Frick HPS 36 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 improper operation.
Rotary Screw Compressor Units
All Refrigerants
Models: 36, 42, and 60
HPS
Form 070.700-IOM (MAR 2021)
Installation–Operation–Maintenance
File: Service Manual–Section 070
Replaces: Nothing
Dist: 3, 3a, 3b, 3c
Check www.FrickCold.com for the latest version of this publication.

HPS Rotary Screw Compressor Units070.700-IOM (MAR 21)
Page 2 Installation - Operation - Maintenance
Contents
General Information
Preface..............................................................................3
Design limitations.............................................................. 3
Job inspection...................................................................3
Transit damage claims.......................................................3
Compressor and unit identication....................................3
Installation
Foundation ........................................................................5
Rigging and handling.........................................................5
Removing the skid.............................................................6
Checking the motor/compressor rotation ..........................6
Compressor/motor coupling installation............................6
Installing the coupling...................................................6
Holding charge and storage ..............................................7
Compressor unit oil...........................................................7
Oil charge..........................................................................7
Oil heater(s) ......................................................................8
Oil lter(s) ......................................................................... 8
Suction valve mounting.....................................................8
Thermosyphon oil cooling (TSOC)..................................... 9
Equipment ....................................................................9
System operation .........................................................9
Oil temperature control................................................ 9
Installation....................................................................9
Liquid injection oil cooling (optional)............................... 10
Water or glycol oil cooling (optional) ..............................10
Economizer (optional) .....................................................11
Economizer load balancing.............................................. 12
Economizing with VSDs...................................................12
Electrical .........................................................................12
Motor VSD package ........................................................12
Current transformer (CT) ratios.......................................13
Minimum burden ratings ................................................. 14
Control power regulator.................................................. 14
Installation of electronic equipment in an industrial
environment.............................................................15
Wire sizing ......................................................................15
Voltage source ................................................................15
Grounding .......................................................................16
Considerations ................................................................17
Conduit ...........................................................................17
Wiring practices .............................................................18
Communications .............................................................19
UPS power and Quantum™ HD panels.............................. 19
Operation
Operation and Start‑Up instructions ............................... 21
HPS compressor.............................................................. 21
Compressor lubrication system .......................................21
No pump oil system ........................................................ 21
Compressor oil separation system ..................................22
Cold‑start system (580 psig DWP) .................................. 22
Capacity regulation and xed volume ratio Vi.................23
Compressor oil cooling systems...................................... 23
Single‑port liquid injection..............................................23
Suction check valve bypass.............................................23
Low ambient operation ...................................................24
Initial start‑up .................................................................24
Initial start‑up procedure ................................................ 24
Quantum™HD EZ‑COOL™liquid injection adjustment
procedure ................................................................ 25
Solenoid control .........................................................25
EZ Cool status ............................................................25
EZ cool PI control.......................................................25
Operation of Danfoss liquid injection valve ..................... 26
Reset to factory setting:............................................. 27
VFD skip frequencies.......................................................27
Normal start‑up procedure .............................................27
Restarting the compressor unit after control power
interruption (plant power failure) ............................... 27
Maintenance
General information ........................................................29
Normal maintenance operations ..................................... 29
General maintenance ...................................................... 29
Compressor shutdown and start‑up................................ 29
General instructions for replacing
compressor unit components................................... 29
Oil lter (OF‑1) cartridge style........................................ 30
Strainer ‑ Liquid injection ...............................................30
Coalescer lter element(s) .............................................. 31
Changing oil .................................................................... 31
Maintenance schedule..................................................... 32
Maintenance program .....................................................33
Vibration analysis............................................................ 33
Oil quality and analysis.................................................... 33
Oil sampling procedure ................................................... 33
Operating log .................................................................. 33
Motor bearings................................................................ 35
Grease compatibility........................................................35
Troubleshooting guide..................................................... 35
Abnormal operation
analysis and correction ............................................35
Servicing the cold‑start valve
(580 psig DWP only) ................................................ 36
Testing pressure transducers...........................................36
Replacing pressure transducers....................................... 37
Temperature sensor ........................................................38
Troubleshooting.......................................................... 38
Replacement ..............................................................38
Oil level switch................................................................38
Replacement ..............................................................39
Troubleshooting the HPS Compressor unit......................39
Troubleshooting the oil separation system...................... 39
Troubleshooting the liquid injection oil cooling system...40
Motor and bare compressor replacement .......................40
SAE straight thread O-ring ttings assembly procedure . 40
Operating log sheet ........................................................ 44
Forms
HPS Compressor prestart checklist .................................45
Start‑up report................................................................ 46
Vibration data sheet........................................................ 50

HPS Rotary Screw Compressor Units 070.700-IOM (MAR 21)
Page 3General Information
General Information
Preface
This manual describes the installation, operation, and
maintenance procedures of Frick HPS Rotary Screw
Compressor Units.
For information about the functions of the Quantum™HD
control panels, communications, specications, and wiring
diagrams, see publication series 090.040-O, 090.040-M,
090.040-CS, and 090.040-SPC.
It is most important that these units be correctly applied
to an adequately controlled refrigeration system. Consult
your authori zed Frick representative for their expert guid-
ance in this determination.
Performance and continued satisfaction with these units
depends on the following factors:
• Correct installation
• Correct operation
• Regular, systematic maintenance
To ensure correct installation and application, select
the appropriate equipment and connect to a correctly
designed and installed system. The engineering plans,
piping layouts, and other system design materials must be
detailed in accordance with the best practices and local
codes, such as those outlined in ASHRAE literature.
A refrigeration compressor is a vapor pump. To ensure
that working uid in the liquid state is not being ingested,
ensure the following points:
• Select controls carefully. Ensure they are in good oper-
ating condition.
• Correctly size piping and 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 standstill periods are
reasonable.
• Size high side components in the system and compres-
sor design limits.
It is best practice to superheat the entering vapor tem-
perature to the compressor to 10°F, or 5.6°C, above the
refriger ant saturation temperature. This ensures that all
refrigerant at the compressor suction is in the vapor state.
Design limitations
The compressor units 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™.
Job inspection
Immediately upon delivery examine all crates, boxes and
exposed compressor and com ponent surfaces for dam age.
Unpack all items and check against shipping lists for any
discrepancy. Examine all items for damage in transit.
Transit damage claims
All claims must be made by consignee. This is an ICC
requirement. Request immediate inspection by the agent
of the carrier and be sure the correct claim forms are
executed.
Report damage or shortage claims im mediately to Johnson
Controls Inc., Frick Sales Administration Department, in
Waynesboro, PA.
Compressor and unit identication
Each compressor unit has 2 identica tion data plates. The
unit data plate in Figure 1 containing the unit model, serial
number, and Frick sales order number, mounted on the
side of the Quantum™ HD control panel. The compressor
data plate in Figure 2 contains the compressor model and
serial number, mounted on the compressor body.
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 and/or minor injury.
Indicates an operating procedure, practice, or portion thereof that is essential to highlight.
Warning
Caution
Danger
Notice
Figure 1: Unit data plate

HPS Rotary Screw Compressor Units070.700-IOM (MAR 21)
Page 4 General Information
Notice
When inquiring about the compressor or unit, or order-
ing repair parts, provide the model, serial, and FRICK
sales order numbers from these data plates.
Figure 2: Compressor data plate
534B2722
COMPRESSOR SHAFT
CLOCKWISE ROTATION
534B2721
534B2720
534B2719
R22
COMPRESSOR OPERATES ON AND IS
COMPATIBLE WITH THE FOLLOWING
REFRIGERANTS
R290, R1270, NATURAL GAS
COMPRESSOR OPERATES ON AND IS
COMPATIBLE WITH THE FOLLOWING
REFRIGERANTS
R50, R134a, R170, R290, R404A, R410A, R507,
R513A, R600, R600A, R717, R728, R729, R744,
R1150, NATURAL GAS
COMPRESSOR OPERATES ON AND IS
COMPATIBLE WITH THE FOLLOWING
REFRIGERANTS
534C2934H01
SGXB2 4021
US2430125370500010
10241A89999999R
3600 600 41
USA
REFERENCE MATERIAL FIELD ON
SHEET 1 OF PRODUCTION ORDER
REFERENCE TABLE ON
SHEET 2 AND NOTE 3
REFERENCE TABLE
ON SHEET 2
REFERENCE TABLE ON
SHEET 2 AND NOTE 2
GENERATED BY SAP
ASSEMBLY PLANT LOCATION
534C2933H01
USA
US2430129999900010
10241A89999999R
100 CUMBERLAND VALLEY AVENUE
WAYNESBORO, PA 17268
ROTARY SCREW COMPRESSOR
MODEL NO.
MAX DRIVER SPEED MAX ALLOWABLE PRESSURE
PART NO.
RPM PSIG BARG
ASSEMBLED IN
FROM FOREIGN AND DOMESTIC MATERIALS
SERIAL NO.
60
870
6000
HPSH 1510
HPS
package
model
Rotor
diameter,
mm
Rotor
L/D Max. speed
rpm
Geometrical swept
vol. drive shaft end 3550 rpm cfm (m³/h) 4150 rpm cfm (m³/h) 5950 rpm cfm (m³/h)
ft³/rev (m³/h)
HPS 36
157 1.0 6,000 0.05847 (0.00166)
207.6 (353.6) - -
HPS 42 - 242.7 (413.3) -
HPS 60 - - 347.9 (592.6)
Note: Rotor diameter is for HPSH 1510 compressor model
Table 1: Compressor mechanical characteristics
Rotary screw compressor serial numbers are dened by
the following information:
Example: 10240A90000015Z
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 standard conguration
970 66

HPS Rotary Screw Compressor Units 070.700-IOM (MAR 21)
Page 5Installation
Installation
Foundation
If the HPS rotary screw compressor unit ships are mounted
on a wood skid, remove the skid before unit installation.
Warning
Allow space for servicing the unit as indicate on fac-
tory drawings.
The rst requirement of the compressor foundation is that
it must be able to support the weight of the compres-
sor package including coolers, oil, and refrigerant charge.
Screw compressors are capable of converting large quan-
tits of shaft power into gas compression in a relatively
small space and a mass is required to effectively dampen
these relatively high-frequency vibrations.
Firmly anchoring the compressor package to a suitable
foundation by correct application of grout and eliminating
piping stress imposed on the compressor is the best insur-
ance for a trouble-free installation. Use only the certied
general arrangement drawings from Frick to determine the
mounting foot locations and to ensure appropriate clear-
ances around the unit for ease of operation and servicing.
Foundations must be in compliance with local building
codes and materials be of industrial quality.
The oor must be a minimum of 6 in. of reinforced con-
crete, and you can use housekeeping pads. Anchor bolts
are required to rmly tie the unit to the oor. After rigging
the unit into place (See Rigging and handling), you must
shim the feet in order to level the unit. Place the shims so
that the feet are positioned roughly 1 in. above the house-
keeping pad, to allow room for grouting. Work an expan-
sion-type epoxy grout under all areas of the base with no
voids and allow to settle with a slight outward slope so oil
and water can run off of the base.
When installing on a steel base, implement the following
guidelines to correctly design the system base:
• Use I-beams in the skid where the screw compressor
are attached to the system base. Run the I-beams par-
allel to the package feet and support the feet for their
full length.
• Weld the compressor unit feet continuously to the sys-
tem base at all points of contact.
• Do not mount the compressor unit on vibration isola-
tors, in order to hold down package vibration levels.
• The customer’s foundation for the system base needs
to fully support the system base under all areas, but
most certainly under the I-beams that support the com-
pressor package.
When installing on the upper oors of buildings, take extra
precautions to prevent normal package vibration from be-
ing transferred to the building structure. It may be neces-
sary to use rubber or spring isolators, or a combination of
both, to prevent the transmission of compressor vibration
directly to the structure. However, this may increase pack-
age vibration levels because the compressor is not in con-
tact with any damping mass. The mounting and support of
suction and discharge lines is also very important. Rubber
or spring pipe supports may be required to avoid trans-
ferring resonant energy into the building structure at any
pipe supports close to the compressor package. It is best
to employ a vibration expert in the design of a mounting
arrangement.
In any screw compressor installation, it is necessary to
support suction and discharge lines in pipe hangers (pref-
erably within 2 ft [0.6 m] of vertical pipe run) so that the
lines won’t move if disconnected from the compressor.
See the following table for allowable ange loads.
Table 2: Allowable ange loads
Nozzle
size
NPS
Moments, ft-lb
(N.m) Load, lb (N)
Axial
MR
Vert.
MC
Lat.
ML
Axial
PVert. VC
Lat.
VL
125
(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)
Consult a licensed architect to determine the foundation
requirements for any large engine or turbine drive.
When applying screw compressors at high pressures, the
customer must be prepared for package vibration and
noise higher than the values predicted for normal refrig-
eration duty. Correct foundations and installation methods
are vital, and even then, sound attenuation or noise cur-
tains may be necessary to reduce noise to desired levels.
For more detailed information on the foundation, refer to
070.210-IB, Screw Compressor Foundations.
Rigging and handling
Warning
This screw compressor package may be top-heavy.
Use caution in rigging and handling.
To move the unit with rigging using a crane and spreader
bar, hook into the four lifting eyes on the oil separator.
• If a motor is mounted, make appropriate adjustments in
the lifting point to compensate for motor weight.
• Make adjustments to the lifting point for any additions
to the standard package, such as an external oil cooler,
because this affects the center of balance.
Refer to supplied engineering drawings to determine the
package center of gravity.
You can move the unit with a forklift by forking under the
skid, or you can skid into place with pinch bars by pushing
against the skid.

HPS Rotary Screw Compressor Units070.700-IOM (MAR 21)
Page 6 Installation
Caution
Never move the unit by pushing or forking against
the separator shell or its mounting supports.
Removing the skid
If the unit is rigged into place, you can remove the skid
by taking off the nuts and bolts that are fastening the unit
mounting supports to the skid before lowering the unit
onto the mounting surface.
If the unit is skidded into place, perform the following steps:
1. Remove the cross members from the skid
2. Remove the nuts anchoring the unit to the skid.
3. Using a 10-ton jack under the separator, raise the unit
at the compressor end until it clears the two mounting
bolts.
4. Spread the skid to clear the unit mounting support,
then lower the unit to the surface.
5. Repeat procedure on opposite end.
Checking the motor/compressor
rotation
Warning
Make sure coupling hubs are tightened to the shaft
before rotating the motor to prevent them from
coming loose and possibly causing serious injury or
death.
Warning
Injury may occur if loose clothing or hair becomes
entangled on the spinning motor shaft.
Compressor rotation is
clockwise when facing the
end of the compressor
shaft. Do not, under any
circumstance, attempt to
check the motor rotation
with the coupling center
Table 3: Coupling data
Drive
coupling
part
number
Disc pack locknut Compressor hub
clamping bolts Motor hub clamping bolts Keyway setscrew
Torque Size
UNF Torque Size UNF Torque Size UNF Torque Size UNC
ft-lb N⋅m ft-lb N⋅m ft-lb N⋅m ft-lb N⋅m
720C0313H01 40 54 7/16-20 23 31 5/16-24 23 31 5/16-24 22 30 5/16-18
720C0313H03 58 79 1/2-20 23 31 5/16-24 41 56 3/8-24 22 30 5/16-18
720C0313H04 58 79 1/2-20 23 31 5/16-24 41 56 3/8-24 22 30 5/16-18
720C0313H05 58 79 1/2-20 23 31 5/16-24 41 56 3/8-24 22 30 5/16-18
720C0313H08 58 79 1/2-20 41 56 3/8-24 41 56 3/8-24 63 85 1/2-13
720C0313H09 58 79 1/2-20 41 56 3/8-24 41 56 3/8-24 63 85 1/2-13
720C0313H10 58 79 1/2-20 41 56 3/8-24 66 89 7/16-20 63 85 1/2-13
720C0313H11 58 79 1/2-20 41 56 3/8-24 66 89 7/16-20 63 85 1/2-13
720C0313H12 58 79 1/2-20 41 56 3/8-24 66 89 7/16-20 63 85 1/2-13
section installed, because this may result in damage to the
compressor. Bump the motor to check for correct com-
pressor rotation. After verica-
tion, install disc drive spacer, as
applicable.
Compressor/motor
coupling installation
HPS compressors are primarily de-
signed for connecting to an electric
drive motor using a tunnel mount.
If the application requires it, the
compressor can also be driven with
a foot-mounted motor. The tunnel
mount ensures correct alignment of the compressor and
motor so that the shaft seal and coupling operate correctly.
Figure 3: Direction of rotation
Figure 4: Motor tunnel
The rotor and bearing design set limitations must not be
exceeded (See CoolWare). Refer to Compressor Control
Panel instructions in 090.040-O, Quantum HD Control Pan-
el for additional information on setpoint limits. No align‑
ment is required in the eld. See Figure 5.
Installing the coupling
Figure 5: Coupling
1. Install the motor and compressor coupling hubs and
keys on their respective shafts. Ensure that they can
slide horizontally so that after installing the disc packs,
no axial stress is transferred to the disc packs by a
stuck coupling hub. Use no lubricants.
2. Rotate both hubs so that the keys are 180° opposed.

HPS Rotary Screw Compressor Units 070.700-IOM (MAR 21)
Page 7Installation
With the
hubs mount-
ed and the
axial spacing
set, proceed
to place
the spacer
between
the two hub
anges. Take
care when
handling
the spacer.
Be sure the
spacer is fully supported at this time. Damage to the
unitized ex discs may result after they have been
installed if the spacer is not fully supported.
3. Install the unitized ex disc. Start a bolt through a bolt
hole in the spacer. Put the unitized ex disc between
the hub and spacer until a bushing hole in the unitized
ex disc lines up with the bolt. Slide the bolt through
the bushing hole in the unitized ex disc. To avoid
thread damage, ensure that every other bolt is installed
in the opposite direction as shown in the photo.
4. Install the locknut until it is snug. Make sure that all
bolt threads are clean and lightly oiled. Do not torque
any locknuts at this time. Now pivot the unitized ex
disc until the other bushing holes in the ex disc are in
line with the bolt holes in the spacer. Install the rest of
the spacer bolts at this time. The remaining bolts for
this end of the coupling can be installed through the
hub bolt holes and ex disc bushing holes.
5. Install the unitized ex disc in the other end of the
coupling. Ensure the unitized ex disc, when installed,
looks at and parallel with the mating hub and spacer
anges.
6. See Table 3 for torque values for the disc pack lock-
nuts. Hold the bolts in place while the locknuts are
torqued.
7. Center the coupling between the shafts. Ensure that
the keys are fully engaged in their keyways.
8. Tighten the motor and compressor shaft clamping bolts
evenly. See Table 3 for torque values.
9. See Table 3 for torque values for the keyway set-
screws.
Notice
Only after tightening the shaft clamping bolts to
their nal torque can the keyway set screws be
tightened. If the keyway set screws are tightened
before the shaft clamping bolts are tightened, then
the hubs can be cocked on the shaft.
Notice
Do not use any lubricant on these bolts.
Holding charge and storage
Each HPS compressor unit is pressure and leak tested at
the factory and then thoroughly evacuated and charged
with dry nitrogen to ensure the integrity of the unit during
shipping and short term storage before installation.
Caution
Take care when entering the unit to ensure that the
nitrogen charge is safely released.
Warning
Holding-charge shipping gauges on separator and
external oil cooler are rated for 30 psig (2.07 bar) and
are for checking the shipping charge only. They must
be removed before pressure testing the system and
before charging the system with refrigerant. Failure
to remove these gauges may result in catastrophic
failure of the gauge and uncontrolled release of re-
frigerant resulting in serious injury or death.
Keep units in a clean, dry location to prevent corrosion
damage. Reasonable consideration must be given to the
care for the solid-state components of the control panel.
Contact Frick service for long-term storage requirements.
Compressor unit oil
Warning
Do not mix oils of different brands, manufacturers, or
types. Mixing of oils may cause excessive oil foam-
ing, nuisance oil level cutouts, oil pressure loss, gas
or oil leakage and catastrophic compressor failure.
Notice
The Frick oil charge shipped with the unit is the best
suited lubricant for the conditions specied at the
time of purchase. If there is any doubt due to the re-
frigerant, operating pressures, or temperatures, refer
to Frick Oil publication 160.802-SPC.
Oil charge
Notice
Oil may migrate from the wet sump area to the dry
coalescer area during transportation and handling.
Before commissioning the compressor, check for any
oil migration. Oil transfer may be needed.
Table 4: HPS models
HPS models Compressor
model Oil charge, gal. (L)
HPS 36, 42, 60 HPSH 1510 35 (132.5)
Note: Includes total in horizontal oil separator and piping.
Add 5 gal. for oil cooler.
Figure 6: Coupling bolt orientation

HPS Rotary Screw Compressor Units070.700-IOM (MAR 21)
Page 8 Installation
The normal charging level is midway in the top sight glass
located midway along the oil separator shell. The normal
operating level is midway between the top sight glass
and bottom sight glass. Table 4 gives the approximate oil
charge quantity.
Add oil by attaching the end of a suitable pressure type
hose to the oil drain valve located under the oil separator
(see Figure 7). Using a pressure-type pump and the ap-
propriate Frick oil, open the drain valve and pump oil into
the separator.
Notice
Evacuation of the oil separator assists the ow of oil
into the unit. Also, ll slowly because oil lls up in
the separator faster than it shows in the sight glass.
Figure 7: Oil drain valve
Oil distillers and similar equipment that act to trap oil must
be lled before unit operation to normal design outlet
levels. The same pump that charges the unit may be used
for lling these auxiliary oil reservoirs.
Notice
The sight glass located in the coalescing-end of the
separator near the separator discharge connection
must remain empty.
Oil heater(s)
Standard units are equipped with one to two 500 W
oil heaters, providing sufcient heat to maintain the oil
temperature for most indoor applications during shutdown
cycles to permit safe start-up. If additional heating capac-
ity is necessary, because of low ambient temperature,
contact Johnson Controls-Frick. The heaters are energized
only when the unit is not in operation.
Warning
Do not energize the heaters when there is no oil
in the unit, because the heaters burn out. The oil
heaters are energized whenever 120 V control power
is applied to the unit and the compressor is not run-
ning, unless the 16 amp circuit breaker in the control
panel enclosure is turned off.
Oil lter(s)
Notice
Use of lter elements other than Frick may cause
warranty claim to be denied.
The oil lters and coalescer elements shipped with the
unit are best suited to ensure correct ltration and opera-
tion of the system.
Suction valve mounting
The suction isolation valve is shipped loose from the fac-
tory, so that you can install it at various positions within
the suction line piping to the compressor.
Do not install the valve at the compressor suction with
ow against the cone/button. See Figure 8 for correct
orientation.
When the isolation valve is installed in this position,
uneven ow is generated across the suction check valve,
which is mounted at the inlet to the compressor. This
uneven ow causes the disks in the check valve to strike
against the stop pin, and eventually damage the internals
of the check valve.
If the isolation valve is mounted at the compressor suc-
tion, install with ow across the cone/button (Figure 8
- Bottom).
Design your system piping accordingly.
Caution
After removing the suction sealing disc, conrm that
the check valve hinge pin is in the vertical position! If
the hinge pin is not in vertical position, then failure
of the check valve may occur.
Figure 8: Valve installation

HPS Rotary Screw Compressor Units 070.700-IOM (MAR 21)
Page 9Installation
System operation
Liquid refrigerant lls the cooler shell-side up to the Ther-
mosyphon receiver liquid level.
Hot oil (above the liquid temperature) owing through the
cooler causes some of the refrigerant to boil and vapor-
ize. The vapor rises in the return line. The density of the
refrigerant liquid/vapor mixture in the return line is con-
siderably less than the density of the liquid in the supply
line. This imbalance provides a differential pressure that
sustains a ow condi tion to the oil cooler. This relationship
involves:
• Liquid height above the cooler.
• Oil heat of rejection.
• Cooler size and piping pressure drops.
The liquid/vapor returned from the cooler is separated in
the receiver. The vapor is vented to the condenser inlet and
need only be reliquied because it is still at condenser pres-
sure (see Figure 9).
Oil temperature control
Oil temperature generally runs about 15°F to 35°F (8.3°C
to 19.4°C) above the high-side condensing tempera ture. In
many cases, oil cooling is not required due to the low heat
of compression for CO2 applications:
• High-side 65°F to 105°F
condensing temperature: (18.3°C to 40.6°C)
• CO2 discharge 80°F to 140°F
temperature:(26.7°C to 60°C)
Installation
The welded plate-type thermosyphon oil cooler with oil-
side piping and a thermostatically controlled mixing valve
are factory mounted and piped. The customer must supply
and install all piping and equip ment located outside of
the shaded area on the piping diagram with consideration
given to the following:
• Ensure the refrigerant source, thermosyphon or system
receiver, is in close proximity to the unit to minimize
piping pressure drop.
• The liquid level in the refrigerant source must be a
minimum calculated height above the center of the oil
cooler.
• Install a safety valve if using refrigerant isolation valves
for the oil cooler.
Notice
The component and piping arrangement shown in
the following gure is intended only to illustrate the
operating principles of thermosyphon oil cooling. Other
component layouts may be better suited to a specic
installation. Refer to publication 070.900-E for addi-
tional information on Thermosyphon Oil Cooling.
Thermosyphon oil cooling (TSOC)
The refrigerant for TSOC (on a high pressure package) is
piped from the high side of the cascade system. Ther-
mosyphon oil cooling is an economical, effective method
for cooling oil on screw compressor units. Ther mosyphon
cooling uses liquid refrigerant at condenser pressure and
temperature that is partially vaporized at the condenser
temperature in a plate and shell vessel, cooling the oil to
within 35°F (19.4°C) of that temperature. The vapor, at
condensing pressure, is vented to the condenser inlet and
reliquied. This method is the most cost-effective of all
currently applied cooling systems because no compres sor
capacity is lost or compressor power penalties incurred.
The vapor from the cooler need only be condensed, not
compressed. Refrigerant ow to the cooler is automatic,
driven by the thermosyphon principle and cooling ow
increases as the oil inlet temperature rises.
Equipment
The basic equipment required for a thermosyphon system
consists of the following components:
• A source of liquid refrigerant at condensing pressure
and temperature, located in close proximity to the unit
to mini mize piping pressure drop. The liquid level in the
refrigerant source must be a minimum calculated height
above the center of the oil cooler.
• A plate and shell oil cooler with:
–Plate side: Oil 1000 psig (6894.8 kPa) design
–Shell side: Refrigerant 1000 psig (6894.8 kPa) design
Due to the many variations in refrigeration system design
and physical layout, several systems for ensuring the
above criteria are possible.
Figure 9: Condenser/Receiver
Note: Example using ammonia as the high-side refrigerant
95°F (35°C)
2.5 lb/ft3
95°F
(35°C)
36 lb/ft3

HPS Rotary Screw Compressor Units070.700-IOM (MAR 21)
Page 10 Installation
The level-control method (see Figure 12) uses a oat level
control on the receiver to close a solenoid valve feeding
the evaporator when the liquid falls below that amount
necessary for 5 min of liquid injection oil cooling.
Figure 12: Level control
Table 5: Liquid injection system line sizes
Refrigerant HPS
model Line
size
5 min supply,
lb (kg)
Liquid volume,
ft3 (m3)
R-744
Cascade
36 0.75 51 (23.13) 0.85 (0.024)
42 57 (25.85) 0.95 (0.027)
60 88 (39.92) 1.46 (0.041)
Conditions: Cascade: -60°F (-51.1°C) Evap, and 20°F
(-6.7°C) Cond, 10°F (-12.2°C) suction (line) superheat.
Water or glycol oil cooling
(optional)
The plate-and-shell and welded-plate type water or glycol
oil cooler is mounted on the unit complete with all oil pip-
ing. The customer must supply adequate water connec-
tions. Determine the size of the oil cooler supplied with
the unit, as outlined on the Frick P&I diagram and general
arrangement drawings. The water or glycol supply must be
sufcient to meet the required ow.
The glycol or water entering temperature must be no
lower than 60°F (15.6°C).
A closed-loop system is best practice for the water or glycol
side of the oil cooler. Careful attention to water treatment
is essential to ensure adequate life of the cooler if cooling
tower water is used. It is imperative to regularly analyze the
condition of cooling water or glycol closed-loop uids as
necessary, and maintain at a pH of 7.4, but not less than 6.0
for regular heat exchanger life.After initial start-up of the
compressor package, clean the strainer at the inlet of the oil
cooler several times in the rst 24 hours of operation.
In some applications, the plate and shell oil cooler may
be subjected to severe water conditions including high
temperature and/or hard water conditions. This causes
accelerated scaling rates, which degrades the perfor-
mance of the heat exchanger. A chemical cleaning process
extends the life of the plate and shell heat exchanger. It is
important to establish regular cleaning schedules.
Cleaning: A 3% solution of phosphoric or oxalic acid is ap-
propriate. Other cleaning solutions can be obtained from
your local distributor, but they must be suitable for stain-
less steel. The oil cooler may be cleaned in place by back
ushing with an appropriate solution for approximately 30
min. After back ushing, rinse the heat exchanger with
fresh water to remove any remaining cleaning solution.
Figure 10: TSOC piping arrangement
• The thermosyphon oil cooler is supplied with oil side-
piped to the compressor unit and stub ends supplied on
the refrigerant side.
• A refrigerant-side safety valve is required in this loca-
tion only when refrigerant isolation valves are installed
between the cooler and thermosyphon receiver. If no
valves are used between the cooler and TSOC receiver,
the safety valve on size the TSOC receiver to handle
the volume of both vessels. Then, you an eliminate the
safety valve on the cooler vent (liquid refrigerant side).
• The system receiver must be below the thermosyphon
receiver in this arrangement.
Liquid injection oil cooling
(optional)
The liquid injection system provided on the unit is self-
contained but requires the connection of the liquid line,
sized as shown in Table 5.
It is imperative that an uninterrupted supply of high pres‑
sure liquid refrigerant be provided to the injection system
at all times. Two items of extreme impor tance are the
design of the receiver/liquid injection supply and the size
of the liquid line.
It is best practice that the receiver be sufcient ly oversized
to retain a 5-min supply of refrig erant for oil cooling. The
evaporator supply must be secondary to this consider-
ation. There are two methods of accomplishing this.
The dual dip tube method (see Figure 11) uses two dip
tubes in the receiver. The liquid injection tube is below the
evapor ator tube to ensure continued oil cooling when the
receiver level is low.
Figure 11: Dual dip tube
CALCULATED
HEIGHT