2 Mode 3 Mode 4 VFD Hi amp Low PI Control Miscellaneous Sequencing Condenser Screen Saver Motor Winding RTD s Setup Motor Bearing RTD s Setup Motor Temperature Thermistor Setup 4 20 Motor Drive Signal Calibrated Channel Cold alignment Configuration Direction Coolant Loop Temp Setup Cooling Fan Motor I O Setup Cooling Fan Rotation Checked Oil pump motor rotation Motor rotation 4 20 Output Calibration Liquid Makeup Valve Coolant Temp Valve Economizer Makeup Valve Package Compressor Pump Dual Pump Drive Refrigerant K Factor Filter PowerPac ERE FRICK POWERPAC 170 600 IOM JUN 11 Ev JOHNSON CONTROLS FORMS Page 19 Page 2 Unit Serial Frick Order No Capacity Control Setpoints Setpoint Regulation Setpoint Regulation Safeties High Low Load Inhibit High Low Load Inhibit Prop Band Force Unload Prop Band Force Unload Dead Band Warning Dead Band Warning Cycle Time Sec Sec Warning Delay Sec Cycle Time Sec
3. IPS Overall Motor Inboard Coupled End Horizontal IPS Overall Vertical IPS Overall Axial IPS Overall Compressor Inboard Coupling End Female Axial Direction IPS Overall Compressor Outboard Nondrive End Vertical Direction IPS Overall Motor Outboard Noncoupled End Horizontal IPS Overall Vertical i IPS Overall Axial IPS Overall 9 FRICK POWERPAC 170 600 IOM JUN 11 Frick INSTALLATION OPERATION MAINTENANCE Page 23 Index A Ammonia 15 anchoring 7 brine 8 C capacity control 4 CO2 13 compressor data plate 3 compressor oil 4 COMPRESSOR PRESTART CHECKLIST 17 compressor rotation 10 Continuously Loaded System 8 cooling towers 8 D demand oil pump 4 drainage system 8 drainage valve 11 E elastomeric gear 10 electrical on off regulator 12 electric wiring 8 evaporator 8 11 F float valve 8 12 float vessel 12 flow switch 8 foundations 7 Fresh water 8 H horizontal liquid separator 6 hot gas ejector 13 L level sensor 13 liquid separator 6 M MAINTENANCE 14 brine temperature 14 Cooling agents 16 environment 15 Evaporating temperature 14 Excessive condensing pressure 14 First Aid 15 noncondensable gases 14 Oils 16 PSM procedures 16 Troubleshooting 14 Ventilating 16 VIBRATION DATA SHEET 22 mechanical float valve 12 motor alignment 10 moto
4. CONDENSER EVAPORATOR DRIPTRAY M1 I Figure 10 170 600 IOM JUN 11 MAINTENANCE The operator must be familiar with the unit and this instruc tion manual in order to service and maintain the PowerPac unit properly Before dismantling any portion of the unit it is important to make sure that the pressure in the unit or its components has been equalized to atmospheric pressure Parts to be dismantled must not contain refrigerant Operator safety is improved by using gloves and face pro tection It is suggested that a suitable gas mask be at hand It is useful to have spare gaskets available for replacement use Only use the recommended Frick oil specified for your PowerPac unit When handling refrigerants oils brines etc personal safety and protection of the environment should have a very high priority Use only the refrigerant for which the unit was originally designed Before starting the dismantling servicing process remove all main fuses switch off all electric components on the compressor unit and LOCK THE MAIN SWITCH Make sure that the motor cannot start up inadvertently Make sure that there is no over pressure and no refrigerant in the part to be dismantled Close all necessary stop valves Use the prescribed tools and check that they are properly maintained and in good working condition In explosion proof areas use tools suited for this specifi
5. 170 600 IOM JUN 11 ay JOHNSON CONTROLS INSTALLATION OPERATION MAINTENANCE Page 21 Page 4 Unit Serial Frick Order No P amp ID Setpoints Name Control Action Control Point Device Source Device Channel Setpoint Dead Band Prop Band Integral Gain Communications Compressor ID Comm 1 Comm 2 Comm 3 Baud Rate Baud Rate Baud Rate Data Bits Data Bits Data Bits Stop Bits Stop Bits Stop Bits Parity Parity Parity RS 485 Connection RS 485 Connection RS 485 Connection Protocol Protocol Protocol Use Map File Ethernet IP Data Naming Data Protocols Address Type Host Name ModBus TCP IP Address Work Group Ethernet I P Gateway Address Comments Profinet Subnet Mask Web Server Port 170 600 1OM JUN 11 FRICK POWERPAC Page 22 INSTALLATION OPERATION MAINTENANCE Frick BY JOHNSON CONTROLS VIBRATION DATA SHEET 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 RAM Motor Serial Number RPM Frame Size H P Refrigerant Ambient Room Temperature F Operating Conditions SUCTION DISCHARGE OIL SEPARATOR Slide Valve Position Compressor Inboard Coupling End Male Axial Direction ____ IPS Overall Compressor Inboard Coupling End Vertical Direction
6. CONCENTRATED VAPOR 1 Force the eyelids open and rinse eyes immediately for at least 30 minutes with salt water solution 2 Call a doctor immediately FRICK POWERPAC 170 600 1OM JUN 11 Page 15 SKIN BURNS FROM LIQUID SPLASHES OR CONCENTRATED VAPOR 1 Wash immediately with large quantities of water and continue for at least 15 minutes Remove contaminated clothing carefully while washing 2 Call a doctor immediately 3 After washing apply wet compresses saturated with a sterile isotonic 0 996 NaCI solution salt water to affected areas until medical assistance is available FOLLOW YOUR COMPANY GUIDELINES FOR PROCESS SAFETY MANAGEMENT PSM ADDITIONAL FACTS ABOUT R 717 Ammonia is easily absorbed by water At 59 F 15 C 1 06 qt 1 liter of water can absorb approximately 1 1 Ib 05 kg liquid ammonia or approximately 185 gal 700 liters ammonia vapor Even small amounts of ammonia in water are enough to destroy marine life if allowed to pollute waterways and lakes Because ammonia is alkaline it will damage plant and ani mal life if released into the atmosphere in large quantities Refrigerant evacuated from a refrigeration plant must be charged into refrigerant cylinders intended for this specific refrigerant If the refrigerant is not to be reused return it to the supplier or to an authorized incineration plant Halocarbon refrigerants are colorless and odorless Their presence is undetec
7. MODEL SERIAL and Johnson Controls Frick SALES ORDER NUMBERS from these data plates as es Frick BY JOHNSON CONTROLS PACKAGED CHILLER UNIT SMSC MODEL NO REFRIGERANT MAX DESIGN PSC 0 00 ME YEAR od 100 CV AVENUE WAYNESBORO PA 17268 PHONE 717 762 2121 UNIT DATA PLATE c ee Frick BY JOHNSON CONTROLS ROTARY SCREW COMPRESSOR MODEL NO SERIAL NO MAX ALLOWABLE MAX DRIVER PRESSURE PSIG SPEED RPM WAYNESBORO PA 17268 O O COMPRESSOR DATA PLATE 170 600 1OM JUN 11 Liquid Separator Evaporator Compressor PACKAGED AMMONIA CHILLER UNITS PowerPac is a complete factory manufactured liquid refrigeration unit intended for water or brine cooling It is engineered and manufactured to meet the exacting require ments of the industrial refrigeration market All components have been designed and arranged to assure reliability acces sibility and ease of service Units are completely assembled with all interconnecting refrigerant piping and internal wir ing The PowerPac unit is controlled by the Quantum MLX control and capacity regulating system The unit can be equipped with these optional features Dual Oil Filters and Unit Mounted Solid State Starter Packages Contact Johnson Controls Frick for details This unit should only be charged with the refrigerant for which
8. Temperature Liquid Slug Shutdown Is Above F for Sec Package Safeties Low Compressor Oil Temperature Pull Down Warning Delay Sec Capacity Position Shutdown Delay Sec Amount of Time Sec High Compressor Oil Temperature Pump Down Warning Delay Sec On When Suction Above PSIG Delay Min Shutdown Delay Sec DX Circuit Low Compressor Oil Pressure 1 Action Warning PSI Delay Sec Off When Below Shutdown PSI Delay Sec On When Above High Filter Pressure 2 Action Warning PSI Delay Min Off When Below Shutdown PSI Delay Min On When Above Main Oil Injection Liquid Injection Shutdown PSI Delay Sec On When Above Delay Sec Oil Heater Off Above Dual Port Transition High Level Shutdown Delay Sec Low Oil Level Delay Sec Hot Gas Bypass Oil Pump Lube Time Before Starting Sec Power Assist Sec Dual Pump Transition Time Sec 170 600 IOM JUN 11 Page 20 Page 3 FRICK POWERPAC INSTALLATION OPERATION MAINTENANCE Unit Serial Frick Order No Compressor Motor Setpoints and Information Motor Name Plate VFD Manufacturer Motor Amps Maximum Drive Output 96 Frame Size Volts Minimum Drive Output 96 H P Service Factor Remote Control RPM Horsepower Rate Of Increase Delay Serial CT Factor Rate Of Decrease Delay Service Factor Recycle Delay Min Capacity Control Voltage High Motor Amps When Slide Valve Reaches 96 Hz Load Inhibit Drive Speed Reaches Design Force Unload Variable Speed Min Slide Valve Position Co
9. They may differ from those stated VENTILATING A REFRIGERATION PLANT If itis necessary to ventilate a refrigeration plant make sure you observe the following Never release refrigerants directly into the atmosphere When ventilating an R 717 plant you must use an ap proved air ventilator Released air must pass through an open water container in which the remnants of R 717 refrigerant will be absorbed Send the water containing R 717 to an authorized incineration plant COOLING AGENTS Standard PowerPac units are designed to use glycol or water as the cooling agent Other cooling agents include Salt solutions brines of calcium chloride CaCl or sodium chloride NaCl In general all brines must be considered harmful to nature Use caution when charging or purging a refrigeration plant Never empty brines down a sewer or into the environment The brine must be collected in suitable containers clearly marked with the contents and sent to an approved incin eration plant OILS To lubricate screw compressors included in the PowerPac units use only Semisynthetic hydrotreated oil When changing the oil in the compressors and when empty ing the vessels the used oil must be charged into containers marked waste oil and sent to an approved incineration plant NOTE The owner of the refrigeration plant is responsible for ensuring compliance with all Federal state and local regulations PSM procedures
10. be of industrial quality The floor shall be a minimum of 6 inches 152 mm of re inforced concrete Housekeeping pads are recommended Anchor bolts are required to tie the unit firmly to the floor Once the package is rigged into place See HANDLING and MOVING it must be shimmed in order to level the unit The shims should be placed to position the package rails one inch 25 4 mm above the housekeeping pad to allow space for grouting An expansion type epoxy grout must be worked under all areas of the base filling all voids It should be allowed to settle with a slight outward slope so oil and water can run off of the base When installing on the upper floors of buildings extra precautions should be taken to prevent normal package vibration from being transferred to the building structure It may be necessary to use rubber or spring isolators or a combination of both to prevent the transmission of com pressor vibration directly to the structure However this may increase package vibration levels because the compressor is not in contact with any damping mass Rubber or spring pipe supports may be required to avoid exciting the building structure at any pipe supports close to the chiller package It is best to employ a vibration expert in the design of a proper mounting arrangement Proper foundations and proper installation methods are vital and even then sound attenuation or noise curtains may be required to reduce noise to desire
11. occur during operation Scheduled maintenance tasks for the equipment and when how to carry them out safely To prevent accidents assembly and disassembly of compo nents should be carried out by authorized personnel only It is important that the operating personnel familiarize themselves with the contents of this manual in order to ensure proper and efficient operation Johnson Controls is not liable for damage occurring during the warranty period where this is attributable to incorrect operation For information about the functions of the Quantum LX control panel communications specifications and wiring diagrams see publication series 090 020 O M CS and E90 020 SPC For information about the functions of the compressor packages see publications 070 410 IOM and 070 610 IOM It is most important that these units be properly applied to an adequately controlled refrigeration system Your authorized Johnson Controls Frick representative should be consulted for expert guidance in this determination Proper performance and continued satisfaction with these units is dependent upon CORRECT INSTALLATION PROPER OPERATION REGULAR SYSTEMATIC MAINTENANCE To ensure correct installation and application the equipment must be properly selected and connected to a properly de signed and installed system The Engineering plans piping layouts etc must be detailed in accordance with the best practices and local codes such as those
12. should be routinely followed 5 POWERPAC 170 600 1OM JUN 11 Frick FORMS Page 17 READ THIS FIRST COMPRESSOR PRESTART CHECKLIST The following items MUST be checked and completed by the installer prior to the arrival of the Frick Field Service Supervisor Details on the checklist can be found in this manual Certain items on this checklist will be reverified by the Frick Field Service Supervisor prior to the actual start up Mechanical Checks Electrical Checks Confirm that motor disconnect is open Confirm that main disconnect to motor starter and micro Isolate suction pressure transducer is open Pressure test and leak check unit Confirm that electrical contractor has seen this sheet Evacuate unit ALL PERTINENT WIRING information and drawings Remove compressor drive coupling guard Confirm proper power supply to the starter package Remove coupling center and DO NOT reinstall Confirm proper motor protection breaker sizing motor rotation must be checked without center __ Confirm that all wiring used is stranded copper and is Check for correct position of all hand stop and check 14 AWG or larger sized properly valves PRIOR to charging unit with OIL or REFRIGERANT Confirm all 120 volt control wiring is run in a separate Charge unit with correct type and quantity of oil conduit from all high voltage wiring Lubricate electric drive motor bearings PRIOR to Confirm all 120 vol
13. teeth Center the gear and hub assembly so there is equal engagement on both shafts Adjust the space between hubs as specified in the Coupling Data Table below COUPLING DATA TABLE Coupling Hub CH Keyway Series Min Max Min Spacing Torque Dr Size Setscrew Torque In mm In mm In mm In mm In mm Ft Lb Nm UNC Ft Lb Nm 1 4 20 UNC 13 5 16 18 40 7 5 16 24 UNF 13 5 16 18 74 6 3 8 24 UNF 13 5 16 18 74 6 3 8 24 UNF 13 5 16 18 1 2 20 UNF 13 5 16 18 1 2 20 UNF 13 5 16 18 Ll Frick BY JOHNSON CONTROLS COMPRESSOR UNIT OIL DO NOT MIX OILS of different A WARNING brands manufacturers or types Mixing of oils may cause excessive oil foaming nuisance oil level cutouts oil pressure loss gas or oil leakage and catastrophic compressor failure NOTE The 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 refrigerant operating pressures or temperatures refer to Frick Oil publication 160 802 spc for guidance For standard PowerPac units use only semisynthetic hy drotreated oil as provided by Johnson Controls Frick Semisynthetic hydrotreated oil is a synthetic oil with a low vapor pressure This greatly reduces the amount of oil that is passed with the R 717 discharge gas from the compressor to the separator during operation The resul
14. 15 GENERAL Sz etie ute sete MOI Rida Pe LU Lp AR Dea EL aM MIT ee 15 EYE INJURIES FROM LIQUID SPLASHES OR CONCENTRATED 15 SKIN BURNS FROM LIQUID SPLASHES OR CONCENTRATED VAPOR ssssssssseeeeeeeemeneeenenn enm nennt hn nnhnnnt tls s s nnne hnnntr sene 15 ADDITIONAL FACTS ABOUT R7717 x t aeu eoe eh eere xoc D eter eet ee e oce roe canned Pie ce e oe o acte ton 15 PROTEGTING THE ENVIRONMENT hee eeu eie e ke lated aa a ee DOSE 15 ADDITIONAL FACTS ABOUT REFRIGERAN IS 3 rto otio Ee Eoo pe eta elie DESEE eee ve ie onde eR eT EDEPOL pubs Due eee 15 VENTILATING A REFRIGERATION 8 16 COOLING AGENT Se cies eee esti eet ett th ete sath et oth an ca tae ee et 16 OllS uet TO Se CE AEN BE PR fa EA ENESE SAE AEE cbe Pos ore eR Es Ferr 16 Ll Frick BY JOHNSON CONTROLS PREFACE This manual has been prepared to acquaint the owner and serviceman with the INSTALLATION OPERATION and MAIN TENANCE procedures as recommended by Johnson Controls Frick for PowerPac Chiller Units Dangers resulting from failure to comply with safety pre cautions when operating the equipment and performing maintenance tasks How to start operate and stop the equipment safely How to respond when problems
15. UMPDOWN After pressure testing evacuate the refrigeration system to remove any atmospheric air or moisture 170 600 1OM JUN 11 The boiling point of a liquid is defined as the temperature at which the vapor pressure is equal to atmospheric pressure The boiling point of water is 212 F 100 C If the pressure is lowered so is the water s boiling point The table indicates the boiling point of water at very low pressures BOILING POINT AT PRESSURE of WATER F C IN H2O mm 41 5 3 6 6 63 50 10 4 9 9 14 59 15 6 8 12 73 68 20 9 5 17 80 For pumpdown use a vacuum pump that empties the pack age of both air and water vapor The vacuum pump must be able to lower the pressure to approximately 0 05 in H2O 0 1 mm Hg and it must be equipped with a gas ballast valve Use this valve as much as possible in order to prevent the condensation of water vapor in the vacuum pump IMPORTANT NEVER use the refrigeration compressor to pump down a system For pumpdown to be satisfactory the final pressure must be lower than 2 7 in H20 5 mm Hg NOTE There is a risk that any water still present in the refrigeration system may freeze if the ambient tempera tures drops below 50 F 10 C If this occurs add heat to the environment of the components because ice does not evaporate easily OPERATING LOG Monitor the condition of the package Log data manu ally using the History and Trending ca
16. Warning Delay VFD Prop Band Shutdown VFD Prop Band Shutdown VFD Integ Time Sec Shutdown Delay Sec VFDInteg Time Sec Shutdown Delay Sec Channel Channel Auto Cycle Low Suction Auto Cycle Low Suction Start Load Inhibit Start Load Inhibit Start Delay Min Force Unload Start Delay Min X Force Unload Stop Warning Stop Warning Stop Delay Min Warning Delay Sec Stop Delay Min Warning Delay Sec Shutdown Shutdown Shutdown Delay Sec Shutdown Delay Sec Compressor Safeties High Discharge Temperature High Suction Pressure Load Inhibit Load Inhibit PSIG Force Unload Force Unload PSIG Warning Start Differential Warning PSIG Warning Delay Sec Pressure Below Warning Delay Sec Shutdown 50 PSI Shutdown PSIG Shutdown Delay Sec Shutdown Delay Sec High Discharge Pressure Dual Mode Economizer Regulation Modes 1 amp 3 Modes2 amp 4 On When Above Load Inhibit PSIG PSIG Off When Below Force Unload PSIG PSIG Override Discharge Pressure Warning PSIG PSIG Port Value Warning Delay Sec Sec Pressure Input Shutdown PSIG PSIG Fixed Pressure Setpoint Shutdown Delay Sec Sec Maximum Discharge Pressure PSIG Highest Cap To Permit Start Balance Piston Start Period Before Cap Increase On Stopping Period For Cap Unload Off Compressor Auto Mode Min Cap 96 Ignore Delay _ Min Capacity Unload Assist Rate Fail Delay _ Min Separator Velocity Ref Oil Log Delay Sec Compression Ratio Liquid Slug Warning Main Oil Injection On When Discharge
17. ally as indicated in the table in Technical Data Check the amount by weighing the refrigerant cylinders on a scale The liquid level in the liquid separator should be no higher than 2 5 inches 64 mm 6 Close the charge valve and slowly increase capacity to 10096 Never leave the unit unattended A CAUTION during the first 60 minutes following start up DRAINING REFRIGERANT Use the following procedure to drain refrigerant from the unit Run the system normally Manually reduce the chiller package capacity to minimum Connect the drain valve to a refrigerant vessel approved for this purpose The connection must be made with an approved refrigerant hose Check that the vessel is large enough A WARNING to hold the entire Sante being overfilled and that is made for the particular refrigerant used DO NOT charge the vessel beyond 90 liquid volume Before connecting the vessel place it in chilled water or cool it by some other means Open the drainage valve and stop valve on the refrigerant vessel Close valves that supply liquid refrigerant to the evaporator Using this procedure the evaporator is pumped down and the condensed liquid transferred to the refrigerant vessel After dismantling the refrigerant vessel and protecting cap must both be weighed to ensure that the vessel is not overfilled Net and gross weights stamped into the vessel include the weight of the protecting cap SYSTEM P
18. auuesececececauaeseeeeeceeeauaeeseceeceesuaeuceeeeeeeesaueueceeeeeeesaaeeeeeeeeessaaeneeeeeeeseas 5 OMS COOWING 22 6 ret nee ace TAB vefte id tait Sh cor ABT eM cd to ok Me ON Te he Ra e Ie d 5 rnm a A ae ee ace he es ee A 5 SEMIWELDEDB PIATE CONDENSER vee tek Uren id octets roe tetto green nce eie agere ie toed eee 5 SEMIWEEDED P ATE EVAPORATOR sie itio reto lette so be ete tgs otc Tegan ew et 5 QUANTUM LX CONTROEGENTER 2 5x24 4 903 a A Le coh ks Ma LIN ALL LS AE 5 LIQUID REERIGERANT SEPARATOR nit oed pee CS OC pn an OU o TIE baud 6 INSTAELATION d et Eon aab e ds cur cii cv cu Doe av cus cp 7 FOUNDATIO eae heehee tele lt ot ies Sate 7 PANDUNG ANO MOVIN G Pe lh I i SG SN eru cde ear AS i elie 7 BRINE WATER SYSTEMS 0 0044 2 1 1 0 0 0016100 06000 8 000096 EE 8 EFECTRIC AWIRIN S retos ote coii 8 5 Ma tat 9 OPERATION a rte isa AE M CE ME D LI ROME 10 PRESTART GHEGCKI IS v te ocio ect ets Coe c rete gn e
19. ay have a built in oil cooler The unit can also be equipped with other types of condensers FRICK POWERPAC INSTALLATION OPERATION MAINTENANCE Page 5 170 600 1OM JUN 11 SEMIWELDED PLATE EVAPORATOR The evaporator is a plate heat exchanger consisting of a number of cassettes carefully adapted to the actual operating conditions The cassettes are assembled bolted together in a frame made for the actual design pressure The refriger ant evaporates inside the cassettes and brine is cooled on the outside The evaporator in Figure 2 is of the flooded type which means that it is filled with boiling refrigerant This liquid leaves the liquid separator and is led to the evaporator through the drop leg Dry Suction Liquid Makeup Liquid Separator 9 Brine Water Inlet Wet Return Drop Leg t Fi 5 EE 8 2 gt Evaporator Brine Water Outlet Figure 2 Semiwelded Plate Evaporator When the water or brine is cooled in the evaporator on its way through the brine water connections the refrigerant boils and a mixture of liquid and vapor flows through the wet return and into the liquid separator From here the su perheated vapor is led to the compressor through the dry suction while the separated liquid is collected at the bottom of the liquid separator The system is self circulating and needs no pump on the refrigerant side Liquid runs from the high pressure side and is supplied to the li
20. c purpose Also use electrical protection equipment and tools suited for electrical operation purposes Use only Johnson Controls original spare parts other parts may impair the safety of the compressor unit TABLE 1 EXCESSIVE CONDENSING PRESSURE FRICK POWERPAC Page 14 MAINTENANCE LLLI d Frick BY JOHNSON CONTROLS TROUBLESHOOTING AND CAPACITY MEASUREMENT OPERATING CONDITIONS Variations in pressures and temperatures within the cooling cycle can provide information about the operating state of the chiller package Suction and condensing pressures as well as the tempera tures of suction and discharge gas can provide important information Small changes in the variable pressures and temperatures are sufficient to create considerable changes in the operat ing conditions These issues highlight the importance of using the Operat ing Log TROUBLESHOOTING An error in the system often leads to changes in operating conditions but not to a total shutdown For that reason check the operating state of your PowerPac at regular intervals Refer to compressor manuals for further detail CAPACITY MEASUREMENT If the system does not produce the capacity indicated check for possible sources of error Before taking any action check the possible causes indicated in Tables 1 and 2 below INCORRECT CAPACITY MEASURING The PowerPac chiller is equipped with a Fricke Quantum LX control system for control an
21. ckage NOTES 1 Reference OSHA Safety And Health Standards 29 CFR 1910 sections 1910 179 and 1910 184 2 Hooks chains cables and spreader bars shall meet manu facturer s recommendations and shall not be overloaded 3 This unit shall be lifted using the four lifting lugs welded to the base as shown above Shackles and screw pins shall be provided by others as shown in Figure 5 as minimum 4 Spreader bars and balancing chains must be used to pre vent instability and damaging or straining system piping instrumentation or vessels 5 Adjust cables or chains to ensure that the package skid is stable and lifted in a level manner 6 Lifting must be done by a qualified operator ANCHOR SHACKLE WITH SCREW PIN MIN RECOMMENDED RATING 24 000 LB NOMINAL SHACKLE SIZE 114 LO Figure 5 170 600 IOM JUN 11 LIFTING LUG CAPACITY LB LUG NOMINAL BEAM CABLE ANGLE MEMBER SIZE VERTICAL 45 W10 19 400 14 990 BRINE WATER SYSTEMS For the most efficient operation of the unit ensure a full flow of either water or brine through the evaporator Full flow is achieved by using either of systems A or B in Figure 6 Brine water to from PowerPac Circulating pump Brine water to from the system Modulating 3 way valve Buffer tank Figure 6 A Continuously Loaded System The cooling media cir culates continually through the system and
22. d levels For more detailed information on Screw Compressor Foun dations please request Frick publication S70 210 IB HANDLING AND MOVING Use a crane and rigging whenever the unit is moved DO NOT USE A FORKLIFT Refer to the engineering drawings provided with the unit for shipping weight Spreader bars should be used on CAUTION both the length and width of the package to prevent damage to the package CAUTION must also be used in locating the lifting ring Appropriate adjustment in the lifting point should be made to compensate for the center of gravity FRICK POWERPAC INSTALLATION Page 7 170 600 1OM JUN 11 SPREADER BAR VIEWA A SPREADER BAR i BY OTHERS CHAIN OR CABLE RATED ACCORDINGLY Figure 4 The unit may be top heavy Lifting A WARNING operators must use extreme care to check the level and stability of the load before lifting the load more than a few inches Impose an imbalance by sequentially adding weight to each corner and carefully observing the load reaction to make sure the load does not shift Balancing chains cables or straps are essential in both directions to prevent load shift and instability during rigging Call Johnson Controls Frick Engineering for an estimate of the location of the center of gravity of the package if one is not given The center of gravity may NOT be located in the center of the pa
23. d regulation of the package capacity according to leaving brine water temperature The Quantum LX has a display to read the operating conditions The pressures and temperatures indicated are not exact They can only be used to perform approximate capacity calculations Exact measurements should be calculated in accordance with ASHRAE procedures Cause Remedies Insufficient water flow through the condenser Adjust water supply or clean the strainer Fouling in the condenser Clean the condenser Overheated cooling water Obtain colder cooling water or reduce compressor capacity The plant is overcharged Drain refrigerant into an empty vessel Air or noncondensable gases in the system Remove air from the condenser A condensing temperature 2 F lower results in 196 additional cooling capacity TABLE 2 EVAPORATING TEMPERATURE TOO LOW Causes Remedies Fouling in the evaporator Clean the evaporator Inspect the oil return system Add more refrigerant to the plant Oil in the evaporator Insufficient refrigerant charge An evaporating temperature 2 F higher results in 4 additional cooling capacity Ll Frick BY JOHNSON CONTROLS First Aid In Case Of Ammonia Accidents Chemical Formula Nh Refrigerant R 717 GENERAL Ammonia is easy to identify It has a strong distinctive odor that is noticed by most people even at very low harmless concentrations Ammonia serves as its own warning agent so that no one
24. de Warning Delay Sec Skip Frequency Bands Bearing Type Shutdown Delay Sec Bottom Top Motor Coupling Low Motor Amps Shut Down Delay Sec Confirmed Running Motor Amps Starting Motor Amps Ignore Period Vyper Standby Time PHD Monitoring Setpoints Compressor Bearing Suction End Delay High Warning gF Sec High Shutdown gF Sec Motor Bearing Shaft Side Delay High Warning F Sec High Shutdown F Sec Motor Stator Stator 1 Delay High Warning F Sec High Shutdown F Sec Stator 3 Delay High Warning F Sec High Shutdown F Sec Remote Capacity Deadband High Compressor Oil Pressure Shutdown PSI Delay Sec Sec Vyper Coolant Setpoints Vyper Coolant Low Temp Alarm Delay Shutdown Delay High Temp Alarm Delay Shutdown Delay Condenser Control Condenser Control Setpoint Discharge End Delay Digital Controls Step Order High Warning gF Sec Module A High Shutdown gF Sec Module B Module C Module D Opposite Shaft Side Delay Step Up Dead Band PSI High Warning F Sec Step Up Delay Sec High Shutdown F Sec Step Down Dead Band PSI Step Down Delay Sec High Pressure Override PSI High Pressure Override Delay Sec Stator 2 Delay High Warning F Sec Analog Controls Analog Output A High Shutdown F Sec Analog Output B Proportional Band PSI Integration Time Sec High Limit PSI Low Limit Sec Miscellaneous Max Slide Valve Timer 1 10 Sec Max Discharge Pressure PSI Max Discharge and Oil Temp F Y JOHNSON CONTROLS ERE FRICK POWERPAC
25. e and leak tested at the factory and then thoroughly evacuated and charged with dry nitrogen to ensure the integrity of the unit during shipping and short term storage prior to installation NOTE Care must be taken when entering the unit to ensure that the nitrogen charge is safely released Holding charge shipping gauges on AWARNING separator and external oil cooler are rated for 30 PSIG and are for check ing the shipping charge only They must be removed before pressure testing the system and before charging the system with refrigerant Failure to remove these gauges may result in catastrophic failure of the gauge and uncontrolled release of refrigerant resulting in serious injury or death All units must be kept in a clean dry location to prevent corrosion damage Reasonable consideration must be given to proper care for the components of the microprocessor panel and related instrumentation Units which will be stored for more than two months must have the nitrogen charge checked periodically Packaged equipment and all vessels should be visually in spected to verify that all components are intact undamaged and that the configuration is consistent with the sales order requirements Temporary coverings such as tarps or shrink wrap should be inspected to ensure that they are not trapping water in contact with the equipment Enclosures should be checked for accumulated water and drained as applicable The packaged equi
26. ice Supervisor should arrive to find the above items completed He should find an uncoupled compressor drive unit to verify motor rotation and alignment and energized oil heaters with the oil at the proper standby temperatures Full compliance with the above items will contribute to a quick efficient and smooth start up The Start up Supervisor will 1 Verify position of all valves 6 Verify and finalize alignment if applicable 2 Verify all wiring connections 7 Calibrate slide valve and slide stop 3 Verify compressor motor rotation 8 Calibrate temperature and pressure readings 4 Verify oil pump motor rotation 9 Correct any problem in the package 5 Verify the of FLA on the micro display 10 Instruct operation personnel NOTE Customer connections are to be made per the electrical diagram for the motor starter listed under the installation section and per the wiring diagram listed under the maintenance section of the IOM Please complete and sign this form amp fax to 717 762 8624 as confirmation of completion Frick Sales Order Number Print Name Compressor Model Number Company Unit Serial Number Job Site Contact End User Name Contact Phone Number Address of Facility City State Zip Signed FRICK POWERPAC 170 600 JUN 11 Page 18 FORMS Frick Start up Report Frick Order No Sold To Contact Name Date End User Contact Name Phone End User Address Fax No City State Zip Start up Representat
27. ion This makes impurities remain in the refrigeration system in an ever increasing concentration also increasing their harmful effects Using a drainage system can minimize the concentration of impurities This drains off some of the polluted cooling tower water and replaces it with fresh water This drainage system consists of a hand operated adjusting valve Position 5 Figure 7 that is opened sufficiently to drain the polluted cooling tower water to a treatment system Fresh water is provided through the float valve shown at Position 3 COOLING TOWER Air in Air out Float valve Pump Adjusting valve with outlet to treatment system Condenser Overflow pipe Figure 7 ELECTRIC WIRING All electric wiring inside the PowerPac unit has been con nected at the factory on units ordered with solid state package mounted starters or mounted variable frequency drives External wiring connections that must be established once the PowerPac unit is installed are 1 Mounting of main power supply cable to the control panel 2 Mounting of control line for starting of the condenser pump 3 Mounting of control line for starting of the evaporator pump 4 Mounting of flow switch if any 5 Mounting of outside thermostat if any 9 FRICK POWERPAC 170 600 1OM JUN 11 Frick INSTALLATION Page 9 HOLDING CHARGE AND STORAGE Each PowerPac chiller is pressur
28. it was designed Once charged with refrigerant connected to electricity and with pipe connections established to water brine the unit is ready for operation COMPRESSOR The Frick XJF or SGC rotary screw compressor has been designed utilizing the latest technology to offer the most reli able and energy efficient unit currently available Compressor casings are designed and tested in accordance with the re quirements of ANSI ASHRAE 15 safety code and are designed for 400 psig working pressure The rotors are manufactured from forged steel and use the latest asymmetric profiles The compressor incorporates a complete antifriction bearing design for reduced power consumption improved efficiency and reduced maintenance The bearings provide an Lio life in excess of 100 000 hours at design conditions The XJF compressor incorporates a simple mechanism that adjusts the compressor volume ratio during operation to the most efficient of three possible volume ratios depend ing on system requirements The SGC Compressor includes FRICK POWERPAC Page 4 INSTALLATION OPERATION MAINTENANCE a Frick BY JOHNSON CONTROLS Condenser Quantum LX a patented method of varying the internal volume ratio to match the system pressure ratio Either compressor reduces the power penalty associated with over under compression The compressor unit is a Frick standard unit complete with oil separator oil return system stop val
29. ive Unit General Information Unit Model it Customer Package Identification Compressor Serial Separator National Board Unit Serial Oil Cooler National Board Evaporator National Board Serial Condenser National Board Serial Oil Pot National Board H P Receiver National Board Economizer National Board Suction Accumulator National Board Refrigerant Oil Filters Lube Oil Type Design Operating Conditions Oil Cooling 9 Suct Disch Micro Information Micro Type Program Software Ver and Date UL Serial Digital I O Board 1 Serial 3t Software Ver and Date Digital I O Board 2 Serial Software Ver and Date Analog Board 1 Serial Software Ver and Date Analog Board 2 Serial Software Ver and Date Compressor Motor Starter Drive Information Manufacturer Part Model Starter Type Serial Input Voltage Voltage Range Phase Hz Current Output Voltage Phase Hz Max FLA Max LRA Min Load FLA Job FLA Logic Board Serial U33 Prog Ver Date P N U34 Prog Ver Date P N U45 Prog Ver Date P N Harmonic Filter Serial Prog Ver Date P N Frick Interface Serial Prog Ver Date P N CT Location Checked CT Phase CT Ratio Transition Time DBS Ver Oil Pump Information Pump Mfg Model Serial Motor Mfg H P Motor RPM Service Factor Volt HZ FLA Design Code Starter Size Cooling Fan Information Motor HP RPM Service Factor Volt Hz FLA Cooling Fans Special Options
30. l but note that a small amount of liquid may be left when dismantling the float vessel The vent valve Figure 9 is located in the middle of the end cover of the float housing and allows access to the top of the float housing through a tube Electrical Regulation To regulate the liquid level in the condenser a level sensor registers the liquid level The level is converted to a signal which is sent to the Quantum LX panel The Quantum LX panel controls the opening degree of the motorized expan sion valve Level Sensor x Actuator Expansion Valve Figure 9 Ll Frick BY JOHNSON CONTROLS PURGING THE SYSTEM Purging of air or other noncondensable gases is required in order to keep high performance of the system and avoid corrosion of the equipment which could endanger the safety of persons and equipment When purging a refrigeration system make sure to observe the following Refrigerants must not be released into the atmosphere except CO which can be released slowly into the atmo sphere When purging an R 717 system use an approved air purg er The purged air must pass through an open container of water for any remaining R 717 to be absorbed The water mixture mus
31. n of rotation of the oil pump c Mount the coupling and check that the tolerances and the alignment are in accordance with the instructions concern ing the coupling d Connect the vacuum pump to valve position 414 see piping diagram and evacuate the unit to a vacuum of approximately 4to 5 mm Hg A thermostatic vacuum meter may be used to measure the pressure If necessary charge dry air or nitrogen until the pressure reaches 1 bar Evacuate again to 4 to 5 Hg e Usually the unit has been charged with oil from the factory If not see the procedure about Oil Charging in the Operating manual for the compressor FRICK POWERPAC OPERATION Page 11 170 600 IOM JUN 11 CHARGING REFRIGERANT The refrigerant charge for a PowerPac unit is very small in relation to the large cooling capacity Most of the refriger ant liquid is present in the evaporator by design The total amount of refrigerant is indicated on the engineering drawing included with the unit 1 Connect a refrigerant cylinder to the charge valve Purge the charge hose with refrigerant before tightening the union nut on the valve 2 Open the charge valve Refer to the Start up procedure outlined above to initiate compressor operation 3 Start the compressor as described in the Control Panel manual 4 Check the compressor for any abnormal noises and make sure that the compressor is building differential pressure 5 Charge the amount of refrigerant gradu
32. ontal three stage design with integral sump The separator is designed and constructed in accordance with ASME Section VIII Div 1 Replaceable coalescent separator elements are provided for final gas oil separation of particles down to less than 1 micron OIL COOLING The compressor oil is cooled using a semiwelded plate heat exchanger that is integral with the refrigerant condenser The heat exchanger plates are AISI 316 stainless steel construc tion Maximum design working pressure is 300 or 400 psig MOTOR A factory mounted flanged motor is close coupled to the compressor The compressor motor assembly requires no field coupling alignment Standard motors are open drip proof ODP have class B insulation and 1 15 service factor SEMIWELDED PLATE CONDENSER Condenser Motorized Expansion Valve Figure 1 Semiwelded Plate Condenser Semiwelded plate heat exchangers have plates constructed of AISI 316 Stainless Steel Gaskets are a two piece construc tion for excellent compatibility with refrigerant and cooling media The plate heat exchangers can be disassembled for easy cleaning and capacity modification Like the evaporator the CPHE condenser is a plate heat exchanger and the number of cassettes is exactly adapted to the current operating conditions Refrigerant condenses between the welded plates which make up the cassettes and the cooling water circulates in the channels between the cassettes The plate condenser m
33. outlined in ASHRAE literature A refrigeration compressor is a VAPOR PUMP To be certain that it is not being subjected to liquid refrigerant carryover itis necessary that refrigerant controls are carefully selected and in good operating condition that load surges are known and provisions made for control and that operating cycles and defrosting periods are reasonable 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 FRICK POWERPAC INSTALLATION OPERATION MAINTENANCE Page 3 170 600 1OM JUN 11 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 executed Report damage or shortage claims immediately to Johnson Controls Frick Sales Administration Department in Waynes boro PA CHILLER AND UNIT IDENTIFICATION Each chiller unit has 2 identification data plates The unit data plate containing unit model serial number and Johnson Controls Frick sales order number is mounted on the side of the compressor base The compressor data plate contain ing compressor model and serial number is mounted on the compressor body NOTE When inquiring about the compressor or unit or ordering repair parts provide the
34. pabilities of the Fricke Quantum LX See the Quantum LX Operating Manual shipped with the package This operating log should be maintained at regular intervals providing important information about the cause of any undesired changes in the operating state The operating log should also contain data about the com pressor s cooling system functions and whether there are unusual noises or vibrations HIGH PRESSURE REGULATING SYSTEM The PowerPac unit is equipped with either a mechanical high pressure float valve or an electrical sensor and motorized expansion valve Both systems are mounted at the outlet of the condenser and regulate the liquid level in the condenser At the same time they control the expansion between the low pressure and high pressure sides of the chiller unit Mechanical Float Valve The mechanical float valve Figure 8 is mounted on the condenser liquid outlet resulting in a compact design and a very low liquid charge FRICK POWERPAC Page 12 OPERATION LLL cd Frick BY JOHNSON CONTROLS Figure 8 The float valve has a bypass boring Position 1 This ensures that a pressure equalization occurs at standstill between the high and low pressure sides with a subsequent emptying of liquid from the float housing The hole is placed below liquid leve
35. pment and all vessels should be visually inspected for rust paint fade paint blisters and surface im perfections that may have occurred as a result of handling and storage damage The paint may indicate some visual not functional deterioration especially epoxy paint coatings Water spots and chalking are typical flaws of exposed epoxy Amerlock 385 paint systems and some minor rust staining will occur at locations such as casing splits flanges and tags We recommend touching up these areas Touch up paint can be purchased from the Baltimore Parts Center Packaged equipment and all vessels are purged and placed under a regulated dry nitrogen purge pressure of 5 to 15 psig Gauges are installed in the appropriate locations to confirm that the nitrogen pressure is being maintained Gauges should be checked every two weeks If within the first three months of storage inspection records indicate a repetitive loss of nitrogen charge then the Frick Service department should be contacted To prevent damage to the shaft seals and false brinelling of the antifriction bearings the drive shafts for the compressor drive motor oil pump and motor should be rotated every two weeks The drive shafts should be rotated 90 degrees beyond one full rotation All drive motors shipped from the factory have prelubricated bearings to sustain the motor over the short term Care must be taken to keep the bearings dry and moisture free Water and or condensa
36. quid separator through the liquid makeup line QUANTUM LX CONTROL CENTER The Quantum LX is a control and monitoring system for supervision and regulation of the chiller unit It is factory mounted and completely wired with all required safety and operating devices The control system includes as standard a single NEMA 4 control panel housing microprocessor control and electrical termination points Included in the microprocessor is time proportioning capacity control first out annunciation prealarms volume ratio controls real time clock control access code protection lead lag sequencing alternate suction pressure operation trending and more The operating conditions at the time of the compressor s last ten alarms or shutdowns are stored in memory providing the ultimate in service and troubleshooting convenience A built in telecommunications interface is standard enabling connection to a remote computer or control device 170 600 1OM JUN 11 FRICK POWERPAC Erike Page 6 INSTALLATION OPERATION MAINTENANCE Frick LIQUID REFRIGERANT SEPARATOR The liquid separator Figure 3 is of the horizontal type and especially designed for plants with small refrigerant charges and small variations in liquid level The liquid level can be checked on the liquid level column sight glass Position 9 A horizontal liquid separator is specifically designed for critically charged units with small variations in liquid level This level mus
37. r Hutch eeu ce deh ase ros Eoo tele gre ce resents 10 CHECKING MOTOR COMPRESSOR 22 2 26 000 000666 10 COMPRESSOR MOTOR COUPLING 5 02 0 2000 0 0 00000 000010 0 0 10 COMPRESSOR UNIT 11 EVACUATION LC UHR 11 CHARGING REFRIGERANT eI TAA 11 AR cn recante LO eMe AR e darn Sa cq A necis eu Si ee Do ee e 11 SYXSTEM PUMPDOM N tester oT oes 11 la ds SN CARS COR m 12 HIGH PRESSURE REGULATING SY STEM 22535 ae reece elt 12 PURGINGTHE SYSTEM t Meo CERE Ce EE Ie e ee oett Lee 13 AUTOMATIC OIL RETURN 5 5 2 13 MAINTENANCE concione nad de hec Potato ata e qve er tuvo e ti 14 TROUBLESHOOTING AND CAPACITY 5 14 GAPACITY MEASUREMEN T zn rU tunt Depto AG eco Lodo oio SO Coetu al coL aL A c e 14 INCORRECT CAPACITY 14 FIRST AID IN CASE OF AMMONIA 5
38. rized expansion valve 12 N nitrogen charge 9 noncondensable gases 13 O oil pump 4 oil separator 5 operating log 12 P plate heat exchanger 5 PowerPac 1 3 4 8 9 10 11 12 13 14 16 pressure testing 11 Q Quantum LX 3 5 12 14 R refrigerant charge 11 S Semisynthetic hydrotreated oil 11 SGC Compressor 4 sight glass 6 solenoid valves 13 Spreader bars 7 start up 11 SuperFilter Il 4 System with load variations 8 T telecommunications interface 5 thermostat 8 U unit data plate 3 V vacuum pump 12 vapor pressure 12 variable frequency drives 8 vent valve 12 vent valves 8 VIBRATION DATA SHEET 22 W water 8 water expert 8 water quality 8 Water treatment 8 X XJF compressor 4 Form 170 600 2011 06 r JOHNSON CONTROLS Supersedes S170 600 IOM 2008 06 J 100 CV Avenue Subject to change without notice Waynesboro PA 17268 1206 USA Published in USA GUI 1C Johnson N Phone 717 762 2121 FAX 717 762 8624 2011 Johnson Controls Inc ALL RIGHTS RESERVED Controls www johnsoncontrols com frick
39. t be sent to an authorized incineration plant Halocarbon refrigerants CFC HCFC and HFC cannot be absorbed by water An approved air purger must be fitted to the system This must be checked regularly by use of a leak detector All precautionary measures practicable must be taken to prevent and minimize leakage of refrigerant from refrigeration and air conditioning systems to the atmosphere NOTE The occurrence of air is usually an indication of poor maintenance or lack of thoroughness at installation If the chiller contains air it tends to gather on the high pressure side of the system NOTE R 717 systems should be purged on a regular basis to avoid atmospheric air and other noncondensable gases AUTOMATIC OIL RETURN SYSTEM The small amount of oil leaving the compressor unit with the discharge gas is eventually collected at the bottom of the evaporator if the refrigerant is ammonia A reservoir is mounted in this location This oil is automatically returned to the compressor Oils used with halocarbons are skimmed from the surge drum then returned to the compressor The float switch controls solenoid valves M1 and M2 shown in Figure 10 With a rising oil level the built in reed switch will activate the solenoid valves The oil is conveyed to the compressor suction line by means of the hot gas ejector E1 With a falling oil level the solenoid valves will close FRICK POWERPAC INSTALLATION Page 13 170 600 IOM JUN 11
40. t control wiring is run in a separate checking motor rotation conduit from oil pump and compressor motor wiring Check oil pump alignment if applicable Confirm no high voltage wiring enters the micro panel Check for correct economizer piping if applicable at any point __ Check separate source of liquid refrigerant supply if Check current transformer for correct sizing and instal applicable liquid injection oil cooling lation __ Check water supply for water cooled oil cooler if ap Check all point to point wiring between the micro and plicable water cooled oil cooling motor starter Check thermosyphon receiver refrigerant level if ap __ Confirm all interconnections between micro motor plicable thermosyphon oil cooling starter and the system are made and are correct Check for PROPER PIPE SUPPORTS and correct founda Ensure all electrical panels are free from installation tion debris METAL PARTICLES and moisture __ Check to ensure ALL piping INCLUDING RELIEF VALVES is completed After the above items have been checked and verified Close the main disconnect from the main power supply to the motor starter Close the motor starter disconnect to energize the micro Manually energize oil pump and check oil pump motor rotation Manually energize compressor drive motor and check motor rotation Leave micro energized to ensure oil heaters are on and oil temperature is correct for start up Summary The Frick Field Serv
41. t is noticeably lower oil consumption Because semisynthetic hydrotreated oils do not mix well with R 717 there is a considerable reduction of any content of this oil taken from the compressor into the refrigeration system The high viscosity index of semisynthetic hydrotreated oils makes the oil slide off evaporator plates more easily and gather on the bottom of the evaporator Then the oil is re turned to the compressor via the automatic oil return system Frick ester based synthetic lubricants are especially suited for HFC refrigerants R 134A R 507 R 404 and the new refrigerant blends Frick synthetic oils are custom blended with additives for oxidation inhibition corrosion protection defoaming and antiwear Synthetic oils have extremely low pour points The low pour point makes it specially suited for low temperature refrigeration applications The high thermal stability of Frick synthetic oil resists breakdown and extends service intervals Consult factory for application assistance EVACUATION When the chiller unit has been installed in its final position and all connections for refrigerant water and electricity instruments potential equalizer connection ATEX only and safety switches have been connected proceed as follows a Check that the direction of rotation of the motor is cor rect with the coupling dismantled The direction of rotation is marked by an arrow on the compressor end cover b Check the directio
42. t not be more than 2 inches 51 mm above the bottom of the liquid separator The separation of liquid from gas is achieved efficiently by leading the return lines to both ends of the liquid separator This reduces the gas velocity in the liquid separator and allows time for the liquid to collect before the gas travels to the compressor Figure 3 Liquid Separator TSAA n Frick BY JOHNSON CONTROLS INSTALLATION FOUNDATION NOTE Allow space for servicing at both ends of the unit A minimum of 24 inches 610 mm is recommended The first requirement of the package chiller foundation is that it must be able to support the weight of the package including oil and refrigerant charge Screw compressors are capable of converting large quantities of shaft power into gas compression in a relatively small space and a mass is required to effectively dampen these relatively high fre quency vibrations Firmly anchoring the chiller package to a suitable founda tion by proper application of grout and elimination of piping stress imposed on the package is the best insurance for a trouble free installation Use only the certified general arrangement drawings from Johnson Controls Frick to determine the mounting locations and to allow for recom mended clearances around the unit for ease of operation and servicing Foundations must be in compliance with local building codes and materials should
43. the evaporator B System with load variations Example air conditioning system with several adjustable cabinets in which the cool ing media flow can be varied The modulating 3 way valve will maintain a constant cooling media flow throughout the evaporator Installation of a buffer tank is recommended as shown in Position 5 Figure 6 NOTE Install vent valves Position 1 Figure 6 at the highest point in the system as well as at the drainage valves Position 2 which are located at the lowest point Connections and valves for chemical cleaning should be installed All cold piping should be insulated in order to avoid condensation Water Treatment For Heat Exchangers Often brine and water for industrial refrigeration plants contain impurities that can create a coating on the heat conducting surfaces This reduces the heat transmission In some cases this coating can cause corrosion of the heat conducting surfaces Use a 12 mesh or finer filter for water or brine in evaporator and condenser circuits This makes it important to monitor brine and water quality Consult a water expert concerning additives to the system before installing the system Warranty does not include any damage that may occur due to harmful impurities in the system FRICK POWERPAC Page 8 INSTALLATION es D Frick BY JOHNSON CONTROLS Attention is drawn to the fact that all cooling towers experi ence a constant loss of water due to evaporat
44. tible without instrumentation Their ability to displace oxygen can make them deadly Never mix R 717 with halocarbon refrigerants PROTECTING THE ENVIRONMENT Many countries have passed legislation in an effort to reduce pollution and preserve the environment Be especially careful with the following substances refrigerants cooling media brines etc lubricating oils ADDITIONAL FACTS ABOUT REFRIGERANTS Refrigerants usually have a natural boiling point which lies a good deal below 32 0 C This means that liquid refrig erants can be extremely harmful if they come into contact with skin or eyes In high concentrations R 717 causes respiratory problems When ammonia vapor and air mix between 15 to 28 vol ume the combination is explosive and can be ignited by an electric spark or open flame 170 600 JUN 11 POWERPAC Page 16 SAFETY Frick When halocarbon vapors come into contact with open flame or hot surfaces over approximately 572 F 300 C they de compose to produce poisonous chemicals These chemicals have a very strong odor warning us of their presence Oil mist in the ammonia vapor increases this risk significantly as the point of ignition falls below that of the mixture ratio stated Usually the strong smell of ammonia will give ample warning of its presence before concentrations become dangerous Check official limits in the location A CAUTION of your installation
45. tion will cause the bearing cages to rust and cause premature failure 170 600 JUN 11 FRICK POWERPAC Page 10 OPERATION Frick OPERATION EOUPLING PRESTART CHECKLIST A clamping style Elastomeric Coupling is used in most After the PowerPac has been installed and all connections applications This coupling for refrigerant water and electricity instruments and safety consists of two drive hubs 1 switches have been completed proceed as follows and a gear type Hytrel or EDPM and neoprene drive Check the rotation direction of the motor with the coupling spacer The split hub is dismantled to be certain it is correct arrow the clamped to the shaft by compressor end cover marks the proper direction of tightening the clamp screws rotation See PRESTART CHECKLIST in FORMS section Torque is transmitted from px the motor through an elastomeric gear which floats freely CHECKING MOTOR COMPRESSOR ROTATION between the hubs Because of the use of a motor compressor adapter housing no field alignment is necessary Make sure coupling hubs are tight AWARNING ened to the shaft before rotating the 1 Inspect the shaft of the motor and compressor to ensure motor to prevent them from flying that no nicks grease or foreign matter is present off and possibly causing serious injury or death 2 Inspect the bores in the coupling hubs to make sure that Injur
46. ves motor etc COMPRESSOR CAPACITY CONTROL Effective capacity control is achieved by use of a slide valve which provides infinite adjustment from 10096 down to 2596 of full load for an XJF compressor and down to approximately 1296 of full load on an SGC Compressor Variable speed drives control capacity through changes in rotor speed They are used for higher efficiency under par tially loaded conditions Variable speed drives also provide faster response to changes in system load LUBRICATION SYSTEM The compressor oil is superior quality semisynthetic hydro treated oil for ammonia applications The oil provides high thermal stability for improved breakdown characteristics and extended service intervals The compressor is designed specifically for operation without an oil pump Otherwise oil required for main oil injection and lubrication is provided by positive gas differential pressure All compressor oil passes through our new Fricke SuperFilter ll specifically designed for increased particle capture cleaner oil and extended com pressor operation SuperFilter ll actually cleans oil cleaner than new It is also designed for horizontal mounting and furnished with isolation stop valves and drain connections for ease of servicing Booster and some low pressure dif ferential high stage applications will require the demand oil pump option Ll Frick BY JOHNSON CONTROLS OIL SEPARATOR RESERVOIR The oil separator is a horiz
47. will voluntarily remain in a room in which concentrations have become hazardous Because ammonia is lighter than air adequate ventilation is the best means of preventing a concentration Experience has shown that ammonia is difficult to ignite and under normal conditions it is a very stable compound NOTE In concentrations greater than 15 ammonia can form ignitable mixtures with air and oxygen It should always be treated with respect Basic rules of First Aid 1 Call a doctor immediately 2 Be prepared Keep an irrigation bottle available contain ing a sterile isotonic 0 9 NaCl solution salt water 3 A shower bath or water tank should be available near all major ammonia installations 4 Individuals applying first aid should be properly protected to avoid further injury INHALATION 1 Move affected personnel into fresh air immediately and loosen clothing to facilitate breathing 2 Call a doctor ambulance with oxygen equipment im mediately 3 Keep the patient still and warmly wrapped in blankets 4 If mouth and throat are burnt thermal or chemical burn let the conscious patient drink water a little at a time 5 Ifthe patient is conscious and the mouth is not burnt give hot sweet tea or coffee never force feed an unconscious person 6 Oxygen may be administered but only when authorized by a doctor 7 If breathing stops apply artificial respiration EYE INJURIES FROM LIQUID SPLASHES OR
48. y may occur if loose clothing they are free of burrs dirt and grit A CAUTION etc becomes entangled on the spin a ning motor shaft 3 Check that the keys fit the hubs and shafts properly COMPRESSOR ROTATION IS COMPRESSOR 4 Slide one hub onto each shaft as far as possible It may CLOCKWISE WHEN FACING a be necessary to use a screwdriver as a wedge in the slot THE END OF THE COMPRES gt SOR SHAFT Under NO condi c tions should the motor rotation be checked with the coupling center installed as damage to the compressor may result Bump the motor to check for correct compressor rotation After verification install the disk drive spacer as applicable 6 Torque the clamping bolts and the keyway set screws in both hubs to the torque value given in the Coupling Data COMPRESSOR MOTOR COUPLING Table DO NOT USE ANY LUBRICANT ON THESE BOLTS INSTALLATION The PowerPac chiller has compressor to motor alignment through the use of a machined cast iron tunnel This tunnel is factory set through machining tolerances ensuring mo tor compressor alignment No alignment is required in the field For replacement motors the shaft alignment should be checked and tolerances verified with the Johnson Controls Frick service department to open the bore before the hubs will slide onto the shafts 5 Hold the elastomeric gear between the hubs and slide both hubs onto the gear to fully engage the mating
Download Pdf Manuals
Related Search