Johnson Controls Frick PowerPac Owner's manual
PowerPac™
PACKAGED CHILLER UNITS
Form 170.600-IOM (JUN 2011)
INSTALLATION - OPERATION - MAINTENANCE
File: SERVICE MANUAL - Section 170
Replaces: S170-600 IOM (JUN 08)
Dist: 3, 3a, 3b, 3c
THIS MANUAL CONTAINS RIGGING, ASSEMBLY, START-UP,
AND MAINTENANCE INSTRUCTIONS. READ THOROUGHLY
BEFORE BEGINNING INSTALLATION. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR DEATH,
DAMAGE TO THE UNIT, OR IMPROPER OPERATION.
Please check www.johnsoncontrols.com/frick for the latest version of this publication.
FRICK® POWERPAC™
INSTALLATION - OPERATION - MAINTENANCE
170.600-IOM (JUN 11)
Page 2
Contents
INSTALLATION ............................................................................................................................................... 7
OPERATION .................................................................................................................................................10
MAINTENANCE ............................................................................................................................................14
FRICK® POWERPAC™
INSTALLATION - OPERATION - MAINTENANCE
170.600-IOM (JUN 11)
Page 3
PREFACE
CORRECT INSTALLATION
PROPER OPERATION
REGULAR, SYSTEMATIC MAINTENANCE
JOB INSPECTION
TRANSIT DAMAGE CLAIMS
CHILLER AND UNIT IDENTIFICATION
unit
data plate
compressor data plate
NOTE: When inquiring about the compres sor or unit, or
ordering repair parts, provide the MODEL, SERIAL, and
Johnson Controls-Frick SALES ORDER NUMBERS from
these data plates.
COMPRESSOR DATA PLATE
UNIT DATA PLATE
100 CV AVENUE, WAYNESBORO, PA. 17268
PHONE: 717-762-2121
MAX DESIGN
PRESSURE:
YEAR
SERIAL NO:
REFRIGERANT:
PACKAGED CHILLER UNIT
MODEL NO:
SALES ORDER NUMBER:
PSIG
kPa
FRICK® POWERPAC™
INSTALLATION - OPERATION - MAINTENANCE
170.600-IOM (JUN 11)
Page 4
PACKAGED AMMONIA CHILLER UNITS
PowerPac™
COMPRESSOR
Frick
COMPRESSOR CAPACITY CONTROL
LUBRICATION SYSTEM
cleaner
than new
Booster and some low-pressure dif-
ferential high-stage applications will require the demand
oil pump option.
Liquid Separator
Evaporator
Condenser
Economizer
Compressor
Quantum™LX
FRICK® POWERPAC™
INSTALLATION - OPERATION - MAINTENANCE
170.600-IOM (JUN 11)
Page 5
OIL SEPARATOR/RESERVOIR
OIL COOLING
MOTOR
SEMIWELDED PLATE CONDENSER
Condenser
Level Sensor
Level Pipe Motorized
Expansion
Valve
Figure 1 - Semiwelded Plate Condenser
SEMIWELDED PLATE EVAPORATOR
Evaporator
Drop Leg
Brine/Water Outlet
Wet Return
Brine/Water Inlet
Liquid Makeup
Liquid
Separator
Dry Suction
Figure 2 - Semiwelded Plate Evaporator
QUANTUM™LX CONTROL CENTER
FRICK® POWERPAC™
INSTALLATION - OPERATION - MAINTENANCE
170.600-IOM (JUN 11)
Page 6
LIQUID REFRIGERANT SEPARATOR
9
6 3
8
7
Figure 3 - Liquid Separator
FRICK® POWERPAC™
INSTALLATION
170.600-IOM (JUN 11)
Page 7
The unit may be top heavy. Lifting
operators must use extreme care to
check the level and stability of the
load before lifting the load more than a few inches. Impose
an imbalance by sequentially adding weight to each corner
and carefully observing the load reaction to make sure the
load does not shift. Balancing chains, cables or straps are
essential in both directions to prevent load shift and
instability during rigging. Call Johnson Controls-Frick
Engineering for an estimate of the location of the center
of gravity of the package if one is not given. The center
of gravity may NOT be located in the center of the package.
NOTES:
Figure 5
INSTALLATION
FOUNDATION
NOTE: Allow space for servicing at both ends of the unit.
A minimum of 24 inches (610 mm) is recommended.
HANDLING AND MOVING
DO
NOT USE A FORKLIFT. Refer to the engineering drawings
provided with the unit for shipping weight.
Spreader bars should be used on
both the length and width of the
package to prevent damage to the
package. CAUTION must also be used in locating the lifting
ring. Appropriate adjust ment in
the lifting point
should be
made to compensate for the center of gravity.
Figure 4
FRICK® POWERPAC™
INSTALLATION
170.600-IOM (JUN 11)
Page 8
LIFTING LUG CAPACITY, LB/LUG
NOMINAL BEAM
MEMBER SIZE
CABLE ANGLE
VERTICAL 45°
W8 15,200 14,990
W10 19,400 14,990
Figure 6
A: Continuously Loaded System:
B:System with load variations:
NOTE: Install vent valves (Position 1, Figure 6) at the
highest point in the system as well as at the drainage
valves (Position 2), which are located at the lowest point.
Water Treatment For Heat Exchangers
important
Warranty does not include any damage that may occur
due to harmful impurities in the system.
BRINE / WATER SYSTEMS
Figure 7
ELECTRIC WIRING
FRICK® POWERPAC™
INSTALLATION
170.600-IOM (JUN 11)
Page 9
HOLDING CHARGE AND STORAGE
NOTE: Care must be taken when entering the unit to
ensure that the nitrogen charge is safely released.
Holding-charge shipping gauges on
separator and external oil cooler are
rated for 30 PSIG and are for check-
ing the shipping charge only. They must be removed
before pressure testing the system and before charging
the system with refrigerant. Failure to remove these
gauges may result in catastrophic failure of the gauge and
uncontrolled release of refrigerant resulting in serious
injury or death.
FRICK® POWERPAC™
OPERATION
170.600-IOM (JUN 11)
Page 10
OPERATION
PRESTART CHECKLIST
An arrow on the
compressor end-cover marks the proper direction of
rotation. (See PRESTART CHECKLIST in FORMS section)
CHECKING MOTOR/COMPRESS OR ROTA TION
Make sure coupling hubs are tight-
ened to the shaft before rotating the
motor to prevent them from ying
off and possibly causing serious injury or death.
Injury may occur if loose clothing,
etc, becomes entangled on the spin-
ning motor shaft.
COMPRESSOR ROTATION IS
CLOCKWISE WHEN FACING
THE END OF THE COMPRES-
SOR SHAFT. NO
COMPRESSOR/MOTOR COUPLING
INSTALLATION
COMPRESSOR
COUPLING
1.
2.
3.
4.
5.
6.
DO NOT USE ANY LUBRICANT ON THESE BOLTS.
COUPLING DATA TABLE
Coupling Hub
CH Between Shaft Spacing Shaft Engagement Face
Spacing
Clamp Bolt Keyway
Series Min. Max. Min. Max.
Torque (Dry)
Size Setscrew Torque Size
Size In. mm In. mm In. mm In. mm In. mm Ft-Lb Nm Ft-Lb Nm UNC
6 2 50.8 2¾ 69.9 1 25.4 1ZB\zn 49.2 7/8 22.2 15 20.3 1/4-20 UNC 13 17.6 5/16-18
72B\zn 58.7 3M\zn 87.3 1 25.4 2C\zn 55.6 1Z\zn 27.0 30 40.7 5/16-24 UNF 13 17.6 5/16-18
82>\zn 65.1 4 101.6 1Z\zn 27.0 2½ 63.5 1Z\, 28.6 55 74.6 3/8-24 UNF 13 17.6 5/16-18
93Z\zn 77.8 4B\, 117.5 1M\zn 36.5 3 76.2 1M\zn 36.5 55 74.6 3/8-24 UNF 13 17.6 5/16-18
10 3>\zn 90.5 5¼ 133.4 1ZZ\zn 42.9 3½ 88.9 1ZZ\zn 42.9 130 176.3 1/2-20 UNF 13 17.6 5/16-18
11 4Z\, 104.8 5M\, 149.2 1M\, 47.6 4101.6 1M\, 47.6 130 176.3 1/2-20 UNF 13 17.6 5/16-18
FRICK® POWERPAC™
OPERATION
170.600-IOM (JUN 11)
Page 11
COMPRESSOR UNIT OIL
DO NOT MIX OILS of different
brands, manufacturers, or types.
Mixing of oils may cause excessive
oil foaming, nuisance oil level cutouts, oil pressure loss,
gas or oil leakage and catastrophic compressor failure.
NOTE: The Frick oil charge shipped with the unit is the
best suited lubricant for the conditions specied at
the time of purchase. If there is any doubt due to the
refrigerant, operating pressures, or temperatures, refer
to Frick Oil publication 160-802 spc for guidance.
Johnson Controls-Frick.
EVACUATION
CHARGING REFRIGERANT
TechnicalData
Never leave the unit unattended
during the rst 60 minutes following
start-up.
DRAINING REFRIGERANT
Check that the vessel is large enough
to hold the entire charge without
being overlled and that it is made
for the particular refrigerant used. DO NOT charge the
vessel beyond 90% liquid volume .
Open
SYSTEM PUMPDOWN
FRICK® POWERPAC™
OPERATION
170.600-IOM (JUN 11)
Page 12
Electrical Regulation
Figure 8
Figure 9
BOILING POINT AT PRESSURE
of WATER °F (°C) IN. H2O (mm HG)
IMPORTANT: NEVER use the refrigeration compressor to
pump down a system.
NOTE: There is a risk that any water still present in the
refrigeration system may freeze if the ambient tempera-
tures drops below 50°F (10°C). If this occurs, add heat
to the environment of the components because ice does
not evaporate easily.
OPERATING LOG
HIGH PRESSURE REGULATING SYSTEM
Mechanical Float Valve
Expansion Valve
Actuator
Level Sensor
Vent Valve
FRICK® POWERPAC™
INSTALLATION
170.600-IOM (JUN 11)
Page 13
PURGING THE SYSTEM
NOTE: The occurrence of air is usually an indication of
poor maintenance or lack of thoroughness at installation.
If the chiller contains air, it tends to gather on the high
pressure side of the system.
NOTE: R-717 systems should be purged on a regular basis
to avoid atmospheric air and other noncondensable gases.
AUTOMATIC OIL RETURN SYSTEM
Figure 10
FRICK® POWERPAC™
MAINTENANCE
170.600-IOM (JUN 11)
Page 14
TABLE 1 - EXCESSIVE CONDENSING PRESSURE
Cause Remedies
TABLE 2 - EVAPORATING TEMPERATURE TOO LOW
Causes Remedies
MAINTENANCE
the recommended Frick oil specied
LOCK THE MAIN SWITCH
TROUBLESHOOTING AND
CAPACITY MEASUREMENT
OPERATING CONDITIONS
TROUBLESHOOTING
CAPACITY MEASUREMENT
INCORRECT CAPACITY MEASURING
FRICK® POWERPAC™
SAFETY
170.600-IOM (JUN 11)
Page 15
First Aid In Case Of Ammonia Accidents
(Chemical Formula: Nh3 – Refrigerant R-717)
GENERAL
NOTE: In concentrations greater than 15%, ammonia can
form ignitable mixtures with air and oxygen. It should
always be treated with respect.
Basic rules of First Aid
Call a doctor immediately.
Be prepared
INHALATION
Call a doctor/ambulance with oxygen equipment im-
mediately
not
only
EYE INJURIES FROM LIQUID SPLASHES OR
CONCENTRATED VAPOR
Call a doctor immediately.
SKIN BURNS FROM LIQUID SPLASHES OR
CONCENTRATED VAPOR
Call a doctor immediately.
FOLLOW YOUR COMPANY GUIDELINES FOR PROCESS
SAFETY MANAGEMENT (PSM).
ADDITIONAL FACTS ABOUT R-717:
return
Never mix R-717 with halocarbon refrigerants.
PROTECTING THE ENVIRONMENT
ADDITIONAL FACTS ABOUT REFRIGERANTS
Refrigerants
FRICK® POWERPAC™
SAFETY
170.600-IOM (JUN 11)
Page 16
over approximately 572°F (300°C
Check ofcial limits in the location
of your installation. They may differ
from those stated.
VENTILATING A REFRIGERATION PLANT
Never
Released air must pass through
an open water
COOLING AGENTS
OILS
NOTE: The owner of the refrigeration plant is responsible
for ensuring compliance with all Federal, state, and local
regulations. PSM procedures should be routinely followed.
FRICK® POWERPAC™
FORMS
170.600-IOM (JUN 11)
Page 17
READ THIS FIRST: COMPRESSOR PRESTART CHECKLIST
The following items MUST be checked and completed by the installer prior to the arrival of the Frick Field
Service Supervisor. Details on the checklist can be found in this manual. Certain items on this checklist will
be reveried by the Frick Field Service Supervisor prior to the actual start-up.
Mechanical Checks
DO NOT reinstall
PRIOROILREFRIGERANT
PRIOR
PROPER PIPE SUPPORTS
ALLINCLUDING RELIEF VALVES
Electrical Checks
ALL PERTINENT WIRING
METAL PARTICLES
After the above items have been checked and veried:
DO NOT energize compressor drive motor !
Summary: The Frick Field Service Supervisor should arrive to nd the above items completed. He should nd an uncoupled
compressor drive unit (to verify motor rotation and alignment) and energized oil heaters with the oil at the proper
standby temperatures. Full compliance with the above items will contribute to a quick, efcient and smooth start-up.
The Start-up Supervisor will:
NOTE: Customer connections are to be made per the electrical diagram for the motor starter listed under the
installation section and per the wiring diagram listed under the maintenance section of the IOM.
Please complete and sign this form & fax to 717-762-8624 as conrmation of completion.
FRICK® POWERPAC™
FORMS
170.600-IOM (JUN 11)
Page 18
Start-up Report
Unit General Information
Micro Information
Compressor Motor Starter / Drive Information
Oil Pump Information
Cooling Fan Information
Special Options
Prestart Checks
Conguration
Capacity Channel Direction Package
Miscellaneous:
FRICK® POWERPAC™
FORMS
170.600-IOM (JUN 11)
Page 19
Page 2
Capacity Control Setpoints
Setpoint Regulation Safeties Setpoint Regulation Safeties
High Low High Low
Auto Cycle Low Suction Auto Cycle Low Suction
Compressor Safeties
High Discharge Temperature High Suction Pressure
High Discharge Pressure Dual Mode Economizer
Package Safeties
Low Compressor Oil Temperature Pull Down
High Compressor Oil Temperature Pump Down
DX Circuit
Low Compressor Oil Pressure #1 Action
High Filter Pressure #2 Action
Main Oil Injection Liquid Injection
Oil Heater Off Above
High Level Shutdown Delay
Low Oil Level Delay Hot Gas Bypass
Oil Pump Lube Time Before Starting Power Assist
Dual Pump Transition Time
FRICK® POWERPAC™
INSTALLATION - OPERATION - MAINTENANCE
170.600-IOM (JUN 11)
Page 20
Page 3
Compressor Motor Setpoints and Information
Motor Name Plate VFD
Remote Control
Recycle Delay Capacity Control
High Motor Amps
Variable Speed Min. Slide Valve Position
Skip Frequency Bands
Bottom Top
Low Motor Amps
Vyper Coolant Setpoints
PHD Monitoring Setpoints Condenser Control
Compressor Bearing Condenser Control Setpoint
Suction End Delay Discharge End Delay Digital Controls Step Order
Motor Bearing
Shaft Side Delay Opposite Shaft Side Delay
Motor Stator
Stator 1 Delay Stator 2 Delay
Analog Controls
Stator 3 Delay
Miscellaneous
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