160.100-IO EZ-Cal High Pressure Cut-Out Test Block and ...

EZ-CAL™ HIGH PRESSURE CUT-OUTTEST BLOCK & CALIBRATION KIT

Form 160.100-IO (APR 2018) INSTALLATION - OPERATIONFile: SERVICE MANUAL - Section 160Replaces: 160.100-IO (FEB 2018)Dist: 3, 3a, 3b, 3cRevised:

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

THIS MANUAL CONTAINS RIGGING, ASSEMBLY, START-UP, AND MAINTENANCE INSTRUCTIONS. READ THOROUGHLY

BEFORE BEGINNING INSTALLATION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR DEATH,

DAMAGE TO THE UNIT, OR IMPROPER OPERATION.

160.100-IO (APR 2018)

EZ-CAL™ HIGH PRESSURE CUT-OUT TEST BLOCK & CALIBRATION KITINSTALLATION - OPERATION

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

SAFETY PRECAUTION DEFINITIONS

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

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

Contents

GENERAL INFORMATION

Preface .............................................................................. 3Design Limitations ............................................................. 3Unit Inspection .................................................................. 3Transit Damage Claims ...................................................... 3Kit Maintenance ................................................................ 3Test Block Dimensional Outline & Port Locations .............. 4

INSTALLATION

Retrofit Installation ............................................................ 5

OPERATION

Operation Instructions & Testing ....................................... 7Principles of Operation ...................................................... 7Operation Procedure Example ........................................... 8

WARNING

CAUTION

DANGER

NOTICE

160.100-IO (APR 2018)


General Information

PREFACEThis manual has been prepared to acquaint the owner and serviceman with the INSTALLATION and OPERATION pro-cedures as recommended by Frick® Industrial Refrigeration for the EZ-CAL™ High Pressure Cut-out Test Block and Calibration Kit.

Both ASHRAE 15 and IIAR-2 safety standards prohibit the use of an intervening stop valve in the compressor discharge line leading to the high-pressure-limiting device (High Pressure Cut-out, or HPCO).

The IIAR-6 standard will require testing of the HPCO yearly to show the function of the device to shut down an operating compressor. The standard does not allow removal and bench testing of the HPCO or testing on a shutdown compressor.

There is a safe, simple calibration solution that complies with safety standards.

The Frick EZ-CAL™ test block is designed to be installed be-tween the compressor discharge connection and the HPCO. The unit provides a simple calibration method in compliance with safety standards, while reducing the risk of prematurely lifting a safety relief valve with a resultant ammonia release.

It is most important that these units be properly applied to an adequately controlled refrigeration system. Your authori zed Frick® representative should be con sulted for their 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 HPCO unit should be connected to a properly designed and installed system.

NOTICETrained personnel are required for

handling and installation.

DESIGN LIMITATIONSThe compressor units are designed for operation within the pressure and temperature limits as shown in Frick® publica-tion 070.610-SED.

UNIT INSPECTIONImmediately upon delivery examine the box and components for dam age. Unpack all items and check against shipping lists for any discrepancy. Examine all items for damage in transit.

TRANSIT DAMAGE CLAIMSAll claims must be made by consignee. This is an ICC re-quirement. Request immediate inspection by the agent of the carrier and be sure the proper claim forms are execut ed.

Report damage or shortage claims im mediately to John-son Controls, Frick® Sales Ad ministration Depart ment, in Waynes boro, PA.

KIT MAINTENANCEIf, in the course of regular use, any component in the EZ-CAL™ block or calibration kit fails to work or any com-ponent becomes damaged, the damaged component should be discarded and replaced with a new one.

160.100-IO (APR 2018)


EZ-CAL™ TEST BLOCK DIMENSIONAL OUTLINE & PORT LOCATIONS

NOTES:1. Dimensions are in inches unless indicated otherwise.2. Constructed of 316/316L ASTM A479.3. Max. Press./Temp. Rating: 2,500 psi from -55°F to 150°F (-48°C to 65°C), 1,000 psi up to 300°F (148°C).4. Recommended tubing from EZ-CAL™ block to the compressor is stainless steel, minimum 3/8".

(3 7/8)

(1 5/8)1/4 NPTINLET

(7/16)

(1 3/16)

1/4 NPT PRESSURETRANSDUCER PORT

2X (5/16)MOUNTING HOLES (1 1/8)

(1 1/8)(1 1/4)

(5 7/8)

(3)

(2 1/2)

QUICK CONNECTWITH BODY PROTECTOR

(3/8) LATCH LOCK(LOCKS IN THIS POSITION ONLY)

Figure 1. Test Block Dimensional Outline

160.100-IO (APR 2018)

EZ-CAL™ HIGH PRESSURE CUT-OUT TEST BLOCK & CALIBRATION KITINSTALLATION

Installation

PE

MOTORCOMPRESSOR

SUCTION

DISCHARGE

PI

C

R

EZ-CAL™ HPCOCALIBRATION BLOCK

DISCHARGE PRESSURE & HPCOTRANSDUCER

LOCKABLE '2' POSITIONVALVE (RUN/CALIBRATE)

TEMPORARILY INSTALLEDFOR FIELD CALIBRATION

PERMANENTLYINSTALLED

TEST PORT CONNECTION

MASTER GAUGE

HAND OIL PUMP

REFRIGERATIONOIL SUMP

CONNECTION HOSETO TEST PORT

HIGH PRESSURE CUT-OUT CALIBRATION DIAGRAM

RUN POSITION

CALIBRATE POSITION

DISCH PRESSURE

RETROFIT INSTALLATIONDuring installation of the test block, care should be taken to minimize total system volume from the test block to the HPCO. Directly installing the HPCO discharge pressure transducer on the test block will keep the volume low, and be much easier to pressurize during testing.

WARNINGThis section must be read and un der stood before installing or performing any main tenance or service to the unit.

When installing or performing service you must take several precau tions to ensure your safety:

1. If unit is running, press [stop] key.

2. Disconnect power from unit before performing any maintenance.

3. Wear proper safety equipment when compressor unit is opened to atmosphere.

4. Ensure adequate ventilation.

5. Take necessary safety precautions required for the re-frigerant being used.

WARNINGClose all compressor package isolation valves prior to servicing the unit. Failure to do so may result in seri-ous injury.

NOTICERecommended tubing from the EZ-CAL™ block to the compressor is stainless steel, minimum 3/8".

Figure 2. HPCO Calibration Diagram

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160.100-IO (APR 2018)

EZ-CAL™ HIGH PRESSURE CUT-OUT TEST BLOCK & CALIBRATION KITOPERATION

Operation

OPERATION INSTRUCTIONS & TESTINGThe Frick® EZ-CAL™ test block, 720B0129H01, is designed to be installed between the compressor discharge connection and the discharge pressure limiting device, (the high pressure cut-out, or HPCO).

Figure 3. Test Block in Test & Run Position

Figure 4. Test Block in Run Position

The valve is lockable in the RUN position.

PRINCIPLES OF OPERATIONTEST BLOCK

The test block functions as a low pressure drop check valve, not a stop valve, in the line from the discharge pressure source to the HPCO. In the RUN position the HPCO is fully open to the discharge pressure source.

In the TEST position an external pressure source is con-nected to the test connection quick connect and when the valve is switched to TEST position, the external source is connected directly to the HPCO. This allows the function of the HPCO and pressure setting to be confirmed by applica-tion of external pressure while comparing the compressor discharge pressure reading to a master gauge.

Once the HPCO is confirmed to trip the compressor at the correct set point, the valve is switched back to run mode and any high pressure trapped above the check valve is relieved back to the system. Should an actual high pressure event occur, even during testing, the check valve in the test block

will open and expose the HPCO to the high pressure level, still allowing protection of the compressor during testing of the HPCO.

One EZ-CAL™ test block should be installed permanently on each compressor and only be used when the HPCO is to be tested. They can be locked in the RUN position during normal operation, but the compressor is still protected from a high pressure event in either operational position.

NOTICELeaving the test block valve in the TEST position after testing is complete can trap the external pressure be-tween the HPCO and the test port.

The only risk by leaving the test block valve in the TEST posi-tion after testing is complete is trapping the external pressure between the HPCO and the test port. The discharge pressure reading on the control panel would not see the decrease in discharge pressure as the system is returned to normal op-eration. Returning the test block valve to RUN position after test opens a direct two-way connection between discharge pressure and the HPCO transducer or switch.

During installation of the test block, care should be taken to minimize total system volume from the test block to the HPCO. Directly installing the HPCO on the test block will keep the volume low, and be much easier to pressurize during testing.

TEST PUMP CALIBRATION KIT (720B0129G01)

Figure 5. Calibration Kit in Hard Case with Hose

The test pump calibration kit comes complete with hydraulic test pump, a 15 foot quick connect hose, oil reservoir, and calibrated master gauge – all suitable for use with refrigera-tion oil as the pressurizing media.

The pump is used to connect to the quick connect test port on the test block. Once the test block is switched to the TEST position, operation of the test pump will allow the technician to raise the pressure measured at the HPCO until the run-ning unit is proven to stop at the correct cut-out pressure.

The actual cut-out pressure can be compared between the pressure display on the control panel and the master gauge included with the test pump. If the reading is beyond the permissible tolerance (generally 2.5% of cut-out pressure), the control panel should be recalibrated to read correctly at the set point.

160.100-IO (APR 2018)


If used to test a pressure switch, and the switch does not function to stop the compressor at the correct set point, the switch should be properly adjusted or replaced, and re-tested to show proper cut-out within tolerance. Once testing is complete the pump can be removed at the quick connect to the block, and the block can be switched back to the RUN position.

Any test refrigeration oil used during the testing will drain harmlessly into the compressor sump without introducing non-condensable gas to the system. The test pump is then ready to calibrate the next compressor HPCO.

OPERATION PROCEDURE EXAMPLE1. Each technician that is using this test block and test pump for calibration should be trained in general ammonia refrigeration safety practices (or other refrigerants used). All technicians need to be aware they are dealing with high pressure toxic or flammable gases and due caution is es-sential to assure safety. We suggest that each facility review this example procedure and modify as necessary to assure safety in their facility.

NOTICEThe test block and calibration kits are refrigerant spe-cific and the refrigerant to be used must be specified at time of order. O-ring material will vary between different refrigerants.

2. The test block and calibration kits are refrigerant specific and must be ordered with the refrigerant to be used specified. O-ring material will vary between different refrigerants.

3. Remove test pump from hard carrying case. Inspect for any damage.

4. Familiarize yourself with the components and operation of the pump and gauge.

GAUGE

ZEROMAXMIN CONFIG ENTER

Needle Bleed Valve

Vernier Control

Top Port 1/4” FNPT

Gauge Display

Side Port 1/8” FNPTfor optional ReliefValve only (P/N 1010050)

Fill Port and Cap

Media Reservoir

Stroke Limiter

Fill Line

Figure 6. Calibration Kit Pump and Gauge

5. Select an oil that is compatible with the refrigeration system being calibrated and with the MECP10K pump. Frick oils 3, 9, 9S, 11, and 11S are all suitable for ammonia systems, but it is not recommended to change the oil used in the pump back and forth. Pick an oil for the pump and always use the same oil and pump together to avoid O-ring swell or shrinkage issues.

6. The pump is equipped with a safety relief valve set to 500 psi to avoid overpressure of the pump or hose during the test. This safety valve is adjustable with an allen wrench. It is advisable to test the function of the safety valve with CAUTION before the first time the pump is used to be sure it will not open at a normal test pressure. The hose and pump are designed for operation pressures well above normal refrigeration pressure.

7. Fill the reservoir to the fill line with clean refrigeration oil then reinstall the fill plug finger tight. During use do not let the reservoir drop below 50% of the reservoir capacity. (Do-ing so may allow air to be introduced into the test system).

Figure 7. Oil Reservoir and Fill Plug

160.100-IO (APR 2018)


8. Use only the provided hose between the pump and block. The provided hose is rated for the system pressures it will be exposed to, and has internal check valves to prevent leakage of refrigerant into the pump or from the hose once disconnected.

Figure 8. Adjust gauge to zero

9. Press enter to turn on the gauge. If the reading is not zero, press zero to adjust for atmospheric pressure.

10. The male-end of the hose connects to the test block.

Figure 9. Hose Connection (Male End)

11. The female-end of the hose connects to the test pump and gauge unit.

Figure 10. Hose Connection (Female End)

12. Close needle bleed valve on pump, clockwise, and posi-tion Vernier dial about middle position. Insert quick connect fitting labeled “pump end” into the hand pump quick connect at red guide sleeve. It should “click” into place.

Figure 11. Calibration Pump Vernier Dial

13. The hose can trap high pressure oil or gas between the pump and the check valve. Read the gauge reading to see if internal pressure is trapped in the hose from the last use. The pressure can be “carefully” bleed off to the reservoir by slowly opening the bleed valve. If air or refrigerant is trapped in the hose it can foam the oil in the reservoir, so open the bleed slowly if pressure is shown on the gauge. Once pres-sure is relieved close the bleed valve, (turn clockwise).

14. On first use the hose should be filled with oil to avoid pushing air into the system. Push the stroke limiter into the prime mode position to allow the handles to have maximum travel. Hold the center post of the block end quick connect in while working the pump handles until oil comes out of the hose end.

NOTE: this can take many strokes of the pump depending on the volume of the hose and whether the pump has been used in a while. It is important to hold the reservoir reasonably level to allow the pump to properly fill between strokes. Slow operation of the pump is more effective than fast operation, to give the plunger time to properly fill on each pump stroke.

15. See image below.

GAUGE

ZEROMAXMIN CONFIG ENTER

Figure 12. Avoiding air in the hose/system

160.100-IO (APR 2018)


16. Once fluid starts to exit the end of the hose switch the valve on the test block to test position and connect the hose to the test port on the test block.

Figure 13. Block in TEST Position

17. Insert the hydraulic hose (block end) into the test port of the test block.

Figure 14. Attaching Hydraulic Hose

18. Equipment is now ready for testing. The block valve is shown in the test position.

Figure 15. Block remains in TEST Position

19. Squeeze the pump handles until the master gauge starts to show a sharp rise in pressure.

Figure 16. Checking Reading on Gauge

20. The person conducting the test should be able to see the reading from the discharge pressure sensor on the control panel begin to rise and follow the pressure increase created by the test pump once the pump pressure exceeds the dis-charge pressure. As the test pressure begins to approach the cut-out set-point, the stroke limiter button can be pushed in, (from the back side of pump), while the handles are squeezed together to put the pump in “pump mode” where the pres-sure increase can be controlled more precisely. NOTE: Failure to use the stroke limiter will greatly reduce the mechanical advantage the user has and will limit the maximum pressure that can be generated with reasonable handle pressure.

21. See below.

Figure 17. Using the Stroke Limiter

22. As the test pressure approaches the cut-out set point, the final pressure adjustment can be made by turning the Vernier dial. The Vernier is capable of fine pressure adjustment but only a few psi.

160.100-IO (APR 2018)


23. See below.

Figure 18. Vernier Dial Adjustment

24. If the HPCO fails to stop the compressor from operating when the HPCO reaches its set point, repairs will be required. The transducer on discharge pressure will need to be re-calibrated to the master gauge, within allowable tolerance, (IIAR-6 proposes a maximum disagreement of 2.5% of set point pressure). A HPCO switch will need to be adjusted (if possible), or replaced.

25. See final image on 23.

26. Once the HPCO is proven to stop the compressor within allowable tolerance at set point, the calibration is complete and should be documented.

27. The block end of the test hose can be removed from the test block while the test valve is still in the test position. Internal check valves are used to prevent oil leakage in either direction.

Figure 19. Detaching Hydraulic Hose

28. The test block valve can then be switched back to run position, You should observe the panel reading dropping back to the normal discharge pressure reading once the valve position is switched to run. The compressor can be restarted, as necessary, and the test block can be locked in run position with the lock ring in the handle.

Figure 20. Block in RUN Position

29. There is still oil pressure trapped in the hose after the test. This can be left in the hose if it will be used immediately to calibrate another compressor. If not being used immediately, the pressure can be slowly bled off by opening the bleed valve on the pump. There should be no refrigerant trapped in the hose if the above procedure was followed. But, use CAUTION when bleeding the hose in case any gas is in the hose, as it will cause bubbles in the oil reservoir which can spray oil out of the reservoir, Unless a check valve fails to function there should never be ammonia vapor in the test hose, but always open the bleed valve cautiously as any vapor in the hose will be fed back to the reservoir.

30. Once the testing and calibration is complete the pump and hose can be drained of oil and safety quick connect plugs can be inserted in the test port connectors on the block and pump to keep the connections clean.

Figure 21. Using Safety Quick Connect Plugs

31. To assure the master gauge is accurate to NIST (National Institute of Standards and Technology) it should be calibrated to a dead weight tester or master calibration gauge on a scheduled basis with certificate and date maintained.

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

Form 160.100-IO (2018-04)Supersedes: 160.100-IO (2018-02)

Subject to change without noticePublished in USA • 04/18 • PDF

© 2018 Johnson Controls Int'l PLC - ALL RIGHTS RESERVED

April 2018 Form Revisions

p.4 – Added block dimensions and port locationsp.5 – Added tubing notice

– Added Figure numbers throughout

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