Frick HPS 2709 User manual

This manual contains installation, operation, 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 incorrect operation.
Rotary Screw Compressor
HPS 2709 and 2712
HPS 4009 and 4012
Check www.FrickCold.com for the latest version of this publication.
Form 070.750-IOM2 (JUN 2022)
Installation – Operation – Maintenance
File: Service Manual – Section 070
Replaces: 070.750-IOM2 (JAN 2021)
Dist: 3, 3a, 3b, 3c

070.750-IOM2 (JUN 22)
Page 2
HPS 273 and 407 Rotary Screw Compressor
Installation - Operation - Maintenance
Indicates an imminently hazardous situation that, if not avoided, results in death or serious injury.
Indicates a potentially hazardous situation or practice that, if not avoided, results in death or
serious injury.
Safety precaution denitions
Indicates a potentially hazardous situation or practice that, if not avoided, results in damage to
equipment or minor injury.
Indicates an operating procedure, practice, or portion thereof,which is essential to highlight.
Table of Contents
General information
Introduction .....................................................................3
Design limitations .............................................................3
Job inspection ..................................................................3
Standard bare compressor ...............................................3
Transit damage claims ......................................................3
Compressor identication ................................................3
Long-term storage............................................................5
Preparing the compressor for storage..........................5
Maintaining the compressor in storage ........................6
Description........................................................................ 6
HPS 273 and 407 compressors .................................... 6
Compressor lubrication system ...................................6
Oil pump, optional........................................................ 7
Balance piston oil requirements and regulation............7
Construction details ..........................................................8
Design limits................................................................. 8
Vibration and sound data.................................................. 9
Installation
Outline dimensions .........................................................11
Holding charge and storage ............................................11
Rigging and handling.......................................................11
Lifting instructions......................................................11
Foundation ......................................................................12
Motor mounting, for foot-mounted motor only .............. 12
Compressor/motor coupling requirements ................. 12
Coupling alignment requirements,
for foot-mounted motor only ..................................... 13
Customer connections ....................................................13
Compressor oil ................................................................ 14
Oil system .......................................................................14
Oil pump .........................................................................14
Oil heaters: heating wires and insulation ....................... 14
Oil filters .........................................................................14
Oil cooling requirements ................................................. 14
Dehydration/evacuation test ...........................................15
Electrical installation .......................................................15
Compressor hydraulic system..........................................15
Operation
Operation and start-up instructions ............................... 17
Ambient temperature effect on compressor operation ..17
Before starting up the compressor ................................. 17
Calibrating the linear transmitter................................ 17
Using an external source of pressure .......................18
Initial start-up procedure ...............................................18
Normal start-up, shutdown, and standstill
procedures ................................................................ 18
Control system................................................................19
Maintenance
General information ....................................................... 21
General maintenance ..................................................... 21
Changing oil ....................................................................21
Maintenance schedule..................................................... 22
Maintenance program ....................................................23
Vibration analysis ...........................................................23
Oil quality and analysis ................................................... 23
Operating log .................................................................23
Troubleshooting guide .................................................... 23
Abnormal operation
analysis and correction ........................................... 23
Troubleshooting the HPS 273 and 407 compressors.......24
Replacing the capacity linear transmitter: slide valve 24
Replacing a bare compressor ....................................24
Shutdown due to incorrect oil pressure, high stage
and booster ...............................................................24
Forms
Compressor prestart checklist.........................................25
Alignment log for electric motor driver........................... 26
Drive train alignment....................................................... 26
Operating log sheet ........................................................ 26
Vibration data sheet........................................................ 27
Compressor port locations .............................................. 28
Warning
Caution
Danger
Notice

070.750-IOM2 (JUN 22)
Page 3
HPS 273 and 407 Rotary Screw Compressor
Installation - Operation - Maintenance
General information
Note: The information in this document is subject to
change without notice.
Introduction
This manual describes installation, operation, and main-
tenance procedures for HPS 273 and 407 rotary screw
compressors.
Notice
Frick screw compressor repair must only be done by
skilled mechanics who have completed training at
Frick screw compressor school.
It is most important that these compressors are correctly
applied to an adequately controlled refrigerant or gas
system. Consult your authorized Johnson Controls-Frick
representative for expert guidance in this determination.
Correct performance and continued satisfaction with these
units depends on the following factors:
• Correct installation
• Correct operation
• Regular, systematic maintenance
• Relevant package and system engineering
To ensure correct installation and application, select the
appropriate equipment and connect to a correctly de-
signed and installed system. The engineering plans, piping
layouts, for example, must be detailed in accordance with
the best practices and local codes, such as those outlined
in ASHRAE and EN codes.
A screw compressor is a vapor pump. To ensure that
working uid in the liquid state is not being ingested,
follow these checks:
• Select controls carefully. Make sure they are in good
operating condition.
• Correctly size piping and correctly arrange traps, if they
are necessary.
• Check that the suction line has an accumulator or slug-
ging protection.
• Know the load surges and make provisions for control.
• Check that operating cycles and stand still periods are
reasonable.
• Size high-side components within system and com-
pressor design limits.
HPS compressors have small clearances and the compres-
sor package and system must be built with a very high
degree of cleanliness.
Design limitations
HPS compressors are designed for operation within the
pressure and temperature limits, which are specied by
Johnson Controls-Frick and the Johnson Controls-Frick
selection software CoolWare™. They are primarily used for
compressing refrigerant gas and most hydrocarbon gasses.
If your application is for sour gas, there are special
requirements to protect the compressor. Contact Johnson
Controls-Frick Compressor Engineering for application
details.
Delivery inspection
Immediately after delivery examine all crates, boxes, and
exposed compressor and component surfaces for damage.
Unpack all items and check against shipping lists for any
discrepancy. Examine all items for damage in transit.
Standard bare compressor
Items not shipped with bare compressors that are available
include, but are not limited, the following components:
• Motor mount
• Connection ttings
• Coupling
• Solenoid valve manifold block assembly
• Balance piston pressure regulator (BPR) system.
–PLC controller for BPR system
• Service oil pump and ttings for manual calibration of
linear transmitters.
• Insulation jacket: easy on, easy off.
• Linear sensors in split version for higher temperatures.
• Suction and discharge anges
• Suction non-return valve
• Suction strainer
Transit damage claims
All claims must be made by the consignee. This is an ICC
requirement. Request immediate inspection by the agent
of the carrier and be sure to execute the correct claim
forms. Report damage or shortage claims immediately to
Johnson Controls-Frick Sales Administration Department
in Waynesboro, PA.
Compressor identication
Each compressor has an identication data plate, contain-
ing compressor model, and serial number mounted on the
compressor body.
Notice
When inquiring about the compressor or unit, or
ordering repair parts, provide the model, serial, and
Frick sales order numbers from the data plates.

070.750-IOM2 (JUN 22)
Page 4
HPS 273 and 407 Rotary Screw Compressor
Installation - Operation - Maintenance
Figure 1: Identication data plate
The compressor model number designates the size of the
compressor and its volume ratio (Vi) conguration.
Example: HPSS 2709 A
HPSS 27 09 A
Model/series
HPS = High-pressure screw
Bearing arrangement
S = Single radial bearings (273 only)
D = Double radial bearings (273 only)
Rotor diameter
27 = 273 mm
40 = 407 mm
Rotor length designation
09
12
Vi conguration
A= 2.2 – 5.0
B= 1.7 – 3.0
C= 1.3 – 1.96
Rotor length ÷ diameter x 10
Rotary screw compressor serial numbers identify the
factory that the compressor was manufactured in and its
build date. They are dened by the following information:
Example: 1024 0 A 9 0000015 Z
Plant Decade Month Year Global
Seq no.
Additional
Remarks
1024 0 A 9 0000015 Z
Month:
A = JAN, B = FEB, C = MAR, D = APR, E = MAY, F = JUN,
G = JUL, H = AUG, K = SEP, L = OCT, M = NOV, N = DEC
Additional Remarks:
R = Remanufactured
R1 = Rebuild
R2 = Rebuild Plus
Z = Deviation from base conguration.
The nameplates in the following gure show what refriger-
ants are compatible with the compressor as manufactured.
Figure 2: Refrigerant nameplates
Table 1: Compressor long-term storage log
Model Serial no. Compressor, motor oil
pump, and refrigerant
pump shaft rotation one
and a half turns
Rotor
housing
charge
Charge
added
Visual
inspec-
tion
Charge Checked by Date
See

070.750-IOM2 (JUN 22)
Page 5
HPS 273 and 407 Rotary Screw Compressor
Installation - Operation - Maintenance
Figure 3: Nameplate and Vi locations
Callout Component
A Nameplate
See note after Table 5.
Table 2: Geometrical swept volume, 2709 model
m3/h cfm 1.5%
Lpm
1.5%
gpm
1,450 rpm 676 398 169 45
1,750 rpm 816 480 204 54
2,950 rpm 1,375 809 344 91
3,550 rpm 1,655 974 414 109
Table 3: Geometrical swept volume, 2712 model
m3/h cfm 1.5%
Lpm
1.5%
gpm
1,450 rpm 901 530 225 59
1,750 rpm 1,088 640 272 72
2,950 rpm 1,833 1,079 458 121
3,550 rpm 2,206 1,298 552 146
Table 4: Geometrical swept volume, 4009 model
m3/h cfm 1.5%
Lpm
1.5%
gpm
1,450 rpm 2,219 1,303 555 146
1,750 rpm 2,678 1,576 670 177
2,950 rpm 4,514 2,657 1,129 298
3,550 rpm 5,432 3,197 1,358 359
Table 5: Geometrical swept volume, 4012 model
m3/h cfm 1.5%
Lpm
1.5%
gpm
1,450 rpm 2,958 1,741 740 195
1,750 rpm 3,570 2,101 893 236
2,950 rpm 6,018 3,542 1,505 397
3,550 rpm 7,242 4,262 1,811 478
Note: 1.5% oil ow as a percentage of compressor
model’s swept volume
Long-term storage
Long-term storage, is defined between six months and
ve years. Provisions are required, regardless of storage
environment, if start-up and useful operation does not oc-
cur within six months of equipment shipment. Special pro-
visions may be required for storage of less than 6 months
if the storage area is subject to environments with high
humidity, large changes in temperature, dusty atmosphere,
or other unusual environmental conditions.
The standard Johnson Controls-Frick Warranty for an HPS
273 and 407 screw compressors covers 12 months from
start-up or 18 months from shipment, whichever comes
rst. Make arrangements with the local Johnson Controls-
Frick service organization, arranged through factory
service, regarding surveillance and maintenance during
the storage period. It is the customer’s responsibility to
submit a monthly report showing the condition of the unit
and noting any discrepancies to the guidelines listed in this
manual.
Note: Failure to comply with this long-term storage sug-
gestion may void the warranty.
Long-term storage of equipment may lead to the deterio-
ration of components over the period of time. Synthetic
components in the compressor may deteriorate over time
even if they are kept ooded with oil. A warm and dry
environment is essential to minimize environmental and
corrosion damage.
Follow the steps in Preparing the compressor for storage
and Maintaining the compressor in storage to maintain the
screw compressor warranty.
Preparing the compressor for storage
1. Evacuate the compressor to remove moisture.
2. Connect the evacuation lines to the three Schrader
access valves provided with the compressor. One valve
is connected to the compressor suction and the other
two valves are located at the block on the cylinder.
3. Break the vacuum with dry nitrogen and bring pressure
to 0 bar (0 psig).
4. Pump oil into the SM1. Use break-in oil part number
111Q0831809 for storage purposes.
Note: The amount of oil necessary to ll a given compres-
sor model depends on the L/D size involved and
the actual internal clearances of the compressor.
The approximate volume of oil needed to ll the
compressor is between 20 gal to 25 gal for HPS 273
compressors, and 100 gal to 120 gal for HPS 407
compressors.
Note: The gal amount of oil are average values, which
vary based on the specic HPS model.
5. After the compressor is oil charged, pressurize the
compressor to 1.0 bar (14.5 psig) with nitrogen.
See

070.750-IOM2 (JUN 22)
Page 6
HPS 273 and 407 Rotary Screw Compressor
Installation - Operation - Maintenance
Maintaining the compressor in storage
1. Maintain the 0.3 bar to 1.0 bar (4.35 psig to 14.5 psig)
nitrogen charge, but ideally at 1.0 bar (14.5 psig).
2. Rotate the male rotor shaft monthly. Mark the shaft to
ensure the rotor does not return to the original posi-
tion.
3. Store the compressor inside a dry building environ-
ment.
4. Grease the male rotor shaft to prevent rust.
5. Record all information in a compressor long-term
storage log. See Table 1.
Contact Johnson Controls-Frick Service with any questions
regarding long-term storage.
Description
HPS 273 and 407 compressors
The Frick HPS 273 and 407 rotary screw compressors
use mating asymmetrical prole helical rotors to provide
a continuous ow of vapor and are designed for high-
pressure applications. The compressor incorporates the
following features:
• Designed for variable speed drive (VSD) with a range of
600 rpm to 4,200 rpm for the HPS 273 and 3,600 rpm
for the HPS 407. It is also possible to operate with a
xed-speed motor drive at 2,950 rpm or 3,550 rpm or a
xed-speed engine drive at 1,200 rpm.
• The HPS 273 and 407 compressor models use stepless
capacity control providing innite unloading capacity
down to about 20% of full-load capacity.
• The HPS 273 and 407 compressor models have a
moveable slide stop with three Vi ranges offered as
standard:
–2.2 Vi to 5.0 Vi
–1.7 Vi to 3.0 Vi
–1.3 Vi to 1.96 Vi
• High capacity roller bearings to carry radial loads are
used at both inlet and outlet ends of the compressor.
• The high pressure compressor models use heavy duty
four-point ball bearings to carry the axial loads on the
rotor for the HPS 273 and 407 compressor models.
• The high-pressure compressor models use balance
piston assemblies to limit the axial bearing loads. HPS
273 and 407 compressor models use one at the male
and female inlet ends that require pressure regulation
on the oil supply.
• The housings for the HPS 273 and 407 compressor
models are designed for 90 bar (1,300 psig) working
pressure.
• The HPS 273 and 407 compressor models are designed
with multiple ports. See Figure 11 and Figure 12.
• All bearing and control oil is vented to lower pressure
locations inside the compressor, enabling operation
without an oil pump for most applications.
• The shaft seal is designed with a seal ring made of
silicon carbide mated against a similar material, with
carbon and graphite added to the matrix to help
improve startup performance.
The shaft seal housing is designed to maintain operat-
ing pressure on the seal much lower than discharge
pressure for increased seal life.
• Oil injected into the compressor is directed between
the rotor threads to maintain good volumetric and
adiabatic efciency.
• The shaft rotation is clockwise when facing the com-
pressor drive end and is suitable for all types of drives.
Warning
Compressor rotation is clockwise when facing the
compressor drive shaft. Never operate the compressor
in reverse rotation because this can result in damage.
• The suction and discharge anges are ANSI B16.1 Class
600 type for the HPS 273 and 407 compressor models.
System and package piping that connects to the com-
pressor with a matching ange must comply with the
applicable piping code requirements based on design
pressure and temperature of the mating component.
• Suction strainers for the HPS 273 and 407 models are
external to the compressor. The strainer specied must
meet the following requirements at a minimum:
–Filter cloth: SS 304, 30 x 150 mesh, plain Dutch
Weave with 0.009 in. WARP diameter and 0.007 in.
WEFT diameter
–Filter cloth support: 6 mesh with 0.035 in. wire di-
ameter, 0.132 in. openings with 62.7% open area
Compressor lubrication system
The lubrication system on a HPS 273 and 407 compressor
unit performs several functions:
• Provides lubrication to bearings, seal, and rotors
• Provides a cushion between the rotors to minimize
noise and vibrations
• Helps keep the compressor at the correct temperature
and prevents overheating
• Provides oil supply to hydraulically operate the slide
valve and slide stop for the HPS 273 and 407 to provide
capacity and volume control
• Provides oil pressure to the balance piston assemblies
to help increase bearing life
• Provides an oil seal between the rotors to prevent ro-
tor contact or gas bypassing

070.750-IOM2 (JUN 22)
Page 7
HPS 273 and 407 Rotary Screw Compressor
Installation - Operation - Maintenance
Volumizer variable volume ratio control
Screw compressors do not have regulating valves in the
suction and discharge ports of the compressor body to
regulate the opening and closing of ports. Instead, the
geometry of the rotors and housings define the port open-
ings and closings and subsequently the swept volume of the
compressor.
On the inlet end of the compressor, refrigerant vapor fills
the volume of the rotor threads until the rotor rotates to a
position that closes off the suction port. On the discharge
end of the compressor the same rotor thread opens to the
discharge port in the housing, ideally when the pressure
inside the thread is equal to the outside system pressure.
If the internal thread pressure is higher, over-compression
occurs, and if the internal thread pressure is lower, then
under-compression occurs; in both situations the unit is
inefcient. The pressure inside the threads is affected by
temperature, volume, the presence of a non-compressible
liquid, such as the oil, and leakage due to internal clear-
ances. The ratio of the rotor thread volume at the suction
end divided by the rotor thread volume at the discharge
end is dened as the compressor volume ratio (Vi). Because
the mass ow at the suction port and the mass flow at the
discharge port are the same, you can calculate the vol-
umes at these locations using their respective values of gas
densities.
The Frick compressor includes a method of varying the
internal Vi to match the system pressure ratio. Control of
the internal Vi eliminates the power penalty associated with
over- or under-compression. Vi control is achieved by the
use of a slide stop, a movable portion of the rotor hous-
ing assembly that moves axially with the rotors to control
discharge port location.
HPS compressors are available in three different Vi ranges;
2.2 to 5.0, 1.7 to 3.0, and 1.3 to 1.96, and the relationship
between the Vi and slide stop position is shown in the fol-
lowing figure:
Figure 4: HPS compressors volume ratio, Vi
Stepless capacity control
Capacity control is achieved by use of a movable slide valve.
The slide valve moves axially under the rotors to provide
fully modulated capacity control from 100% to approxi-
mately 20% minimum load capacity. Approximate minimum
load capacity varies slightly with compressor model, pres-
sure ratio, discharge pressure level, and rotor speed.
The slide valve is positioned by hydraulic movement of its
control piston. When in the unloaded position, gas is by-
passed back to suction through a recirculation slot before
compression begins and any work is expended, providing
the most efcient unloading method available for part-
load operation of a screw compressor.
Oil pump, optional
A demand oil pump is required for low differential pressure
applications.
Note: CoolWare provides a warning when the oil differen-
tial pressure is too low.
Oil being supplied to the compressor from the oil separa-
tor is at the system discharge pressure minus the pressure
drop in the oil system piping, oil lter, and valves. Oil port-
ing to all parts of the compressor is vented back to a loca-
tion in the compressor’s body that is at a lower pressure
than compressor discharge pressure. All oil entering the
compressor is moved by the compressor rotors, out the
compressor outlet, and back to the system oil separator.
Balance piston oil requirements and regulation
When operating, the discharge pressure of a compressor
can force the rotors back towards the suction, creating a
load on the thrust bearing assembly. In cases where the
discharge pressure is high, this axial load can be exces-
sive for the compressor’s thrust bearings and limit their
operating life. To compensate for this situation, a balance
piston assembly is designed to generate a counter force
that reduces the load on the thrust bearings and increases
their operating life.
In a conventional balance piston arrangement, oil pressure
enters the compressor, which is regulated by an outlet
pressure regulating valve and orice. This regulated oil
pressure acts against an internal piston that generates a
force to counter the rotor thrust. The problem is that the
conventional balance piston regulator is set for a specic
operating condition and when the load or operating condi-
tions vary the balance piston pressure may be insufcient.
HPS models use a motorized balance piston regula-
tor controlled by a programmable logic controller (PLC).
The PLC compensates for the changing compressor load
and conditions by continually calculating the oil pres-
sure required to maintain the necessary counter force.
The PLC accomplishes this by monitoring seven different
inputs: compressor Vi, suction pressure, slide valve posi-
tion, economizer pressure, discharge pressure, operating
speed, and oil pressure. It uses these values to identify the
target pressure for the balance piston regulator in a look
up table. The PLC communicates this new target pressure
to the balance piston regulator controller and the valve is
modulated to generate the target oil pressure.
HPS models have balance pistons on the male and female
inlet end of the compressor rotors with oil supplied
through the SB-2 port.
1.00
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
2.00
3.00
4.00
1.50
2.50
3.50
4.50
5.00
Volume ratio
Vi = 2.2 - 5.0
Vi = 1.7 - 3.0
Vi = 1.3 - 1.96
Slide stop travel (SS), 0% to 100%

070.750-IOM2 (JUN 22)
Page 8
HPS 273 and 407 Rotary Screw Compressor
Installation - Operation - Maintenance
Construction details
Housing
All HPS 273 and 407 screw compressors castings are
60-40-18 ductile iron to ensure structural integrity and me-
chanical and thermal stability under all operating conditions.
Rotors
The rotors are made from quality, wear-resistant rolled
steel to the exacting tolerances of the latest industry stan-
dard asymmetric prole. The six-lobed male rotor directly
connects to the driver. The eight-lobed female rotor is
driven by the male on a thin oil lm.
Bearings
HPS compressors are designed for optimal bearing life.
The HPS 273 and 407 compressor models are designed
with a conventional single-radial bearing design (HPSS). A
double-radial bearing arrangement (HPSD) is available as
an option to handle higher discharge pressure applications.
When evaluating operating conditions of the compres-
sor in CoolWare for performance, give consideration to
changes in those conditions based on operating transients
and seasonal changes. CoolWare automatically congures
the bearing arrangement for optimal life based on these
conditions.
Balance piston
The high pressure compressors are equipped with balance
piston assemblies to reduce load on the axial bearings. Oil
pressure is regulated by a xed or modulating pressure
regulating valve and provides the force necessary to offset
the bearing loads. The pressure setting on the balance
piston pressure regulating valve is important and specied
by Coolware for the specic operating conditions of the
compressor.
Shaft seal
The compressor shaft seal is a single-face balanced type
with a spring-loaded, silicon carbide stationary hardened
surface riding against a rotating seat. Carbon and graph-
ite are added to both surfaces to provide self-lubrication.
During operation, it is vented to low pressure to provide
extended life.
Motor mount
The HPS 273 and 407 series compressors is a foot
mounted, open drive model that can pair with an electric,
engine, or turbine drive.
Design limits
Use CoolWare to determine the limits for a specic
application.
• Maximum suction pressures for the HPS compressors
are limited based on compressor Vi, to avoid over-
compression:
–For A model 2.2 Vi to 5.0 Vi the limit is 27.5 bar
(450 psia)
–For B model 1.7 Vi to 3.0 Vi the limit is 44.8 bar
(650 psia)
–For C model 1.3 to 1.96 Vi the limit is 63.7 bar
(925 psia)
Figure 5: HPS 273 and 407 viscosity requirement as
function of speed
• The maximum discharge temperature for the HPS 273
407 compressor models is limited to 125°C (257°F).
Refer to 160.802-SPC, Compressor Oil Specications
for more detail.
• Screw compressors are oil-ooded machines that use
oil to lubricate bearings, seals, and rotors, and also
to seal clearances in the rotor mesh and control the
compressor’s discharge temperature. Screw compres-
sors however, are designed to compress gases and not
pump liquids, so the amount of oil introduced into the
compressor is regulated. When using variable-speed
motors to drive the compressors, take particular care
to regulate the main oil injection oil ow when slowing
down the driver speed. This is to avoid supplying too
much oil to the compressor, which can result in a failure
due to liquid slugging. If the total oil ow supply to the
compressor is more than 1.5% of the compressor’s
swept volume, and the turndown of the variable-speed
drive is more than 3, the main oil ow must be regulat-
ed. The turndown of a variable-speed drive is dened as
the actual maximum speed of the driver divided by the
actual minimum speed of the driver. CoolWare calculates
the oil ow in Lpm and gpm. See Table 2, Table 3, Table
4, or Table 5 depending on what model you own.
• The UNISAB and Quantum panels have several lay-
ers of control functions to secure reliable operation.
Depending on many operating conditions, they unload
the slide valve and reduce or increase speed to keep
the compressor running in a safe way. Only as a last
resort do they initiate an alarm and ultimately stop the
compressor.
This is particularly true for the HPS 273 and 407
compressor models on applications with high suction
pressure, like fuel gas boosting. The concern is that
the high internal thread pressure may lead to excessive
rotor deection and unwanted contact with the rotor
housing. For this reason, correct calibration of the slide
valve and slide stop is essential.
Note: For 1.3 to 1.96 and 1.7 to 3.0 Vi range machines, the
main oil injection occurs at lower Vi port locations
than compressors operating with the 2.2 to 5.0 Vi
range. This means the UNISAB and Quantum use
lower values for the safeties.
Shaft speed, rpm
1000
20
15
10
5
002000 3000 4000 5000
Viscosity Min., cst
407
273

070.750-IOM2 (JUN 22)
Page 9
HPS 273 and 407 Rotary Screw Compressor
Installation - Operation - Maintenance
• In CO2applications using miscible oil types POE and
PAG, it is critical to keep water content to the lowest
possible. Down to 10 ppm is the goal. The installation
must have large lter dryers with replaceable elements
that you can effectively service and vacuum dry before
putting back into service.
• If the temperature difference becomes greater than or
equal to 250°F (138.9°C) between suction and dis-
charge, unload the slide valve to less than 50% but
above 40%.
• The minimum discharge temperature must be at least
54°F (30°C) above the actual dewpoint of the discharge
gases. This applies to part load conditions and full load
operation.
Vibration and sound data
The rotors balance grade is G 2.5 according to ISO 1940.
The male rotor drive end of the HPS 273 and 407 com-
pressors is keyless.
Effective vibration velocity must not exceed 8 mm/s RMS
(0.32 in./s) anywhere on the compressor. Alarm level is 12
mm/s RMS (0.47 in./s).
Table 6: Number of rotor lobes
Male rotor lobes Female rotor lobes
6 8
Table 7: Critical frequencies
Driver speed, rpm
3,000 3,600 4,200
Exiting member and event Main exciting fre-
quencies (Hz)
Male rotor, rotational, rst order 50 60 72
Male rotor, rotational, second order 100 120 144
Female rotor, rotational, rst 37.5 45 54
Female rotor, rotational, second 75 90 108
Discharge gas pulsation, rst 300 360 432
Discharge gas pulsation, second 600 720 864
Vibration level on the package can be higher, especially
on piping elements, and when the natural frequency of an
element falls together with one of the exciting frequen-
cies. If the vibration level gets too high, a skip frequency
function in the control system activates. After activating,
the motor runs through the critical speed very fast, not
causing any continuously high vibration.

070.750-IOM2 (JUN 22)
Page 10
HPS 273 and 407 Rotary Screw Compressor
Installation - Operation - Maintenance
This page is intentionally left blank.

070.750-IOM2 (JUN 22)
Page 11
HPS 273 and 407 Rotary Screw Compressor
Installation
Installation Rigging and handling
You can move the compressor with rigging, using a crane
or forklift, by hooking into the two lifting rings at each end
of the main housings. Only use the compressor lifting rings
to lift the compressor itself.
Figure 6: Lifting rings
Callout Component
A Lifting rings
Lifting instructions
Lifting rings are located to facilitate the rigging and lifting
of the bare compressor. See Figure 6. Ensure that only a
qualied operator performs the lifting and that they follow
the necessary precautions.
• Lift rings are intended for lifting the bare compressor
only.
• Examine the lift rings for damage before lifting the
compressor. Replace any damaged rings.
• Fully screw in the lift rings and seat them rmly against
the contact surface before lifting.
• Load the lift rings in the vertical direction only.
Ensure that the load is parallel to the threaded portion
of the lift ring. See Figure 7. This may require the use
of a spreader beam. Loading the lift rings at an angle
reduces their load capacity.
• Ensure that the load is level and stable before lifting
more than a few inches.
• Lift the compressor slowly.
• Remove the lift rings from the compressor before
operation. The vibration of a running compressor can
cause the lift rings to loosen and become damaged.
Figure 7: Lifting rings orientation
HPS 273 and 407 compressors are designed to be driven
with an open drive, foot-mounted motor. Do not exceed
the rotor and bearing design set limitations: refer to Cool-
Ware for more information. Refer to 090.040-O, Quantum
HD Control Panel for additional information on setpoint
limits.
Outline dimensions
Find complete dimensions and connection information on
the outline drawing, which you can request by contacting
Johnson Controls-Frick Sales. See Figure 11 and Figure 12.
Holding charge and storage
Every HPS 273 and 407 compressor is pressure and leak
tested at the Johnson Controls–Frick factory and thor-
oughly evacuated and charged with dry nitrogen to ensure
its integrity during shipping and short-term storage before
installation.
Keep all compressors in a clean, dry location to prevent
corrosion damage. For compressors stored for more than
two months, check their nitrogen charge periodically.
See General information for complete instructions and
refer to 020.050-W Limited Warranty Screw Compressor
Purchased for Long-Term Storage for FRICK Bare Screw
compressors.
Warning
Holding-charge shipping gauges, if mounted, are
rated for 2.1 bar (30 psig) and are for checking the
shipping charge only. They must be removed before
pressure testing and operating the system. Failure to
remove these gauges may result in catastrophic fail-
ure of the gauge resulting in serious injury or death.
Access valves are bronze and they must be replaced
with steel plugs when package is assembled.
Caution
This equipment has been pressurized with nitrogen
gas. Temporary valves and gauges have been in-
stalled.
1. Relieve pressure before opening lines or making
eld connections.
2. Remove charging valves or gauges be pressurizing
system.
3. Refer to installation operation and maintenance
manual for additional information.
Escaping gas may cause injury.

070.750-IOM2 (JUN 22)
Page 12
HPS 273 and 407 Rotary Screw Compressor
Installation
Foundation
Each HPS Rotary Screw Compressor is shipped mounted
on a wooden skid. Remove before installing the unit.
Caution
Allow correct spacing for servicing. See the relevant
dimensional outline drawing.
The rst requirement of the compressor foundation is that
it must be able to support the weight. The weights of the
HPS 2709 and HPS 2712 assemblies respectively are 2,132
kg (4,700 lb) and 2,241 kg (4,940 lb). The weights of the
HPS 4009 and HPS 4012 compressor models respectively
are 5,185 kg (11,432 lb) and 5,519 kg (12,167 lb).
Screw compressors are capable of converting large quan-
tities of shaft power into gas compression in a relatively
small space. The compression process creates relatively
high frequency vibrations that require sufcient mass
in the base to effectively dampen them. Refer to FRICK
070.210-IB, Screw Compressor Foundations.
The best insurance for a trouble-free installation is to
rmly anchor the compressor to a suitable foundation
using correct bolting and by preventing piping stress from
being imposed on the compressor. After rigging the com-
pressor into place, you must shim its feet to level it. There
must be absolutely no stresses transferred to the com-
pressor body due to bolting of the feet and anges.
In any screw compressor installation, support suction and
discharge lines in pipe hangers, preferably within 2 ft (0.61
m) of vertical pipe run, so that the lines won’t move if dis-
connected from the compressor. See Table 8 for allowable
ange loads.
Motor mounting, for foot-mounted
motor only
1. Thoroughly clean the motor feet and mounting pads of
grease, burrs, and other foreign matter to ensure rm
seating of the motor.
2. Attach the motor to the base using bolts and motor
raising blocks, if required.
3. Weld the four kick bolts into place so that they are
positioned to allow movement of the motor feet. The
kick bolts are not included with compressor.
4. After setting the motor, check to see that the shafts
are correctly spaced for the coupling being used. Check
the appropriate dimensional outline drawing for the
minimum clearance required between the shaft ends to
change the shaft seal.
Compressor/motor coupling requirements
HPS compressors are arranged for direct motor drive and
require a exible drive coupling to connect the compressor
to the motor. Coupling must be suitable for variable speed.
The HPS 273 and 407 models use a keyless drive shaft.
For a foot-mounted motor, it is essential to correctly align
the coupling to ensure correct bearing and seal perfor-
mance:
1. Select and install the coupling so that it does not trans-
mit any axial load to the compressor shaft.
2. Set up the minimum distance between the compressor
shaft and motor shaft to enable seal removal. See the
relevant outline drawings.
3. Coupling must be able to take up any misalignment
between the motor and compressor. It is critical to the
life of the shaft seal that misalignment is kept to the
minimum possible value. Follow the coupling manu-
facturer’s guidelines for checking and correcting any
misalignment.
Table 8: Allowable ange loads
Nozzle
size NPS
Moments, ft-lbf (N.m) Load, lbf (N)
Axial - MRVert. - MCLat. - MLAxial - P Vert. - VCLat. - VL
1 25 (34) 25 (34) 25 (34) 50 (222) 50 (222) 50 (222)
1.25 25 (34) 25 (34) 25 (34) 50 (222) 50 (222) 50 (222)
1.5 50 (68) 40 (54) 40 (54) 100 (445) 75 (334) 75 (334)
2 100 (136) 70 (95) 70 (95) 150 (667) 125 (556) 125 (556)
3 250 (339) 175 (237) 175 (237) 225 (1,001) 250 (1,112) 250 (1,112)
4 400 (542) 200 (271) 200 (271) 300 (1,334) 400 (1,779) 400 (1,779)
5 425 (576) 400 (542) 400 (542) 400 (1,779) 450 (2,002) 450 (2,002)
6 1,000 (1,356) 750 (1,017) 750 (1,017) 650 (2,891) 650 (2,891) 650 (2,891)
8 1,500 (2,034) 1,000 (1,356) 1,000 (1,356) 1,500 (6,672) 900 (4,003) 900 (4,003)
10 1,500 (2,034) 1,200 (1,627) 1,200 (1,627) 1,500 (6,672) 1,200 (5,338) 1,200 (5,338)
14 2,000 (2,712) 1,800 (2,440) 1,800 (2,440) 1,700 (7,562) 2,000 (8,896) 2,000 (8,896)

070.750-IOM2 (JUN 22)
Page 13
HPS 273 and 407 Rotary Screw Compressor
Installation
Figure 8: SM-1 and SM-2 port cutaways, HPS 273
A
A
B
B
Callout Description Callout Description
ASM-1: port SM-1 orice plug BSM-2: port SM-2 orice plug
Coupling alignment requirements,
for foot-mounted motor only
1. Perform a coupling alignment before start-up.
2. After installing the compressor on the job site, check
alignment again and if necessary, correct before start-
up.
3. After a few hours operation, you must check the align-
ment while the package is still hot. Correct hot align-
ment is critical to ensure the life of the shaft seal and
compressor bearings.
Note: Maximum radial runout is 0.004 in. total indicator
reading.
Maximum axial runout is 0.004 in. total indicator
reading.
4. Use a dial indicator or another appropriate measuring
device to determine the Total Indicator Runout.
5. Check the indicator bracket sag because all brackets
have some exibility.
a. The best way to measure this is to attach the dial
indicator and bracket on a pipe at the coupling span
distance.
b. Zero the indicator in the 12:00 position, and rotate
the pipe so the indicator is in the 6:00 position. The
reading on the indicator in the 6:00 position is the
bracket sag. This value must be included in the dial
indicator readings when afxed to the coupling for
an accurate alignment.
Customer connections
In addition to the suction and discharge connections, the
following ports require piping to operate the compressor:
SB-2: Balance piston
SB-3: Shaft seal, outlet end bearings
SM-1 or SM-2: Main oil injection. SM-1 is only used
for 2.2-5.0 Vi
SB-2a: Inlet bearings
Note: Connecting the main oil injection to the correct port
for your compressor Vi range is critical for correct
lubrication. Only use the SM-1 port for compres-
sors with a 2.2 Vi to 5.0 Vi range. If you are unsure
what Vi range the compressor has, pipe the main oil
injection line to the SM-2 port. The HPS 2709 and
HPS 2712 both have factory-installed orice plugs,
0.469 in. diameter. The factory-installed orice
plugs on the HPS 4009 and HPS 4012 are 0.875 in.
diameter.

070.750-IOM2 (JUN 22)
Page 14
HPS 273 and 407 Rotary Screw Compressor
Installation
Other connections are available for instrumentation and
service as noted on the compressor connections and di-
mensional outline drawing. See Figure 11 and Figure 12.
Note: Total pressure drop is the difference between dis-
charge pressure and oil pressure at the compressor
ports.
This is critical for the correct operation of the balance
piston, which is used to ensure the life of the male and
female axial bearing.
Compressor oil
Warning
Do not mix oils of different brands, manufacturers, or
types. Mixing of oils can cause excessive oil foaming,
nuisance oil level cutouts, oil pressure loss, gas or oil
leakage, and catastrophic compressor failure. Cool-
Ware selects a specic Frick oil for the refrigerant
being used. Depending on the application, a differ-
ent oil can be selected, provided it is of the correct
viscosity and is compatible with the refrigerant and
compressor elastomers.
Notice
Bare compressors are usually shipped without an oil
charge. The oil specified for the compressor opera-
tion is critical. Select the appropriate oil based on
requirements in 160.802-SPC, Compressor Oil Speci-
cations.
Oil system
The entire oil supply system for the compressor must be
designed for a total pressure drop of no more than 1.0 bar
(14.5 psig) with a new oil lter element. This is critical for
the correct operation of the balance piston, which ensures
the life of the male and female axial bearing.
Note: Total pressure drop is the difference between dis-
charge pressure and oil pressure at the compressor
ports.
Oil pump
If your HPS compressor application requires an oil pump,
mount a strainer upstream because this can protect the
pump.
Oil heaters: heating wires and
insulation
Your package must be equipped with oil heaters that
provide sufcient heat to prevent condensation from oc-
curring during startup and shutdown cycles. Insulate the
whole system.
Oil filters
Johnson Controls-Frick engineering must approve in writ-
ing the use of lter elements other than Johnson Controls-
Frick, or a warranty claim may be denied. Oil lter speci-
cation b5 = 75 according to ISO 4572 is required to obtain
oil cleanliness class 16/14/11 according to ISO 4406.
Oil cooling requirements
Compressor oil needs to be cooled to control the dis-
charge temperature, maintain correct oil viscosity, and
to preserve the life of the oil. The discharge temperature
depends on application and operation conditions. Refer to
CoolWare. For a CO2compressor, it is usually around
60°C (140°F). For an ammonia heat pump, it can be
120°C (250°F) or higher.
There are applications that it is normal to have discharge
temperatures as high as 150°C (300°F) An ammonia heat
pump is one example. The higher discharge temperature
permits higher process uid temperatures to be achieved.
Another application that can require higher discharge
temperatures as high as 150°C (300°F) is natural gas
gathering at the wellhead. Moisture is present in the gas
and it is imperative that the discharge temperature is least
17°C (30°F) higher than the dew point of the component,
including water vapor, within the gas stream that has the
highest discharge dew point temperature.
Notice
The discharge temperature requirement is at any load-
ing and capacity, any speed, not only at full load.
1. Open CoolWare and from the Wet/Dry Mode list, se-
lect Water Saturated.
2. Select Calculate to get the discharge dew point tem-
perature for your application.
Oil temperatures as high as 130°C (266°F) can achieve
the necessary discharge temperature to prevent moisture
from condensing in the oil separator. Contact Johnson
Controls–Frick for additional information for natural gas
compression.
The main oil injection line that connects to port SM-1 or
SM-2 must have a regulating valve so it can adjust the oil
ow to maintain the appropriate discharge temperature
at all times. A non-return valve is also required in order
to prevent gas from owing backward into the oil system
under start-up and transition of operating conditions
The regulating valve may need to have a motor so the
actual opening or ow can be controlled by the control
panel. This is often necessary for heat pumps where a
certain capacity, water temperature, and efciency is
expected. It may also be a requirement when the speed
turndown is signicant, from 4,200 rpm to 1,000 rpm for
example for HPS 273 models, because the relative oil ow
may get too high at the lower speed range. Turndown
above 3 requires an automatic valve. Consult CoolWare
and the factory.
When considering minimum supply oil temperature, do
not use a thermostatic three-way bypass mixing valve. For
alternate methods consult Frick Engineering.

070.750-IOM2 (JUN 22)
Page 15
HPS 273 and 407 Rotary Screw Compressor
Installation
Warning
For high temperature applications, consult factory.
Some of the 3-way thermostatic valves do not work
at high temperatures and damage to thermostatic
mixing valves can occur.
A three-way mixing valve, or one of the alternate methods,
provides warm oil to the compressor quickly, reducing the
pressure drop caused by cold, viscous oil. This ensures cor-
rect oil ow and temperature over the full range of operat-
ing conditions. For some applications this valve needs to
be a motor-operated valve controlled by the control panel.
This is necessary for a heat pump where the oil is cooled to
a lower temperature than the condensing temperature.
An ideal oil temperature is the same as the condensing
temperature, for example 80°C (176°F).
In a heat pump application there is a risk the discharge
temperature gets too low at low speed, which means some
hot oil must bypass the oil cooler. Discharge temperature
must be a minimum of 10°C (18°F) above condensing tem-
perature. Consult CoolWare and factory, and refer to PID
diagram examples.
Dehydration/evacuation test
Evacuate the system to 1,500 microns. Valve off the
vacuum pump and hold vacuum for one hour.
Pass: Vacuum cannot rise above the 2,000 micron level
during a one hour hold period.
Fail: Vacuum reading goes above the 2,000 micron
level during a one hour hold period. Identify and
repair any system leaks. Repeat vacuum test until
requirements are met.
Electrical installation
The only electrical connection to make to the compressor
is for the solenoid-operated capacity control valve.
Compressor hydraulic system
Note: The solenoid valves and manifold block are available
as a sales order option.
The compressor hydraulic system actuates the mov-
able slide valve (SV) to load and unload the compressor,
which affects the compressor’s capacity. It also actuates
the moveable slide stop (SS) to increase or decrease the
compressor’s Vi, which determines the compressor’s
compression ratio. The hydraulic cylinder located at the
inlet end of the HPS compressor serves a dual purpose. It
is separated by a xed bulkhead into two sections; the SV
section is to the left of the bulkhead and the SS section is
to the right when you are facing the right side of the com-
pressor. Both operations are controlled by double–acting,
four–way solenoid valves, which are actuated when a sig-
nal from the appropriate microprocessor output energizes
the solenoid valve.
Single acting – (> 10.3 bar [150 psi] pressure differential)
Open valve at SC1
Close valve at SC2
Open valve at BP (bypass)
Compressor loading (single acting): the compressor
loads when SV solenoid YY2 is energized and oil ows
from the unload side of the cylinder out port SC1, through
valve ports A and T to compressor suction. Simultane-
ously, discharge pressure loads the slide valve.
Compressor unloading (single acting): the compres-
sor unloads when SV solenoid YY1 is energized and oil
ows from the oil manifold through valve ports P and A to
cylinder port SC1 and enters the unload side of the cylin-
der. Simultaneously, gas on the load side of the cylinder
is vented through port SC2 and valve BP to compressor
suction.
Notice
To control the rate of loading and unloading, throttle
the needle valve at SC1 port.
Compressor loading or unloading (double acting): the
double-acting capability of the solenoid valves enable for
hydraulic assist in loading or unloading when the pres-
sure differential across the compressor is low, for example
greater than 10.3 bar 150 (psid). HPS compressors are
designed to operate in applications where the differential
pressure is higher than the minimum required and as a re-
sult, double-acting operation is not required or suggested
and doing so without instruction from the factory voids
the compressor warranty.
Warning
Operation of HPS compressors in double-acting
mode may result in severe damage to the internal
cylinder piston and spindle arrangement.

070.750-IOM2 (JUN 22)
Page 16
HPS 273 and 407 Rotary Screw Compressor
Installation
Figure 9: Hydraulic schematic
Callout Description Callout Description
ADirection control valve C Compressor top view
BScrew in ow regulating needle valve D Direction control valve

070.750-IOM2 (JUN 22)
Page 17
HPS 273 and 407 Rotary Screw Compressor
Operation
Operation Before starting up the compressor
Before the start-up, complete the prestart check. See
Prestart checklist in the Forms section.
Calibrating the linear transmitter
A critical step in the start-up procedure is calibrating the
linear transmitters to determine slide valve and slide stop
position and travel. See Figure 10 for linear transmitter.
While it is possible to calibrate the linear transmitters on
the compressor unit, it cannot be done automatically by
the unit controller. The transmitters are electronic devices
that use a 4 mA to 20 mA signal; but because the trans-
mitters are used in a variety of compressor models the
operating range is usually narrowed to 6 mA to 10 mA,
where 6 mA corresponds to the minimum endpoint posi-
tion (0% slide valve or 0% slide stop position) and 10 mA
corresponds to the maximum endpoint position (100%
slide valve or 100% slide stop position). In many cases the
high-pressure compressors is mounted on units using heat
trace and insulation, which can affect the calibration and
operation of the linear transmitters. Calibrate the linear
transmitters with the unit heat trace on and insulation
applied.
Note: The slide valve travel is relatively short because of
the low rotor L/D ratios. As a result, it is important
to use an amp meter during the calibration process
that has a high resolution readout, minimum of
three to four decimal places.
If exposing the mounted transmitter to high temperatures,
a split sensor or transmitter is available. The sensor is in-
stalled under the insulation and exposed to the heat while
the transmitter, connected by a cable, is mounted outside
the insulation and exposed to the ambient air.
Determining the slide valve and slide stop posi-
tion and travel
The slide valve and slide stop travel check is necessary
to define the absolute end positions (0% to 100%) of the
slide valve and slide stop’s movements and is applicable
to all three Vi options. The calibration process is done
automatically by controller, which subsequently uses these
measurements to calculate the Vi and capacity of the
compressor.
The risk of over-compression, and subsequent damage
to the compressor, makes the calibration process of the
linear transmitter and slide valve/stop even more critical
for applications involving high-pressure compressors.
For example, operating a HPS compressor that has a 2.2 to
5.0 Vi with a suction pressure of 10.3 bar (400 psig) at full
load and the maximum slide stop position generates nearly
206.8 bar (3,000 psig) discharge pressure, well above
the design working pressure of the compressor. Operat-
ing the compressor at a high-pressure differential, and
in the unloaded condition, may cause the compressor to
fill with oil and cause slugging. These examples underline
the need to make compressor selections at the lowest Vi
range necessary to achieve the optimal Vi for the system’s
operating conditions. It also demonstrates why not to use
a variable-speed drive motor and the slide valve position
to regulate the compressor load at the same time. Frick
suggests performing the calibration check daily.
Operation and start-up instructions
The Frick HPS 273 and 407 rotary screw compressors are
components in an integrated system. Because of this, the
compressor operation requires some specic conditions to
ensure trouble-free running.
The information in this section provides logical step by
step instructions to correct ly start up and operate the HPS
rotary screw compressor in your unit. Only matters that
may inuence the correct operation of the Frick HPS 273
and 407 compressors are included.
WARNING
The compression process creates noise and operat-
ing screw compressors are loud. Wear the correct
hearing protection when near the compressor during
operation. If people are expected to be in the vicinity
of the running compressor for extended time periods,
provide warnings.
Note: You must read the following subsections and ensure
that you understand the information before at-
tempting to start or operate the unit.
Ambient temperature effect on
compressor operation
Warning
Everything must be heat traced and insulated, even the
compressor.
Warning
When the ambient temperature is below the satura-
tion temperature that the compressor is operating at,
condensing may occur, which may result in damage to
the compressor.
Pay particular attention to the potential for condensa-
tion in units operating with high-pressure compressors.
Their applications often involve conditions where the
ambient temperature is below the saturated tempera-
ture that it is operating at. Additional precautions to
prevent condensation during start up, shutdown, and
when the unit is at standstill are noted in the following
section.
Insulate the package oil separators, the oil piping, and the
oil lter as a minimum requirement. This can preserve the
heat generated by the oil heaters, prevent condensation,
and secure lubrication at start-up.
Always insulate the oil separator for heat pump and fuel
gas compression applications. It is often necessary to
insulate the complete suction line for heat pumps in order
to prevent condensation and possible slugging. In these
cases, heating wires are necessary.
With an automated valve, regulate oil ow to the main
oil port being used (SM-2 or SM-1) in order to continu-
ously achieve the highest possible discharge temperature
needed.

070.750-IOM2 (JUN 22)
Page 18
HPS 273 and 407 Rotary Screw Compressor
Operation
If you expect the compressor to operate below 24 barg
(350 psig) discharge pressure, you can perform the slide
valve or stop travel check while the compressor is running.
Checking the slide stop travel
1. Run the slide valve to its minimum position (unloaded).
2. Run the slide stop to its minimum position and then
move the slide stop to its maximum endpoint.
The full travel of the slide stop from its minimum endpoint
to its maximum endpoint corresponds to the compressor’s
selected Vi range, which is either 2.2 Vi to 5.0 Vi, 1.7 Vi to
3.0 Vi, or 1.3 Vi to 1.96 Vi.
Checking the slide valve travel
1. Place the slide stop at its minimum endpoint.
2. Move the slide valve to its minimum endpoint (SV
unloaded) and then its maximum endpoint (SV is fully
loaded).
This provides the absolute capacity (CAPabs) range of the
compressor from minimum to maximum load.
If you expect the compressor to operate above 24 barg
(350 psig) discharge pressure, perform the slide valve or
stop travel check while the compressor is not running. The
process of operating the slide valve and slide stop from its
minimum endpoint to its maximum endpoint is the same
as the sequence described above. What is different is that
it requires an external source of pressure.
For more detailed calibration instructions refer to
090.040-O, Quantum HD Control Panel.
Using an external source of pressure
If the compressor has an oil pump capable of providing a
minimum of 3.8 bar (55 psi) differential pressure then it is
usable. Be aware however, that it also pumps oil to the
compressor and it is critical to drain all oil from the com-
pressor before startup.
If the compressor unit is not equipped with an oil pump,
an alternative is to use a small portable service oil pump.
If oil pumps are not available, it is possible to use nitrogen
gas (N2) or pressurized dry air. In this case, close off and
purge the compressor before performing the travel check.
After nishing the calibration, place the compressor under
a vacuum and open any stop valves.
Whether using an oil pump, nitrogen gas, or dry air the
compressor package needs to be designed with the nec-
essary access points and isolation valves.
Note: In most cases an external source supplying 3.8 barg
(55 psig) is sufcient to move the slide valve and
slide stop to their minimum and maximum travel
positions. If it requires higher pressure than this to
move the slide valve and slide stop then it is likely
that there is something wrong with the compressor
and it need to be investigated.
Warning
Never provide more than 17.2 bar (250 psig) external
pressure as this may result in signicant damage to
the compressor and bodily harm.
Initial start-up procedure
After performing the prestart check, the compressor unit
is ready for start-up. In low ambient conditions, have oil
heaters and heating wires on for 24 h before start-up. It is
important that an adequate gas load be available to load
test the unit at normal operating conditions. Keep the
following points in mind during initial start-up:
• For correct and safe operation, run the compressor at
the correct speed and discharge pressure. At any speed,
exceeding design conditions creates a potential hazard.
• Immediately after start-up, adjust the oil cooling
system. After 1 h to 3 h, adjust it again after operating
conditions are within expected parameters.
• Pull and clean suction strainer after 24 h of operation.
If it is excessively dirty, repeat every 24 h until the
system is clean. Otherwise, follow the normal
maintenance schedule.
• Frick strongly suggests completing a baseline vibra-
tion analysis for frequencies up to 7,000 Hz at normal
operating conditions so that you can monitor bearing
life can regularly. This means the compressor can
continue to operate and avoids an unnecessary
teardown inspection to check the bearings.
Normal start-up, shutdown, and standstill proce-
dures
1. Conrm that system conditions permit starting the
compressor.
Notice
Ambient temperatures need to be high enough to
prevent excessive condensing; otherwise, initiate oil
heaters 24 h before start up. If using heat tracing,
the wire selected needs to be based on the highest
expected saturation temperature that the system
operates at.
2. Start the unit.
3. Observe the compressor unit for mechanical tight-
ness of the external piping, bolts, and valves. Ensure
that the machine has no oil and vapor leaks. If any of
these occur, shut down the compressor and correct the
problem as necessary using good safety precautions.
Note: The rate of discharge pressure increase during
startup must be slow enough that refrigerant can’t
condense. This very often requires a regulated gas
by-pass valve from the outlet of the package to the
inlet side of compressor to prevent the discharge
temperature from increasing too slowly.

070.750-IOM2 (JUN 22)
Page 19
HPS 273 and 407 Rotary Screw Compressor
Operation
4. After starting the compressor and it is operating, Frick
suggests maintaining suction gas superheat at a mini-
mum of 10°F. If operating at lower than 10°F suction
superheat consult the factory.
5. During shutdown, to avoid condensation on the inlet
side, complete the following steps:
a. Equalize the unit pressure to suction as quickly as
possible
b. While the unit is at standstill, turn on oil heating
and heat tracing to keep the oil warm. Use of heat
tracing or insulation on the SB-3 oil line is particu-
larly important because it feeds oil to the com-
pressor bearings and shaft seal. If using a water or
brine-cooled oil cooler, stop water or brine ow to
prevent oil cooling when the unit is not operating.
c. Evaporate all condensation in the unit before you
restart the unit.
Warning
Restarting the compressor unit with condensate
inside could lead to a catastrophic failure of the
compressor. It is important that all condensation in
the unit is completely evaporated before restarting
the unit.
Control system
The HPS compressor and package requires a dedicated
control system, either Quantum or UNISAB. For details on
operation of these control systems, refer to the respective
IOM manuals.

070.750-IOM2 (JUN 22)
Page 20
HPS 273 and 407 Rotary Screw Compressor
Operation
This page is intentionally left blank.