FRICK® POWERPAC BE Spec Powerpac

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    PowerPac

    PACKAGED CHILLER UNITS

    Form 170.600-IOM (JUN 2011)INSTALLATION - OPERATION - MAINTENANCE

    File: SERVICE MANUAL - Section 170Replaces: S170-600 IOM (JUN 08)Dist: 3, 3a, 3b, 3c

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

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

    DAMAGE TO THE UNIT, OR IMPROPER OPERATION.

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    Contents

    PREFACE........................................................................................................................................................................................3JOB INSPECTION ...........................................................................................................................................................................3TRANSIT DAMAGE CLAIMS ...........................................................................................................................................................3CHILLER AND UNIT IDENTIFICATION ..............................................................................................................................................3

    PACkAGED AMMONIA CHILLER UNITS ..........................................................................................................................................4COMPRESSOR ...............................................................................................................................................................................4COMPRESSOR CAPACITY CONTROL .............................................................................................................................................4LUBRICATION SYSTEM ..................................................................................................................................................................4OIL SEPARATOR/RESERVOIR .........................................................................................................................................................5OIL COOLING .................................................................................................................................................................................5MOTOR .........................................................................................................................................................................................5SEMIWELDED PLATE CONDENSER .................................................................................................................................................5SEMIWELDED PLATE EVAPORATOR ...............................................................................................................................................5QUANTUMLX CONTROL CENTER .................................................................................................................................................5LIQUID REFRIGERANT SEPARATOR ................................................................................................................................................6

    INSTALLATION ............................................................................................................................................... 7FOUNDATION ................................................................................................................................................................................7HANDLING AND MOVING ..............................................................................................................................................................7

    BRINE / WATER SYSTEMS .............................................................................................................................................................8ELECTRIC WIRING ..........................................................................................................................................................................8HOLDING CHARGE AND STORAGE.................................................................................................................................................9

    OPERATION .................................................................................................................................................10PRESTART CHECkLIST .................................................................................................................................................................10CHECkING MOTOR/COMPRESSOR ROTATION .................................................................................................................................10COMPRESSOR/MOTOR COUPLING INSTALLATION .......................................................................................................................10COMPRESSOR UNIT OIL .............................................................................................................................................................. 11EVACUATION ............................................................................................................................................................................... 11CHARGING REFRIGERANT ............................................................................................................................................................ 11DRAINING REFRIGERANT ............................................................................................................................................................. 11SYSTEM PUMPDOWN ................................................................................................................................................................. 11OPERATING LOG .......................................................................................................................................................................... 12HIGH PRESSURE REGULATING SYSTEM ....................................................................................................................................... 12

    PURGING THE SYSTEM ................................................................................................................................................................ 13AUTOMATIC OIL RETURN SYSTEM .............................................................................................................................................. 13

    MAINTENANCE ............................................................................................................................................14TROUBLESHOOTING AND CAPACITY MEASUREMENT .................................................................................................................14CAPACITY MEASUREMENT ..........................................................................................................................................................14INCORRECT CAPACITY MEASURING ............................................................................................................................................14FIRST AID IN CASE OF AMMONIA ACCIDENTS .............................................................................................................................. 15GENERAL .....................................................................................................................................................................................15EYE INJURIES FROM LIQUID SPLASHES OR CONCENTRATED VAPOR .......................................................................................... 15SkIN BURNS FROM LIQUID SPLASHES OR CONCENTRATED VAPOR ........................................................................................... 15ADDITIONAL FACTS ABOUT R-717: ............................................................................................................................................. 15PROTECTING THE ENVIRONMENT ............................................................................................................................................... 15ADDITIONAL FACTS ABOUT REFRIGERANTS ............................................................................................................................... 15VENTILATING A REFRIGERATION PLANT......................................................................................................................................16

    COOLING AGENTS .......................................................................................................................................................................16OILS ............................................................................................................................................................................................ 16FORMS ........................................................................................................................................................................................ 17

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    INSTALLATION - OPERATION - MAINTENANCE170.600-IOM (JUN 11

    Page 3

    PREFACE

    This manual has been prepared to acquaint the owner andserviceman with the INSTALLATION, OPERATION, and MAIN-TENANCE procedures as recommended by Johnson Controls-Fric for PowerPacChiller Units.

    Dangers resulting from failure to comply with safety pre-cautions when operating the equipment and performingmaintenance tass.

    How to start, operate and stop the equipment safely.

    How to respond when problems occur during operation.

    Scheduled maintenance tass for the equipment andwhen/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 familiarizethemselves with the contents of this manual in order toensure proper and efcient operation. Johnson Controlsis not liable for damage occurring during the warrantyperiod where this is attributable to incorrect operation.

    For information about the functions of the QuantumLXcontrol panel, communications, specications, and wiringdiagrams, see publication series 090-020 O, M, CS, andE90-020 SPC. For information about the functions of thecompressor pacages, see publications 070-410 IOM and070-610 IOM.

    It is most important that these units be properly applied to anadequately controlled refrigeration system. Your authorizedJohnson Controls-Fric representative should be consultedfor expert guidance in this determination.

    Proper performance and continued satisfaction with theseunits is dependent upon:

    CORRECT INSTALLATION

    PROPER OPERATION

    REGULAR, SYSTEMATIC MAINTENANCE

    To ensure correct installation and application, the equipmentmust be properly selected and connected to a properly de-signed and installed system. The Engineering plans, pipinglayouts, etc. must be detailed in accordance with the bestpractices and local codes, such as those outlined in ASHRAEliterature.

    A refrigeration compressor is a VAPOR PUMP. To be certain

    that it is not being subjected to liquid refrigerant carryoverit is necessary that refrigerant controls are carefully selectedand in good operating condition; that load surges are nownand provisions made for control; and that operating cyclesand defrosting periods are reasonable.

    JOB INSPECTION

    Immediately upon delivery examine all crates, boxes andexposed compressor and component surfaces for damage.Unpac all items and chec against shipping lists for anydiscrepancy. Examine all items for damage in transit.

    TRANSIT DAMAGE CLAIMS

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

    Report damage or shortage claims immediately to JohnsonControls-Fric Sales Administration Department, in Waynes-boro, PA.

    CHILLER AND UNIT IDENTIFICATION

    Each chiller unit has 2 identication data plates. The unitdata platecontaining unit model, serial number and JohnsonControls-Fric sales order number is mounted on the side othe compressor base. The compressor data plate contain-ing compressor model and serial number is mounted on thecompressor body.

    NOTE: When inquiring about the compressor or unit, orordering repair parts, provide the MODEL, SERIAL, andJohnson Controls-Frick SALES ORDER NUMBERS fromthese data plates.

    COMPRESSOR DATA PLATE

    UNIT DATA PLATE

    100 CV AVENUE, WAYNESBORO, PA. 17268

    PHONE: 717-762-2121

    MAX DESIGNPRESSURE:

    YEAR

    SERIAL NO:

    REFRIGERANT:

    PACKAGED CHILLER UNIT

    MODEL NO:

    SALES ORDER NUMBER:

    PSIG

    kPa

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    PACKAGED AMMONIA CHILLER UNITS

    PowerPac is a complete, factory-manufactured liquidrefrigeration unit intended for water or brine cooling. It isengineered and manufactured to meet the exacting require-ments of the industrial refrigeration maret. All componentshave been designed and arranged to assure reliability, acces-sibility, and ease of service. Units are completely assembledwith all interconnecting refrigerant piping and internal wir-

    ing. The PowerPac unit is controlled by the QuantumLXcontrol and capacity regulating system. The unit can beequipped with these optional features: Dual Oil Filters andUnit-Mounted Solid-State Starter Pacages. Contact JohnsonControls-Fric for details.

    This unit should only be charged with the refrigerant for whichit was designed. Once charged with refrigerant, connectedto electricity and with pipe connections established to water(brine), the unit is ready for operation.

    COMPRESSOR

    The FrickXJF or SGC rotary screw compressor has beendesigned utilizing the latest technology to offer the most reli-able and energy efcient unit currently available. Compressorcasings are designed and tested in accordance with the re-quirements of ANSI/ASHRAE 15 safety code and are designedfor 400 psig woring pressure. The rotors are manufacturedfrom forged steel and use the latest asymmetric proles. Thecompressor incorporates a complete antifriction bearingdesign for reduced power consumption, improved efciency,and reduced maintenance. The bearings provide an L10lifein excess of 100,000 hours at design conditions.

    The XJF compressor incorporates a simple mechanism thatadjusts the compressor volume ratio during operation tothe most efcient of three possible volume ratios, depend-ing on system requirements. The SGC Compressor includes

    a patented method of varying the internal volume ratio tomatch the system pressure ratio. Either compressor reducesthe power penalty associated with over/under compression.

    The compressor unit is a Fric standard unit, complete withoil separator, oil return system, stop valves, motor etc.

    COMPRESSOR CAPACITY CONTROL

    Effective capacity control is achieved by use of a slide valvewhich provides innite adjustment from 100% down to 25%of full load for an XJF compressor and down to approximately12% of full load on an SGC Compressor.

    Variable speed drives control capacity through changes inrotor speed. They are used for higher efciency under par-tially loaded conditions. Variable speed drives also providefaster response to changes in system load.

    LUBRICATION SYSTEM

    The compressor oil is superior quality semisynthetic, hydro-treated oil for ammonia applications. The oil provides highthermal stability for improved breadown characteristics

    and extended service intervals. The compressor is designedspecically for operation without an oil pump. Otherwise, oilrequired for main oil injection and lubrication is provided bypositive gas differential pressure. All compressor oil passesthrough our new FricSuperFilterII, specically designedfor increased particle capture, cleaner oil, and extended com-pressor operation. SuperFilterII actually cleans oil cleanerthan new. It is also designed for horizontal mounting andfurnished with isolation stop valves and drain connectionsfor ease of servicing. Booster and some low-pressure dif-ferential high-stage applications will require the demandoil pump option.

    Liquid Separator

    Evaporator

    Condenser

    Economizer

    Compressor

    QuantumLX

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    OIL SEPARATOR/RESERVOIR

    The oil separator is a horizontal, three-stage design withintegral sump. The separator is designed and constructedin accordance with ASME Section VIII, Div. 1. Replaceablecoalescent separator elements are provided for nal gas/oilseparation of particles down to less than 1 micron.

    OIL COOLING

    The compressor oil is cooled using a semiwelded plate heatexchanger that is integral with the refrigerant condenser. Theheat exchanger plates are AISI 316 stainless steel construc-tion. Maximum design woring pressure is 300 or 400 psig.

    MOTOR

    A factory-mounted anged motor is close-coupled to thecompressor. The compressor/motor assembly requires noeld coupling alignment. Standard motors are open dripproof (ODP), have class B insulation, and 1.15 service factor.

    SEMIWELDED PLATE CONDENSER

    Condenser

    Level Sensor

    Level PipeMotorized

    Expansion

    Valve

    Figure 1 - Semiwelded Plate Condenser

    Semiwelded plate heat exchangers have plates constructedof AISI 316 Stainless Steel. Gasets are a two-piece construc-tion for excellent compatibility with refrigerant and coolingmedia. The plate heat exchangers can be disassembled foreasy cleaning and capacity modication.

    Lie the evaporator, the CPHE condenser is a plate heatexchanger, and the number of cassettes is exactly adaptedto the current operating conditions. Refrigerant condensesbetween the welded plates which mae up the cassettes,and the cooling water circulates in the channels between thecassettes. The plate condenser may have a built-in oil cooler.The unit can also be equipped with other types of condensers.

    SEMIWELDED PLATE EVAPORATOR

    The evaporator is a plate heat exchanger consisting of anumber of cassettes carefully adapted to the actual operatingconditions. The cassettes are assembled/bolted together ina 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 ooded type, whichmeans that it is lled with boiling refrigerant. This liquidleaves the liquid separator and is led to the evaporatothrough the drop leg.

    Evaporator

    Drop Leg

    Brine/Water Outlet

    Wet Return

    Brine/Water Inlet

    Liquid Makeup

    LiquidSeparator

    Dry Suction

    Figure 2 - Semiwelded Plate Evaporator

    When the water or brine is cooled in the evaporator on its

    way through the brine/water connections, the refrigerantboils and a mixture of liquid and vapor ows through thewet return and into the liquid separator. From here the su-perheated vapor is led to the compressor through the drysuction while the separated liquid is collected at the bottomof the liquid separator. The system is self-circulating andneeds no pump on the refrigerant side. Liquid runs from thehigh pressure side and is supplied to the liquid separatothrough the liquid maeup line.

    QUANTUMLX CONTROL CENTER

    The QuantumLX is a control and monitoring system fosupervision and regulation of the chiller unit. It is factorymounted and completely wired with all required safety and

    operating devices. The control system includes as standarda single NEMA 4 control panel housing, microprocessorcontrol, and electrical termination points. Included in themicroprocessor is time-proportioning capacity control, rst-out annunciation, prealarms, volume ratio controls, real-timecloc control, access code protection, lead-lag sequencingalternate suction pressure operation, trending, and moreThe operating conditions at the time of the compressorslast ten alarms or shutdowns are stored in memory, providingthe ultimate in service and troubleshooting convenience. Abuilt-in telecommunications interface is standard, enablingconnection to a remote computer or control device.

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    LIQUID REFRIGERANT SEPARATOR

    The liquid separator, Figure 3, is of the horizontal type andespecially designed for plants with small refrigerant chargesand small variations in liquid level. The liquid level can bechecked on the liquid level column sight glass, Position 9. Ahorizontal liquid separator is specically designed for critically

    charged units with small variations in liquid level. This levelmust not be more than 2 inches (51 mm) above the bottomof the liquid separator. The separation of liquid from gas isachieved efciently by leading the return lines to both endsof the liquid separator. This reduces the gas velocity in theliquid separator and allows time for the liquid to collect beforethe gas travels to the compressor.

    9

    6 3

    8

    7

    Figure 3 - Liquid Separator

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    The unit may be top heavy. Liftingoperators must use extreme care to

    check the level and stability of theload before lifting the load more than a few inches. Impose

    an imbalance by sequentially adding weight to each corneand carefully observing the load reaction to make sure theload does not shift. Balancing chains, cables or straps are

    essential in both directions to prevent load shift andinstability 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 centerof gravity may NOT be located in the center of the package

    NOTES:

    1. Reference OSHA Safety And Health Standards (29 CFR1910), sections 1910.179 and 1910.184.

    2. Hoos, chains, cables and spreader bars shall meet manu-facturers recommendations and shall not be overloaded

    3. This unit shall be lifted using the four lifting lugs welded tothe base as shown above. Shacles and screw pins shalbe 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 pipinginstrumentation or vessels.

    5. Adjust cables or chains to ensure that the pacage (sidis stable and lifted in a level manner.

    6. Lifting must be done by a qualied operator.

    Figure 5

    INSTALLATION

    FOUNDATION

    NOTE: Allow space for servicing at both ends of the unit.A minimum of 24 inches (610 mm) is recommended.

    The rst requirement of the package chiller foundation isthat it must be able to support the weight of the packageincluding oil and refrigerant charge. Screw compressors arecapable of converting large quantities of shaft power intogas compression in a relatively small space and a mass isrequired 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 pipingstress imposed on the package is the best insurance fora trouble-free installation. Use only the certied generalarrangement drawings from Johnson Controls-Frick todetermine the mounting locations and to allow for recom-mended clearances around the unit for ease of operationand servicing. Foundations must be in compliance with local

    building codes and materials should be of industrial quality.The oor 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 rmly to the oor.Once the package is rigged into place (See HANDLING andMOVING), it must be shimmed in order to level the unit.The shims should be placed to position the package railsone inch (25.4 mm) above the housekeeping pad to allowspace for grouting. An expansion-type epoxy grout must beworked under all areas of the base, lling all voids. It shouldbe allowed to settle with a slight outward slope so oil andwater can run off of the base.

    When installing on the upper oors of buildings, extraprecautions 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 acombination of both, to prevent the transmission of com-pressor vibration directly to the structure. However, this mayincrease package vibration levels because the compressoris not in contact with any damping mass. Rubber or springpipe supports may be required to avoid exciting the buildingstructure at any pipe supports close to the chiller package.It is best to employ a vibration expert in the design of aproper mounting arrangement.

    Proper foundations and proper installation methods are vital;and even then, sound attenuation or noise curtains may berequired to reduce noise to desired 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. DONOT USE A FORKLIFT. Refer to the engineering drawingsprovided with the unit for shipping weight.

    Spreader bars should be used onboth the length and width of thepackage to prevent damage to the

    package. CAUTION must also be used in locating the liftingring. Appropriate adjustment in the lifting point should bemade to compensate for the center of gravity.

    Figure 4

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    INSTALLATION170.600-IOM (JUN 11)Page 8

    LIFTING LUG CAPACITY, LB/LUG

    NOMINAL BEAM

    MEMBER SIZE

    CABLE ANGLE

    VERTICAL 45

    W8 15,200 14,990

    W10 19,400 14,990

    1. Brine/water to/from PowerPac 2. Circulating pump 3. Brine/water to/from the system 4. Modulating 3-way valve 5. Buffer tan

    Figure 6

    A: Continuously Loaded System: The cooling media cir-culates continually through the system and the evaporator.

    B:System with load variations:(Example: air conditioningsystem with several adjustable cabinets in which the cool-ing media ow can be varied.) The modulating 3-way valvewill maintain a constant cooling media ow throughout theevaporator. Installation of a buffer tan is recommended, asshown in Position 5, Figure 6.

    NOTE: Install vent valves (Position 1, Figure 6) at thehighest point in the system as well as at the drainagevalves (Position 2), which are located at the lowest point.

    Connections and valves for chemical cleaning should beinstalled. All cold piping should be insulated in order toavoid condensation.

    Water Treatment For Heat Exchangers

    Often, brine and water for industrial refrigeration plantscontain impurities that can create a coating on the heatconducting surfaces. This reduces the heat transmission.In some cases, this coating can cause corrosion of the heatconducting surfaces. Use a 12 mesh or ner lter for wateror brine in evaporator and condenser circuits.

    This maes it importantto monitor brine and water quality.Consult a water expert concerning additives to the systembefore installing the system.

    Warranty does not include any damage that may occurdue to harmful impurities in the system.

    BRINE / WATER SYSTEMSFor the most efcient operation of the unit, ensure a full owof either water or brine through the evaporator. Full ow isachieved by using either of systems A or B in Figure 6.

    Attention is drawn to the fact that all cooling towers experi-ence a constant loss of water due to evaporation. This makesimpurities remain in the refrigeration system in an ever-increasing concentration, also increasing their harmful effects.

    Using a drainage system can minimize the concentration ofimpurities. This drains off some of the polluted cooling towerwater and replaces it with fresh water.

    This drainage system consists of a hand-operated adjustingvalve (Position 5, Figure 7), that is opened sufciently to drainthe polluted cooling tower water to a treatment system. Freshwater is provided through the oat valve shown at Position 3.

    1. Air in 2. Air out 3. Float valve 4. Pump 5. Adjusting valve with outlet to treatment system 6. Condenser 7. Overow pipe

    Figure 7

    ELECTRIC WIRING

    All electric wiring inside the PowerPacunit has been con-nected at the factory on units ordered with solid-state,pacage-mounted starters, or mounted variable frequencydrives.

    External wiring connections that must be established oncethe PowerPacunit is installed are:

    1. Mounting of main power supply cable to the control panel

    2. Mounting of control line for starting of the condenserpump

    3. Mounting of control line for starting of the evaporatorpump

    4. Mounting of ow switch, if any

    5. Mounting of outside thermostat, if any

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    HOLDING CHARGE AND STORAGE

    Each PowerPacchiller is pressure and lea tested at thefactory and then thoroughly evacuated and charged with drynitrogen to ensure the integrity of the unit during shippingand short term storage prior to installation.

    NOTE: Care must be taken when entering the unit toensure that the nitrogen charge is safely released.

    Holding-charge shipping gauges onseparator and external oil cooler arerated for 30 PSIG and are for check-

    ing the shipping charge only. They must be removedbefore pressure testing the system and before chargingthe system with refrigerant. Failure to remove thesegauges may result in catastrophic failure of the gauge anduncontrolled release of refrigerant resulting in seriousinjury or death.

    All units must be ept in a clean, dry location to preventcorrosion damage. Reasonable consideration must be givento proper care for the components of the microprocessorpanel and related instrumentation.

    Units which will be stored for more than two months musthave the nitrogen charge checed periodically.

    Pacaged equipment and all vessels should be visually in-spected to verify that all components are intact, undamagedand that the conguration is consistent with the sales orderrequirements. Temporary coverings such as tarps or shrin-wrap should be inspected to ensure that they are not trappingwater in contact with the equipment. Enclosures should becheced for accumulated water and drained as applicable.

    The pacaged equipment and all vessels should be visuallyinspected for rust, paint fade, paint blisters and surface im-perfections that may have occurred as a result of handlingand storage damage. The paint may indicate some visual,not functional, deterioration, especially epoxy paint coatings.Water spots and chaling are typical aws of exposed epoxy(Amerloc 385) paint systems, and some minor rust stainingwill occur at locations such as casing splits, anges, and tags.We recommend touching-up these areas. Touch-up paint canbe purchased from the Baltimore Parts Center.

    Pacaged equipment and all vessels are purged and placedunder a regulated dry nitrogen purge pressure of 5 to 15 psig.Gauges are installed in the appropriate locations to conrmthat the nitrogen pressure is being maintained. Gaugesshould be checed every two wees. If within the rst three

    months of storage, inspection records indicate a repetitiveloss of nitrogen charge, then the Fric Service departmentshould be contacted.

    To prevent damage to the shaft seals and false brinelling ofthe antifriction bearings, the drive shafts for the compressor,drive motor, oil pump and motor should be rotated everytwo wees. The drive shafts should be rotated 90 degreesbeyond one full rotation.

    All drive motors shipped from the factory have prelubricatedbearings to sustain the motor over the short term. Care mustbe taen to eep the bearings dry and moisture free. Waterand/or condensation will cause the bearing cages to rust andcause premature failure.

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    OPERATION

    PRESTART CHECKLIST

    After the PowerPachas been installed and all connectionsfor refrigerant, water and electricity, instruments and safetyswitches have been completed, proceed as follows:

    Chec the rotation direction of the motor, with the couplingdismantled, to be certain it is correct. An arrow on thecompressor end-cover marks the proper direction ofrotation. (See PRESTART CHECKLIST in FORMS section)

    CHECKING MOTOR/COMPRESSOR ROTATION

    Make sure coupling hubs are tight-ened to the shaft before rotating themotor to prevent them from ying

    off and possibly causing serious injury or death.

    Injury may occur if loose clothing,etc, becomes entangled on the spin-

    ning motor shaft.COMPRESSOR ROTATION ISCLOCKWISE WHEN FACINGTHE END OF THE COMPRES-SOR SHAFT. Under NOcondi-tions should the motor rotationbe checed with the couplingcenter installed as damage tothe compressor may result.Bump the motor to chec for correct compressor rotation.After verication, install the dis drive spacer, as applicable.

    COMPRESSOR/MOTOR COUPLINGINSTALLATION

    The PowerPac chiller has compressor-to-motor alignmentthrough the use of a machined cast iron tunnel. This tunnelis factory set through machining tolerances ensuring mo-tor/compressor alignment. No alignment is required in theeld. For replacement motors, the shaft alignment should becheced and tolerances veried with the Johnson Controls-Fric service department.

    COMPRESSOR

    COUPLING

    A clamping style ElastomericCoupling is used in mostapplications. This couplingconsists of two drive hubsand a gear-type Hytrel or

    EDPM and neoprene drivespacer. The split hub isclamped to the shaft bytightening the clamp screws.Torque is transmitted fromthe motor through an elastomeric gear which oats freelybetween the hubs. Because of the use of a motor/compressoradapter housing, no eld alignment is necessary.

    1.Inspect the shaft of the motor and compressor to ensurethat no nics, grease, or foreign matter is present.

    2.Inspect the bores in the coupling hubs to mae sure thatthey are free of burrs, dirt, and grit.

    3.Chec that the eys t the hubs and shafts properly.4.Slide one hub onto each shaft as far as possible. It maybe necessary to use a screwdriver as a wedge in the slotto open the bore before the hubs will slide onto the shafts.

    5.Hold the elastomeric gear between the hubs and slide bothhubs onto the gear to fully engage the mating teeth. Centerthe gear and hub assembly so there is equal engagement onboth shafts. Adjust the space between hubs as specied inthe Coupling Data Table below.

    6.Torque the clamping bolts and the eyway set screws inboth hubs to the torque value given in the Coupling DataTable. DO NOT USE ANY LUBRICANT ON THESE BOLTS.

    COUPLING DATA TABLECoupling Hub

    CH Between Shaft Spacing Shaft Engagement FaceSpacing

    Clamp Bolt KeywaySeries Min. Max. Min. Max. Torque (Dry)

    SizeSetscrew Torque Size

    Size In. mm In. mm In. mm In. mm In. mm Ft-Lb Nm Ft-Lb Nm UNC

    6 2 50.8 2 69.9 1 25.4 1 49.2 7/8 22.2 15 20.3 1/4-20 UNC 13 17.6 5/16-18

    7 2 58.7 3 87.3 1 25.4 2 55.6 1 27.0 30 40.7 5/16-24 UNF 13 17.6 5/16-18

    8 2 65.1 4 101.6 1 27.0 2 63.5 1 28.6 55 74.6 3/8-24 UNF 13 17.6 5/16-18

    9 3 77.8 4 117.5 1 36.5 3 76.2 1 36.5 55 74.6 3/8-24 UNF 13 17.6 5/16-18

    10 3 90.5 5 133.4 1 42.9 3 88.9 1 42.9 130 176.3 1/2-20 UNF 13 17.6 5/16-18

    11 4 104.8 5 149.2 1 47.6 4 101.6 1 47.6 130 176.3 1/2-20 UNF 13 17.6 5/16-18

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    OPERATION170.600-IOM (JUN 11

    Page 11

    COMPRESSOR UNIT OIL

    DO NOT MIX OILS of differentbrands, manufacturers, or types.

    Mixing of oils may cause excessiveoil 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 thebest suited lubricant for the conditions specied atthe time of purchase. If there is any doubt due to therefrigerant, operating pressures, or temperatures, referto Frick Oil publication 160-802 spc for guidance.

    For standard PowerPacunits, use only semisynthetic hy-drotreated oil as provided by Johnson Controls-Frick.

    Semisynthetic hydrotreated oil is a synthetic oil with a lowvapor pressure. This greatly reduces the amount of oil thatis passed with the R-717 discharge gas from the compressorto the separator during operation. The result is noticeablylower oil consumption.

    Because semisynthetic hydrotreated oils do not mix well withR-717, there is a considerable reduction of any content of thisoil taen from the compressor into the refrigeration system.The high viscosity index of semisynthetic hydrotreated oilsmaes the oil slide off evaporator plates more easily andgather on the bottom of the evaporator. Then, the oil is re-turned to the compressor via the automatic oil return system.

    Fricester-based synthetic lubricants are especially suitedfor HFC refrigerants, R-134A, R-507, R-404 and the newrefrigerant blends. Fricsynthetic oils are custom blendedwith additives for oxidation inhibition, corrosion protection,defoaming, and antiwear. Synthetic oils have extremely lowpour points. The low pour point maes it specially suited forlow temperature refrigeration applications. The high thermalstability of Fricsynthetic oil resists breadown and extendsservice intervals. Consult factory for application assistance.

    EVACUATION

    When the chiller unit has been installed in its nal positionand all connections for refrigerant, water and electricity,instruments, potential equalizer connection (ATEX only) andsafety switches have been connected, proceed as follows:

    a. Chec that the direction of rotation of the motor is cor-rect, with the coupling dismantled. The direction of rotationis mared by an arrow on the compressor end cover.

    b. Chec the direction of rotation of the oil pump.

    c. Mount the coupling and chec that the tolerances and thealignment are in accordance with the instructions concern-ing the coupling.

    d. Connect the vacuum pump to valve position 414 (see pipingdiagram) and evacuate the unit to a vacuum of approximately4 to 5 mm Hg. A thermostatic vacuum meter may be used tomeasure the pressure. If necessary, charge dry air or nitrogenuntil 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 Operatingmanual for the compressor.

    CHARGING REFRIGERANT

    The refrigerant charge for a PowerPacunit is very small, inrelation to the large cooling capacity. Most of the refriger-ant liquid is present in the evaporator by design. The totaamount of refrigerant is indicated on the engineering drawingincluded with the unit.

    1. Connect a refrigerant cylinder to the charge valve. Purgethe charge hose with refrigerant before tightening theunion nut on the valve.

    2. Open the charge valve. Refer to the Start-up procedureoutlined above, to initiate compressor operation.

    3. Start the compressor as described in the Control Panemanual.

    4. Chec the compressor for any abnormal noises and maesure that the compressor is building differential pressure

    5. Charge the amount of refrigerantgradually as indicated inthe table in Technical Data. Check the amount by weighingthe 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

    100%.

    Never leave the unit unattendedduring the rst 60 minutes followingstart-up.

    DRAINING REFRIGERANT

    Use the following procedure to drain refrigerant from the unit

    Run the system normally. Manually reduce the chillepacage capacity to minimum.

    Connect the drain valve to a refrigerant vessel approved

    for this purpose. The connection must be made with anapproved refrigerant hose.

    Check that the vessel is large enoughto hold the entire charge withoutbeing overlled and that it is made

    for the particular refrigerant used. DO NOT charge thevessel beyond 90% liquid volume .

    Before connecting the vessel, place it in chilled water or cooit by some other means.

    Openthe drainage valve and stop valve on the refrigeranvessel.

    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 vesselAfter dismantling, the refrigerant vessel and protectingcap must both be weighed to ensure that the vessel is nooverlled. Net and gross weights stamped into the vesseinclude the weight of the protecting cap.

    SYSTEM PUMPDOWN

    After pressure testing, evacuate the refrigeration system toremove any atmospheric air or moisture.

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    The oat valve has a bypass boring (Position 1). This ensuresthat a pressure equalization occurs at standstill between thehigh and low pressure sides, with a subsequent emptyingof liquid from the oat housing. The hole is placed below

    liquid level, but note that a small amount of liquid may beleft when dismantling the oat vessel .

    The vent valve (Figure 9) is located in the middle of the endcover of the oat housing and allows access to the top ofthe oat housing through a tube.

    Electrical Regulation

    To regulate the liquid level in the condenser, a level sensorregisters the liquid level. The level is converted to a signalwhich is sent to the QuantumLX panel. The QuantumLXpanel controls the opening degree of the motorized expan-sion valve.

    Figure 8

    Figure 9

    The boiling point of a liquid is dened as the temperature atwhich the vapor pressure is equal to atmospheric pressure.The boiling point of water is 212F (100C). If the pressure islowered, so is the waters boiling point. The table indicatesthe boiling point of water at very low pressures:

    BOILING POINT AT PRESSURE

    of WATER F (C) IN. H2O (mm HG)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 pac-age of both air and water vapor.

    The vacuum pump must be able to lower the pressure toapproximately 0.05 in. H2O (0.1-mm Hg), and it must beequipped with a gas ballast valve. Use this valve as muchas possible in order to prevent the condensation of watervapor in the vacuum pump.

    IMPORTANT: NEVER use the refrigeration compressor topump down a system.

    For pumpdown to be satisfactory, the nal pressure must belower than 2.7 in. H2O (5 mm Hg).

    NOTE: There is a risk that any water still present in therefrigeration system may freeze if the ambient tempera-tures drops below 50F (10C). If this occurs, add heatto the environment of the components because ice doesnot evaporate easily.

    OPERATING LOG

    Monitor the condition of the pacage. Log data manu-ally using the History and Trending capabilities of the Fric

    Quantum

    LX. See the Quantum

    LX

    Operating Manualshipped with the pacage.

    This operating log should be maintained at regular intervals,providing important information about the cause of anyundesired changes in the operating state.

    The operating log should also contain data about the com-pressors cooling system functions, and whether there areunusual noises or vibrations.

    HIGH PRESSURE REGULATING SYSTEM

    The PowerPacunit is equipped with either a mechanical highpressure oat valve or an electrical sensor and motorizedexpansion valve. Both systems are mounted at the outlet ofthe condenser and regulate the liquid level in the condenser.At the same time, they control the expansion between thelow pressure and high pressure sides of the chiller unit.

    Mechanical Float Valve

    The mechanical oat valve (Figure 8) is mounted on thecondenser liquid outlet, resulting in a compact design and avery low liquid charge.

    Expansion ValveActuator

    Level Sensor

    Vent Valve

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    Page 13

    PURGING THE SYSTEM

    Purging of air or other noncondensable gases is requiredin order to eep high performance of the system and avoidcorrosion of the equipment which could endanger the safetyof persons and equipment.

    When purging a refrigeration system, mae sure to observethe following:

    Refrigerants must not be released into the atmosphereexcept CO2, 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 ofwater for any remaining R-717 to be absorbed. The watermixture must be sent to an authorized incineration plant.

    Halocarbon refrigerants (CFC, HCFC and HFC) cannot beabsorbed by water. An approved air purger must be ttedto the system. This must be checed regularly by use of alea detector. All precautionary measures practicable must

    be taen to prevent and minimize leaage of refrigerantfrom refrigeration and air conditioning systems to theatmosphere.

    NOTE: The occurrence of air is usually an indication ofpoor maintenance or lack of thoroughness at installation.If the chiller contains air, it tends to gather on the highpressure side of the system.

    NOTE: R-717 systems should be purged on a regular basisto 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 ofthe evaporator if the refrigerant is ammonia. A reservoir ismounted in this location. This oil is automatically returnedto the compressor. Oils used with halocarbons are simmedfrom the surge drum, then returned to the compressor.

    The oat switch controls solenoid valves M1 and M2 (shownin Figure 10). With a rising oil level, the built-in reed switchwill activate the solenoid valves. The oil is conveyed to thecompressor suction line by means of the hot gas ejector E1.With a falling oil level, the solenoid valves will close.

    Figure 10

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    MAINTENANCE170.600-IOM (JUN 11)Page 14

    TABLE 1 - EXCESSIVE CONDENSING PRESSURE

    Cause Remedies

    Insufcient water ow 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 2F lower results in 1% additional cooling capacity.

    TABLE 2 - EVAPORATING TEMPERATURE TOO LOW

    Causes Remedies

    Fouling in the evaporator Clean the evaporator

    Oil in the evaporator Inspect the oil return system

    Insufcient refrigerant charge Add more refrigerant to the plant.

    An evaporating temperature 2F higher results in 4% additional cooling capacity.

    MAINTENANCE

    The operator must be familiar with the unit and this instruc-tion manual in order to service and maintain the PowerPacunit properly.

    Before dismantling any portion of the unit, it is important to

    mae sure that the pressure in the unit or its componentshas been equalized to atmospheric pressure. Parts to bedismantled must not contain refrigerant.

    Operator safety is improved by using gloves and face pro-tection. It is suggested that a suitable gas mas be at hand.

    It is useful to have spare gasets available for replacementuse.

    Only use the recommended Frick oil specied for yourPowerPacunit. When handling refrigerants, oils, brines etc.,personal safety and protection of the environment shouldhave a very high priority.

    Use only the refrigerant for which the unit was originally

    designed.

    Before starting the dismantling/servicing process, removeall main fuses, switch off all electric components on thecompressor/unit, and LOCK THE MAIN SWITCH.

    Mae sure that the motor cannot start up inadvertently.

    Mae sure that there is no over-pressure and no refrigerantin the part to be dismantled.

    Close all necessary stop valves.

    Use the prescribed tools and chec that they are properlymaintained and in good woring condition. In explosion-proofareas, use tools suited for this specic purpose. Also useelectrical protection equipment and tools suited for electricaloperation purposes.

    Use only Johnson Controls original spare parts; other partsmay impair the safety of the compressor/unit.

    TROUBLESHOOTING ANDCAPACITY MEASUREMENT

    OPERATING CONDITIONS

    Variations in pressures and temperatures within the coolingcycle can provide information about the operating state of

    the chiller pacage.Suction and condensing pressures, as well as the tempera-tures of suction and discharge gas, can provide importantinformation.

    Small changes in the variable pressures and temperaturesare sufcient 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,chec the operating state of your PowerPac at regularintervals.

    Refer to compressor manuals for further detail.

    CAPACITY MEASUREMENT

    If the system does not produce the capacity indicated, checfor possible sources of error. Before taing any action, checthe possible causes indicated in Tables 1 and 2 below.

    INCORRECT CAPACITY MEASURING

    The PowerPacchiller is equipped with a FricQuantumLXcontrol system for control and regulation of the pacagecapacity according to leaving brine/water temperature. TheQuantumLX has a display to read the operating conditions.The pressures and temperatures indicated are not exact.They can only be used to perform approximate capacitycalculations. Exact measurements should be calculated inaccordance with ASHRAE procedures.

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    SAFETY170.600-IOM (JUN 11

    Page 15

    First Aid In Case Of Ammonia Accidents(Chemical Formula: Nh3 Refrigerant R-717)

    GENERAL

    Ammonia is easy to identify. It has a strong, distinctive odorthat is noticed by most people, even at very low, harmless

    concentrations. Ammonia serves as its own warning agentso that no one will voluntarily remain in a room in whichconcentrations have become hazardous. Because ammoniais lighter than air, adequate ventilation is the best means ofpreventing a concentration.

    Experience has shown that ammonia is difcult to igniteand, under normal conditions, it is a very stable compound.

    NOTE: In concentrations greater than 15%, ammonia canform ignitable mixtures with air and oxygen. It shouldalways 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%) NaClsolution (salt water).

    3. A shower bath or water tan should be available near allmajor ammonia installations.

    4. Individuals applying rst aid should be properly protectedto avoid further injury.

    INHALATION

    1. Move affected personnel into fresh air immediately, andloosen clothing to facilitate breathing.

    2. Call a doctor/ambulance with oxygen equipment im-

    mediately

    3. keep the patient still and warmly wrapped in blanets.

    4. If mouth and throat are burnt (thermal or chemical burn),let the conscious patient drin water, a little at a time.

    5. If the patient is conscious and the mouth is notburnt, givehot, sweet tea or coffee (never force feed an unconsciousperson).

    6. Oxygen may be administered, but onlywhen authorizedby a doctor.

    7. If breathing stops, apply articial respiration.

    EYE INJURIES FROM LIQUID SPLASHES ORCONCENTRATED VAPOR

    1. Force the eyelids open and rinse eyes immediately for atleast 30 minutes with salt water solution.

    2. Call a doctor immediately.

    SKIN BURNS FROM LIQUID SPLASHES ORCONCENTRATED VAPOR

    1. Wash immediately with large quantities of water andcontinue for at least 15 minutes. Remove contaminatedclothing carefully while washing.

    2. Call a doctor immediately.3. After washing, apply wet compresses (saturated with a

    sterile isotonic (0.9%) NaCl solution (salt water) to affectedareas until medical assistance is available.

    FOLLOW YOUR COMPANY GUIDELINES FOR PROCESSSAFETY MANAGEMENT (PSM).

    ADDITIONAL FACTS ABOUT R-717:

    Ammonia is easily absorbed by water: At 59F (15C)1.06 qt (1 liter) of water can absorb approximately 1.1 lb(.05-g) liquid ammonia (or approximately 185 gal. (700liters) ammonia vapor.

    Even small amounts of ammonia in water are enough todestroy marine life if allowed to pollute waterways andlaes.

    Because ammonia is alaline it will damage plant and ani-mal life if released into the atmosphere in large quantities

    Refrigerant evacuated from a refrigeration plant must becharged into refrigerant cylinders intended for this specicrefrigerant.

    If the refrigerant is not to be reused, returnit to the supplieror to an authorized incineration plant.

    Halocarbon refrigerants are colorless and odorless. Theipresence is undetectible without instrumentation. Theiability to displace oxygen can mae them deadly!

    Never mix R-717 with halocarbon refrigerants.

    PROTECTING THE ENVIRONMENT

    Many countries have passed legislation in an effort to reducepollution and preserve the environment.

    Be especially careful with the following substances:

    refrigerants

    cooling media (brines etc)

    lubricating oils

    ADDITIONAL FACTS ABOUT REFRIGERANTS

    Refrigerantsusually have a natural boiling point which liesa good deal below 32 (0C). This means that liquid refrig-erants can be extremely harmful if they come into contactwith sin or eyes.

    In high concentrations, R-717 causes respiratory problemsWhen ammonia vapor and air mix between 15 to 28 % vol-ume, the combination is explosive and can be ignited by anelectric spar or open ame.

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    SAFETY170.600-IOM (JUN 11)Page 16

    When halocarbon vapors come into contact with open ameor hot surfaces over approximately 572F (300C) they de-compose to produce poisonous chemicals. These chemicalshave a very strong odor warning us of their presence.

    Oil mist in the ammonia vapor increases this ris signicantlyas the point of ignition falls below that of the mixture ratiostated.

    Usually the strong smell of ammonia will give ample warningof its presence before concentrations become dangerous.

    Check ofcial limits in the locationof your installation. They may differfrom those stated.

    VENTILATING A REFRIGERATION PLANT

    If it is necessary to ventilate a refrigeration plant, mae sureyou observe the following:

    Neverrelease refrigerants directly into the atmosphere.

    When ventilating an R-717 plant, you must use an ap-

    proved air ventilator. Released air must pass throughan open watercontainer in which the remnants of R-717refrigerant will be absorbed. Send the water containingR-717 to an authorized incineration plant.

    COOLING AGENTS

    Standard PowerPac units are designed to use glycol orwater as the cooling agent. Other cooling agents include:Salt solutions (brines) of calcium chloride (CaCl2) or sodiumchloride (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, clearlymared with the contents, and sent to an approved incin-eration plant.

    OILS

    To lubricate screw compressors included in the PowerPacunits, 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 containersmared waste oil and sent to an approved incinerationplant.

    NOTE: The owner of the refrigeration plant is responsiblefor ensuring compliance with all Federal, state, and localregulations. PSM procedures should be routinely followed.

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    FORMS170.600-IOM (JUN 11

    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 FieldService Supervisor. Details on the checklist can be found in this manual. Certain items on this checklist wilbe reveried by the Frick Field Service Supervisor prior to the actual start-up.

    Mechanical Checks__ Conrm that motor disconnect is open__ Isolate suction pressure transducer__ Pressure test and lea chec unit__ Evacuate unit__ Remove compressor drive coupling guard__ Remove coupling center and DO NOT reinstall (motor rotation must be checed without center)

    __ Chec for correct position of all hand, stop, and checvalves PRIORto charging unit with OILor REFRIGERANT

    __ Charge unit with correct type and quantity of oil__ Lubricate electric drive motor bearings PRIORto

    checing motor rotation__ Chec oil pump alignment (if applicable)__ Chec for correct economizer piping (if applicable)

    __ Chec separate source of liquid refrigerant supply (ifapplicable, liquid injection oil cooling)

    __ Chec water supply for water-cooled oil cooler (if ap-plicable, water cooled oil cooling)

    __ Chec thermosyphon receiver refrigerant level (if ap-plicable, thermosyphon oil cooling)

    __ Chec forPROPER PIPE SUPPORTSand correct founda-tion

    __ Chec to ensure ALLpiping INCLUDING RELIEF VALVESis completed

    Electrical Checks__ Conrm that main disconnect to motor starter and micro

    is open__ Conrm that electrical contractor has seen this sheet

    ALL PERTINENT WIRINGinformation, and drawings__ Conrm proper power supply to the starter pacage__ Conrm proper motor protection (breaer sizing)__ Conrm that all wiring used is stranded copper and is

    14 AWG or larger (sized properly)__ Conrm all 120 volt control wiring is run in a separate

    conduit from all high voltage wiring__ Conrm all 120 volt control wiring is run in a separate

    conduit from oil pump and compressor motor wiring__ Conrm no high voltage wiring enters the micro pane

    at any point

    __ Chec current transformer for correct sizing and instal-lation

    __ Chec all point-to-point wiring between the micro andmotor starter

    __ Conrm all interconnections between micro, motostarter, and the system are made and are correct

    __ Ensure all electrical panels are free from installationdebris, METAL PARTICLES, and moisture

    Afterthe above items have been checked and veried:__ 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 chec oil pump motor rotation__ Manually energize compressor drive motor and chec motor rotation__ Leave micro energized to ensure oil heaters are on and oil temperature is correct for start-up

    Summary: The Frick Field Service Supervisor should arrive to nd the above items completed. He should ndan uncoupled compressor drive unit (to verify motor rotation and alignment) and energized oil heaters withthe oil at the proper standby temperatures. Full compliance with the above items will contribute to a quickefcient and smooth start-up.

    The Start-up Supervisor will:1. Verify position of all valves2. Verify all wiring connections3. Verify compressor motor rotation

    4. Verify oil pump motor rotation5. Verify the % of FLA on the micro display

    6. Verify and nalize alignment (if applicable) 7. Calibrate slide valve and slide stop 8. Calibrate temperature and pressure readings

    9. Correct any problem in the pacage10. Instruct operation personnel

    NOTE: Customer connections are to be made per the electrical diagram for the motor starter listed under theinstallation section and per the wiring diagram listed under the maintenance section of the IOM.Please complete and sign this form & fax to 717-762-8624 as conrmation of completion.

    Fric Sales Order Number: ______________________Compressor Model Number: _____________________Unit Serial Number: ____________________________End User Name: _______________________________Address of Facility: _____________________________City, State, Zip: ________________________________

    Print Name: ___________________________________Company: _____________________________________Job Site Contact: _______________________________Contact Phone Number:_________________________

    Signed: ______________________________________

    FORMS

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    Start-up Report Fric Order No: ________________________Sold To: _______________________________________ Contact Name:__________________________ Date:__________________End User: ______________________________________ Contact Name:__________________________ Phone:__________________End User Address: ______________________________________________________________________ Fax No:__________________City, State, Zip: _________________________________ Start-up Representative _________________

    Unit General InformationUnit Model # ___________________________________________ Customer Pacage Identication # _________________________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 ConditionsOil Cooling _____________________________________ ___________ 0Suct. / _________ 0Disch.

    Micro InformationMicro Type ________________________ Program Software Ver # _______ and Date __________ UL Serial # __________________Digital I/O Board #1 Serial # _________________________________ 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 ________________________Fric Interface Serial # ____________________ Prog. Ver. ________ Date ___________P/N ________________________CT Location Checed 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

    ______________________ ___________________________ _________________________ ________________________

    Prestart ChecksInstallation, Foundation Compressor PHD Setup Coolant InstalledPosition of all valves Motor PHD Setup 4-20 Coolant Loop Pump Setup

    Proper oil charge Motor Winding RTDs Setup Coolant Loop Temp SetupAll wiring connections Motor Bearing RTDs Setup Cooling Fan Motor I/O SetupStarter Cleanliness Motor Temperature Thermistor Setup Cooling Fan Rotation ChecedAll micro settings 4-20 Motor Drive Signal Calibrated Oil pump motor rotation4-20 CT Channel 16 Setup Cold alignment Motor rotation4-20 Output Calibration Liquid Maeup Valve, Coolant Temp Valve, Economizer Maeup Valve

    Conguration Capacity Channel Direction PackageMode 1 _____________ ___________ ____________ Compressor ______________Mode 2 _____________ ___________ ____________ Pump ______________Mode 3 _____________ ___________ ____________ Dual Pump ______________Mode 4 _____________ ___________ ____________ Drive ___________________________VFD Hi & Low PI Control ___________ ____________ Refrigerant __________ k-Factor _________Miscellaneous: Sequencing ________________ Filter ___________________________

    Condenser ________________ PowerPac ____________ Screen Saver ________________

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    Page 19

    Page 2 Unit Serial # _____________________________ Fric Order No: ____________________________

    Capacity Control Setpoints Setpoint Regulation Safeties 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 ____ Sec Warning Delay ____ Sec

    VFD Prop Band ________ ________ Shutdown _________ VFD Prop Band _______ ________ Shutdown __________VFD Integ. Time ____ Sec _____ Sec Shutdown Delay ___ Sec VFD Integ. Time ____Sec ____ Sec Shutdown Delay ____ Sec Channel ________________________ Channel _________________________

    Auto Cycle Low Suction Auto Cycle Low SuctionStart ________ Load Inhibit __________ Start _________ Load Inhibit __________Start Delay ____ Min Force Unload __________ Start Delay _____ Min 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 _______ SecHigh Discharge Pressure Dual Mode _______________ Economizer ________________Regulation Modes 1 & 3 Modes 2 & 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. ______________ % 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 Temperature Liquid Slug Shutdown ______________ Is Above __________ F for _____ Sec

    Package SafetiesLow Compressor Oil Temperature Pull Down______________________ Warning __________ Delay _____ Sec Capacity Position ________ % Shutdown __________ Delay ______ Sec Amount of Time _________ SecHigh Compressor Oil Temperature Pump Down ____________________ Warning ______ Delay _______ Sec On When Suction Above ____ PSIG Delay _____ Min

    Shutdown ______ Delay _______ Sec DX CircuitLow 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

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    INSTALLATION - OPERATION - MAINTENANCE170.600-IOM (JUN 11)Page 20

    Page 3 Unit Serial # _____________________________ Fric Order No: ____________________________

    Compressor Motor Setpoints and InformationMotor Name Plate VFD Manufacturer ________________ Motor Amps ___________ Maximum Drive Output ___ % Frame Size ______________

    Volts ___________ Minimum Drive Output ___ % H.P. ____________________ Service Factor ___________ Remote Control RPM ___________________

    Horsepower ___________ Rate Of Increase ________ % Delay ____ Sec Serial # _________________CT Factor ___________ Rate Of Decrease _______ % Delay ____ Sec Service Factor ___________

    Recycle Delay__________ Min Capacity Control Voltage _________________High Motor Amps When Slide Valve Reaches ________ % Hz _____________________ Load Inhibit______________ Drive Speed Reaches ________ % Design _________________

    Force Unload__________ Variable Speed Min. Slide Valve Position _______% Code ___________________Warning________ Delay ___ Sec Skip Frequency Bands Bearing Type ________________

    Shutdown________ Delay ___ Sec Bottom Top Motor Coupling _____________ _______ ______

    Low Motor Amps _______ ______Shut Down ________ Delay ______ Sec _______ ______Conrmed Running Motor Amps _______ _______ ______Starting Motor Amps Ignore Period ________ Sec _______ ______

    Vyper Coolant Setpoints

    Vyper Standby Time ______ Vyper Coolant Low Temp. Alarm______ Delay ______ Shutdown ______ Delay ________ High Temp. Alarm______ Delay ______ Shutdown ______ Delay ________

    PHD Monitoring Setpoints Condenser ControlCompressor Bearing ____________ Condenser Control Setpoint _____________

    Suction End Delay Discharge End Delay Digital Controls Step OrderHigh Warning ______ gF _____ Sec High Warning _____ gF _____ Sec Module A ________High Shutdown ____ gF _____ Sec High Shutdown ____ gF _____ Sec Module B ________ Module C ________Motor Bearing______________ Module D ________

    Shaft Side Delay Opposite Shaft Side Delay Step Up Dead Band _________PSIHigh Warning _______ F _____ Sec High Warning ______ F _____ Sec Step Up Delay ________ SecHigh Shutdown _____ F _____ Sec High Shutdown _____ F _____ Sec Step Down Dead Band _________PSI

    Step Down Delay ________ SecMotor Stator_________________ High Pressure Override _________PSI

    High Pressure Override Delay _____ SecStator 1 Delay Stator 2 DelayHigh Warning ______F ______ Sec High Warning _____F ______ Sec Analog ControlsAnalog Output A ___________High Shutdown ____F ______ Sec High Shutdown ____F ______ Sec Analog Output B ___________ Proportional Band ________PSIStator 3 Delay Integration Time _______ SecHigh Warning ______F ______ Sec High Limit ________PSIHigh Shutdown ____F ______ Sec Low Limit _______ Sec

    MiscellaneousRemote Capacity Deadband _______ % Max Slide Valve Timer _______ 1/10 SecHigh Compressor Oil Pressure ________________ Max Discharge Pressure ___________PSIShutdown _____PSI Delay ____ Sec Max Discharge and Oil Temp ________F

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    Page 4 Unit Serial # ________________ Fric Order No: __________________________________________

    P&ID SetpointsName _________________ __________ _________________ __________Control ____________ ____________ ____________ ____________Action ___________ ____________ ____________ ____________Control Point __________________ __________________Device Source _____________ __________ ______________ __________Device Channel ______ ______Setpoint ____________ ____________ ____________ ____________Dead Band ____________ ____________ ____________ ____________Prop. Band ____________ ____________ ____________ ____________Integral Gain ____________ ____________ ____________ ____________

    CommunicationsCompressor ID______Comm 1 Comm 2 Comm 3Baud 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 ProtocolsAddress Type __________ Host Name __________ ModBus TCP ________IP Address __________ Wor Group _________ Ethernet I/P _________Gateway Address __________ Comments __________ Pronet _____________Subnet Mas __________Web Server Port __________

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    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:

    VIBRATION DATA SHEET

    SUCTION DISCHARGE OIL SEPARATOR Slide Valve Position %

    Press # Press # Press # Temp F V.I. Ratio

    Temp F Temp F Temp F F.L.A. %

    Compressor Inboard

    (Coupling End)Vertical Direction____.____ IPS Overall

    Compressor Inboard(Coupling End Male)

    Axial Direction____.____ IPS Overall

    Motor Inboard (Coupled End)

    Horizontal _______.______ IPS Overall Vertical _______.______ IPS Overall

    Axial _______.______ IPS Overall

    Compressor Outboard(Nondrive End)

    Vertical Direction

    ____.____ IPS Overall

    Compressor Inboard(Coupling End Female)

    Axial Direction

    ____.____ IPS Overall

    Motor Outboard (Noncoupled End)

    Horizontal _______.______ IPS Overall Vertical _______.______ IPS Overall

    Axial _______.______ IPS Overall

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    Index

    AAmmonia, 15anchoring, 7

    Bbrine, 8

    Ccapacity control, 4CO2, 13compressor data plate, 3compressor oil, 4COMPRESSOR PRESTART CHECkLIST, 17compressor rotation, 10Continuously Loaded System, 8cooling towers, 8

    Ddemand oil pump, 4drainage system, 8drainage valve, 11

    Eelastomeric gear, 10electrical on/off regulator, 12electric wiring, 8evaporator, 8,11

    Foat valve, 8,12oat vessel, 12

    ow switch, 8foundations, 7Fresh water, 8

    Hhorizontal liquid separator, 6hot gas ejector, 13

    Llevel sensor, 13liquid separator, 6

    MMAINTENANCE, 14

    brine temperature, 14Cooling agents, 16environment, 15Evaporating temperature, 14Excessive condensing pressure, 14First Aid, 15noncondensable gases, 14Oils, 16PSM procedures, 16Troubleshooting, 14Ventilating, 16VIBRATION DATA SHEET, 22

    mechanical oat valve, 12

    motor alignment, 10motorized expansion valve, 12

    N

    nitrogen charge, 9noncondensable gases, 13

    Ooil pump, 4oil separator, 5operating log, 12

    Pplate heat exchanger, 5PowerPac, 1,3,4,8,9,10,11,12,13,14,16pressure testing, 11

    Q

    QuantumLX, 3,5,12,14

    Rrefrigerant charge, 11

    SSemisynthetic hydrotreated oil, 11SGC Compressor, 4sight glass, 6solenoid valves, 13Spreader bars, 7start-up, 11SuperFilterII, 4System with load variations, 8

    Ttelecommunications interface, 5thermostat, 8

    Uunit data plate, 3

    Vvacuum pump, 12vapor pressure, 12variable frequency drives, 8vent valve, 12

    vent valves, 8VIBRATION DATA SHEET, 22

    Wwater, 8water expert, 8water quality, 8Water treatment, 8

    XXJF compressor, 4

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    Form 170-600 IOM (2011-06)Supersedes: S170-600 IOM (2008-06)

    Subject to change without notice

    JOHNSON CONTROLS100 CV AvenueWaynesboro PA 17268-1206 USA