Compressor Unit Oil; Evacuation; Charging Refrigerant; Draining Refrigerant - Johnson Controls Frick PowerPac Installation Operation & Maintenance

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 specified 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.
For standard PowerPac units, use only semisynthetic hy-
™
drotreated oil as provided by Johnson Controls-Frick.
Semisynthetic hydrotreated oil is a synthetic oil with a low
vapor pressure. This greatly reduces the amount of oil that
is passed with the R-717 discharge gas from the compressor
to the separator during operation. The result is noticeably
lower oil consumption.
Because semisynthetic hydrotreated oils do not mix well with
R-717, there is a considerable reduction of any content of this
oil taken from the compressor into the refrigeration system.
The high viscosity index of semisynthetic hydrotreated oils
makes the oil slide off evaporator plates more easily and
gather on the bottom of the evaporator. Then, the oil is re-
turned to the compressor via the automatic oil return system.
Frick ester-based synthetic lubricants are especially suited
®
for HFC refrigerants, R-134A, R-507, R-404 and the new
refrigerant blends. Frick ® synthetic oils are custom blended
with additives for oxidation inhibition, corrosion protection,
defoaming, and antiwear. Synthetic oils have extremely low
pour points. The low pour point makes it specially suited for
low temperature refrigeration applications. The high thermal
stability of Frick ® synthetic oil resists breakdown and extends
service intervals. Consult factory for application assistance.

EVACUATION

When the chiller unit has been installed in its final position
and all connections for refrigerant, water and electricity,
instruments, potential equalizer connection (ATEX only) and
safety switches have been connected, proceed as follows:
a. Check that the direction of rotation of the motor is cor-
rect, with the coupling dismantled. The direction of rotation
is marked by an arrow on the compressor end cover.
b. Check the direction of rotation of the oil pump.
c. Mount the coupling and check that the tolerances and the
alignment are in accordance with the instructions concern-
ing the coupling.
d. Connect the vacuum pump to valve position 414 (see piping
diagram) and evacuate the unit to a vacuum of approximately
4 to 5 mm Hg. A thermostatic vacuum meter may be used to
measure the pressure. If necessary, charge dry air or nitrogen
until the pressure reaches 1 bar. Evacuate again to 4 to 5 Hg.
e. Usually, the unit has been charged with oil from the factory.
If not, see the procedure about Oil Charging in the Operating
manual for the compressor.
FRICK POWERPAC
® ™
OPERATION
The refrigerant charge for a PowerPac
relation to the large cooling capacity. Most of the refriger-
ant liquid is present in the evaporator by design. The total
amount of refrigerant is indicated on the engineering drawing
included with the unit.
1. Connect a refrigerant cylinder to the charge valve. Purge
the charge hose with refrigerant before tightening the
union nut on the valve.
2. Open the charge valve. Refer to the Start-up procedure,
outlined above, to initiate compressor operation.
3. Start the compressor as described in the Control Panel
manual.
4. Check the compressor for any abnormal noises and make
sure that the compressor is building differential pressure.
5. Charge the amount of refrigerant gradually as indicated in
the table in Technical­Data. Check the amount by weighing
the refrigerant cylinders on a scale. The liquid level in the
liquid separator should be no higher than 2.5 inches (64 mm).
6. Close the charge valve and slowly increase capacity to
100%.
Use the following procedure to drain refrigerant from the unit:
• Run the system normally. Manually reduce the chiller
package capacity to minimum.
• Connect the drain valve to a refrigerant vessel approved
for this purpose. The connection must be made with an
approved refrigerant hose.
for the particular refrigerant used. DO NOT charge the
vessel beyond 90% liquid volume .
Before connecting the vessel, place it in chilled water or cool
it by some other means.
• Open the drainage valve and stop valve on the refrigerant
vessel.
• Close valves that supply liquid refrigerant to the evaporator.
• Using this procedure, the evaporator is pumped down and
the condensed liquid transferred to the refrigerant vessel.
After dismantling, the refrigerant vessel and protecting
cap must both be weighed to ensure that the vessel is not
overfilled. Net and gross weights stamped into the vessel
include the weight of the protecting cap.
After pressure testing, evacuate the refrigeration system to
remove any atmospheric air or moisture.
170.600-IOM (JUN 11)

CHARGING REFRIGERANT

unit is very small, in
™
Never leave the unit unattended
during the first 60 minutes following
start-up.

DRAINING REFRIGERANT

Check that the vessel is large enough
to hold the entire charge without
being overfilled and that it is made

SYSTEM PUMPDOWN

Page 11