Frick Vyper 305 Installation Operation & Maintenance
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Frick Vyper 305 Installation Operation & Maintenance

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305 / 254 Horsepower
437 / 362 Horsepower
THIS MANUAL CONTAINS RIGGING, ASSEMBLY, START-UP,
AND MAINTENANCE INSTRUCTIONS. READ THOROUGHLY
BEFORE BEGINNING INSTALLATION. FAILURE TO FOLLOW THESE
INSTRUCTIONS COULD RESULT IN DAMAGE OR IMPROPER
Please check www.johnsoncontrols.com for the latest version of this publication.
Form 100-200 IOM (FEB 2009)
INSTALLATION - OPERATION - MAINTENANCE
File:
Replaces:
Dist:
OPERATION OF THE UNIT.
SERVICE MANUAL - Section 100
S100-200 IOM (NOV 2008)
3, 3a, 3b, 3c

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Summary of Contents for Frick Vyper 305

  • Page 1 Form 100-200 IOM (FEB 2009) INSTALLATION - OPERATION - MAINTENANCE File: SERVICE MANUAL - Section 100 Replaces: S100-200 IOM (NOV 2008) Dist: 3, 3a, 3b, 3c 305 / 254 Horsepower 437 / 362 Horsepower THIS MANUAL CONTAINS RIGGING, ASSEMBLY, START-UP, AND MAINTENANCE INSTRUCTIONS.

  • Page 2: Table Of Contents

    SETTING THE JOB FLA ..........46 POWER FACTOR CAPACITORS ........11 Tables C and D: Job FLA Calculation ......46 SOFT-START SEQUENCE ..........11 FRICK INTERFACE BOARDDIP SWITCH SETTINGS ...47 INTERFACING ELECTRICAL EQUIPMENT ....11 INTERFERENCE WITH ELECTRONIC EQUIPMENT ..12 MAINTENANCE ..............49 SYSTEM OPERATING CONDITIONS ......12 STANDARD MAINTENANCE ........49...

  • Page 3: Preface

    Control panel, communications, specifications, and wiring NOTE: When inquiring about the Vyper or ordering ™ diagrams, please see the applicable and most current Frick spare parts, please provide the MODEl Number and documentation. SERIAl Number from the data plate. It is most important that these units be properly applied to an adequately controlled refrigeration system.

  • Page 4: Installation

    MODElNUMBER DEFINITIONS ™ Vyper Cabinet. ™ VYA_RGF_46 The Frick Vyper is offered in two mounting configurations. ™ The first mounting method is Package mounted. The units are preassembled, prewired, and tested at the factory. Please Input Voltage -46 (460V) consult standard compressor package installation procedures -50 (400V) for this mounting method.

  • Page 5: Vyper Pre-Installation Site Check List

    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 the I.O.M. Certain items on this checklist will be re-verified by the Frick Field Service Supervisor prior to the actual start-up.

  • Page 6: Pre-Startup Inspection

    ™ Operation Site Checklist. Any changes to factory setpoints, it is operating. Once it has moved to one end of the needs to be approved by Frick . Failure to obtain approval stroke, change the Direction back to Forward. This ®...

  • Page 7: General Description

    • Overload: 105% of full load for 7 seconds. for a Frick screw compressor. It controls capacity by reducing compressor speed and optimizing the compressor efficiency • Efficiency: 98% Typical at rated load and frequency.

  • Page 8: Coolant Temperature Limits

    • Voltage drop becomes excessive, rising above the 5% Water Recommendations voltage drop limit. • Johnson Controls-Frick recommends a closed-loop system • Peak voltage applied to the motor windings becomes for the water side of the heat exchanger. excessive and may cause premature motor failure.

  • Page 9: Heat Exchanger Pressure Drop

    VYPER VARIABLE SPEED DRIVE 100-200 IOM (FEB 09) ™ INSTALLATION Page 9 Figure 3 - Minimum Flow Rates - GlYCOl HEAT EXCHANGER PRESSURE DROP exchanger must be known. Figure 4 provides installation designers with pressure drop reference for different mixtures In order to adequately size piping and booster pump require- of propylene glycol and water.

  • Page 10: Power Wiring

    The general specification of the wire is also dictated by the causing large ground flow at the electronic equipment. environment in which it is used. The Frick Vyper is a NEMA 4 ™...

  • Page 11: Transformers

    423 VAC, 3 phase, 50 Hz. occur in Standby mode, only on initial start-up. Impedance Weight (lb) The Frick slide valve will load to the Variable Speed Minimum 5%-6% 1100 Slide Valve Position setpoint, and the Vyper accelerates to the speed corresponding to the Minimum Drive Output setpoint.

  • Page 12: Interference With Electronic Equipment

    A site survey should be mounting screws and soldered to the module. This improves completed with the help of a trained Frick service technician. reliability by eliminating the gate wires and their possible The technician will review the condition of the equipment and failure.
  • Page 13 VARIABLE SPEED DRIVE 100-200 IOM (FEB 09) ™ INSTALLATION Page 13 NOTE: Drawings for specific units can be found in the door of the Vyper drive or check with Frick Engineering department. Figure 6 - Vyper Elementary Wiring Diagram ™...
  • Page 14 100-200 IOM (FEB 09) VYPER VARIABLE SPEED DRIVE ™ Page 14 INSTALLATION between the DC link filter capacitors located on the power filter power unit, the filter incorporates “laminated bus” tech- nology and a series of small film capacitors (C23-C25). The unit and the logic board.
  • Page 15 VYPER VARIABLE SPEED DRIVE 100-200 IOM (FEB 09) ™ INSTALLATION Page 15 NOTE: Typical! Check with engineering for latest drawings. Figure 8 - Harmonic Filter Elementary Wiring Diagram...

  • Page 16: Configuration

    100-200 IOM (FEB 09) VYPER VARIABLE SPEED DRIVE ™ Page 16 INSTALLATION THE “TRAP” FIlTER is standard on all Frick Vyper units the Vyper coolant temperature at the control setpoint for ™ ™ that contain the Harmonic Filter. The trap filter is composed the PID loop.

  • Page 17: Liquid Cooled Vyper P & I Diagram-Economized

    VYPER VARIABLE SPEED DRIVE 100-200 IOM (FEB 09) ™ INSTALLATION Page 17 liquid Cooled Vyper P & I Diagram Economized...

  • Page 18: Liquid Cooled Vyper P & I Diagram-Noneconomized

    100-200 IOM (FEB 09) VYPER VARIABLE SPEED DRIVE ™ Page 18 INSTALLATION liquid Cooled Vyper P & I Diagram Noneconomized...

  • Page 19: Package-Mounted Vyper

    ™ Drive Disconnect Height – covered under Exception 2, a Frick RWF II 134 refrigeration package. Individual systems section 8 of article 404 of the NEC, which states, Switches configurations will vary according to model and horsepower and Circuit Breakers installed adjacent to motors, applianc- sizes selected.

  • Page 20: Vyper ™ Preinstallation Site Checklist

    100-200 IOM (FEB 09) VYPER VARIABLE SPEED DRIVE ™ Page 20 INSTALLATION BlOWER MOTOR ROTATION The Blower Motor rotation is marked on the blower assembly and is to be such that the blower draws into the assemly through the screen and pushes down and through the motor. Figure 9 - Blower Assembly Figure 10 - Blower Motor Rotation...

  • Page 21: Power And Control Wiring Entry Locations

    VYPER VARIABLE SPEED DRIVE 100-200 IOM (FEB 09) ™ INSTALLATION Page 21 POWER AND CONTROl WIRING ENTRY lOCATIONS Dimensions in Inches * Drive HP 305/254 1.63 4.50 9.00 6.38 4.38 35.00 5.50 3.56 6.63 2.00 437/362 6.63 6.75 10.13 2.00 3.25 40.53 2.25...

  • Page 22: External Power And Control Wiring

    100-200 IOM (FEB 09) VYPER VARIABLE SPEED DRIVE ™ Page 22 INSTALLATION EXTERNAl POWER AND CONTROl WIRING the interior of the cabinet. Be sure to leave enough relief in the leads so no undue stresses are transferred to the motor External power and control signals must be brought in and connection location in the interior of the unit.

  • Page 23: Electrical Conduits

    WIRING DIAGRAM OPTIONS ElECTRICAl CONDUITS The National Electrical Code requires thermal protection for motors operating with variable-speed drive systems. Frick • All power wiring must be contained in metallic conduit. employs two types of thermal protection for motors. One • All compressor motor wiring must be in a separate metallic method uses thermistors, and one method uses RTDs.

  • Page 24: Motor Rtd Thermal Protection

    100-200 IOM (FEB 09) VYPER VARIABLE SPEED DRIVE ™ Page 24 INSTALLATION MOTOR RTD THERMAl PROTECTION Figure 17 TEMPERATURE CONTROl VAlVE WIRING Figure 18...

  • Page 25: Motor Cooling Blower Wiring

    VYPER VARIABLE SPEED DRIVE 100-200 IOM (FEB 09) ™ INSTALLATION Page 25 MOTOR COOlING BlOWER WIRING Figure 19 DRAWING NOTES Figure 20...

  • Page 26: Analog Board Wiring

    100-200 IOM (FEB 09) VYPER VARIABLE SPEED DRIVE ™ Page 26 INSTALLATION ANAlOG BOARD WIRING Figure 21...

  • Page 27: Quantum ™ Lx Communications Wiring

    VYPER VARIABLE SPEED DRIVE 100-200 IOM (FEB 09) ™ INSTALLATION Page 27 QUANTUM lX COMMUNICATIONS WIRING INSTAllATION CHECK lIST ™ Figure 22 shows the junction points for the Quantum ™ Before starting the Vyper ™ , be sure that all of the following panel control wiring into the Vyper cabinet.

  • Page 28: Three Installation Steps

    100-200 IOM (FEB 09) VYPER VARIABLE SPEED DRIVE ™ Page 28 INSTALLATION b. Verify power wiring has been connected at the correct connection points and properly seated in accordance with the engineering drawings for the specific installation. c. Separate grounded metal conduits must be provided for input power, output power, and control wiring.
  • Page 29 VYPER VARIABLE SPEED DRIVE 100-200 IOM (FEB 09) ™ INSTALLATION Page 29 Figure 27 - Step 3, Opening the Drain Valve Figure 30 - Step 6, Top Off the Cooling System Figure 31 - Step 7, Replace the Pipe Plug and Tighten Step 7: Replace and tighten the plug on the top of the mani- Figure 28 - Step 4, Close the Drain and Refill the Unit fold using an adjustable wrench.

  • Page 30: Operation

    Proportional Band and VFD Integration Time setpoints. the Vyper . Detailed information about operation and set- ™ tings of the Quantum LX control panel can be found in Frick ™ If less capacity is required, the Quantum LX will first de- ™...
  • Page 31 VYPER VARIABLE SPEED DRIVE 100-200 IOM (FEB 09) ™ OPERATION Page 31 Figure 33 - Home Screen Service level 2: Press the [Menu] Button then Select Operating Values from the Flydown Figure 34 - Home Screen Service level 2: Select Vyper From the Menu The [Vyper] selection leads to an additional flyout menu THE VYPER SCREEN...
  • Page 32 100-200 IOM (FEB 09) VYPER VARIABLE SPEED DRIVE ™ Page 32 OPERATION Figure 35 - Home Screen Service level 2: Select Vyper Drive Setup Figure 36 - Home Screen Service level 2: Select Vyper Drive Setup Vyper screen Service Level 2 is similar to Level 1 but adds permits fast acceleration when the load returns.
  • Page 33 VYPER VARIABLE SPEED DRIVE 100-200 IOM (FEB 09) ™ OPERATION Page 33 Figure 37 - Harmonic Filter Screen Clear VSD Memory: Clear the existing trending values in “0” - no /off “1” - yes / on the Vyper memory. ™ •...

  • Page 34: Quantum ™ Lx Panel Set Up

    Drive, and optional Harmonic Quantum LX control panel. These settings will provide the ™ ™ Filter, on Frick screw compressors via the SFS-229 Frick Quantum LX with the necessary information to safely control ™ Interface Board. This is accomplished through the reception the Vyper ™...

  • Page 35: Setting The User Level

    VYPER VARIABLE SPEED DRIVE 100-200 IOM (FEB 09) ™ OPERATION Page 35 Figure 39 - Setting User level Figure 40 - Home Screen After Changing to Service level 2 SETTING THE USER lEVEl Return to the menu and the Home screen. The home screen will now provide additional information as shown in Press: [Menu→Session].

  • Page 36: Programming

    100-200 IOM (FEB 09) VYPER VARIABLE SPEED DRIVE ™ Page 36 OPERATION PROGRAMMING is selected under the package Drive field. This will allow the Vyper ™ specific screens to be displayed (See Figure 41). Verify that the Vyper ™ is set to Quantum ™...

  • Page 37: Pid Setup

    VYPER VARIABLE SPEED DRIVE 100-200 IOM (FEB 09) ™ OPERATION Page 37 PID SETUP Press: [Setpoints→PID Setup] Figure 43 - PID Setup Drive cooling is set to PID Channel #5. Use the table below to program the proper settings. Parameter Value Name Drive Cooling...

  • Page 38: Setting The Motor Screen

    100-200 IOM (FEB 09) VYPER VARIABLE SPEED DRIVE ™ Page 38 OPERATION SETTING THE MOTOR SCREEN Press: [Setpoints→Motor] Figure 44 - Motor Screen Nameplate “Applied Motor FlA” Calculation These fields should be populated with the motor nameplate information. This is for reference only. Mtr Nameplate SF=1.0 Mtr Nameplate FLA / 1.15 Mtr Nameplate SF=1.15...
  • Page 39 VYPER VARIABLE SPEED DRIVE 100-200 IOM (FEB 09) ™ OPERATION Page 39 Example 2 Table B Parameter Equation Value What are the High Motor Amp setpoints if a 437 HP Vyper ™ is to drive a motor with 1.15 SF and a 534 Amp FLA? Using Load Inhibit = Vyper Amp Limit x 0.97 the Values, determine whether Table A or Table B should be...
  • Page 40 100-200 IOM (FEB 09) VYPER VARIABLE SPEED DRIVE ™ Page 40 OPERATION Example 3 Example 4 What are the High Motor Amp setpoints if a 305 HP Vyper is What are the High Motor Amp setpoints if a 437 HP Vyper ™...

  • Page 41: Vfd And Capacity Control Settings

    Minimum Slide Valve Position - This setting establishes the set lower than the minimum allowable motor speed as recom- minimum Slide Valve position possible while the Frick screw mended by the supplier. Settings of this parameter which are compressor is running. At Minimum Drive Speed, it is the lower than the supplier recommended minimum percentage point at which no further mechanical unloading is allowed.
  • Page 42 Slide Valve Position setting in order to keep the Slide Valve NOTE: Slide Valve Range limited to protect compressor loaded at a much higher level. Frick recommends that the slide valve position for 5:1 applications be set as high as 97%.
  • Page 43 VYPER VARIABLE SPEED DRIVE 100-200 IOM (FEB 09) ™ OPERATION Page 43 Compressor Safeties Screen To prevent the Slide Valve from unloading beyond a high setpoint level (97%) and permit rapid compressor response under load, make the following setting adjustments on the Compressor Safeties Screen: Step 1: Press the [MENU] key and then selecting “Setpoints”...
  • Page 44 100-200 IOM (FEB 09) VYPER VARIABLE SPEED DRIVE ™ Page 44 OPERATION Example 2 - Suggested Control Strategy for Standard 2 to 1 (2:1) Turndown Figure 48 - 2:1 Turndown Suggested Control Strategy The standard 2:1 Turndown Control Strategy is depicted in NOTE: The Variable Speed Minimum Slide Valve Position Figure 48.
  • Page 45 VYPER VARIABLE SPEED DRIVE 100-200 IOM (FEB 09) ™ OPERATION Page 45 Figure 50 - Capacity Control Setpoints Screen With the actual pressure at 21 psig the proportional com- This control strategy is a variation on the generic control ponent would be 20%. The Proportional Component is strategy shown previously.

  • Page 46: Setting The Job Fla

    100-200 IOM (FEB 09) VYPER VARIABLE SPEED DRIVE ™ Page 46 OPERATION SETTING THE JOB FlA The final item for setup of the Vyper ™ is adjusting the Job FLA via trim pot on the Vyper Logic board. The trim pot sets ™...

  • Page 47: Frick Interface Boarddip Switch Settings

    ™ FRICK INTERFACE BOARD DIP SWITCH SETTINGS (Used before Jan 2008) On the Frick Interface Board (Figure 54) on the Vyper ™ right door there is a dip switch array. The array is located at the upper right of the FIB as shown in the photograph below.
  • Page 48 100-200 IOM (FEB 09) VYPER VARIABLE SPEED DRIVE ™ Page 48 MAINTENANCE The callouts on Figures 56 and 57 point out components, indicators and test points that can be used to aid in maintenance amd troubleshooting of fault codes. DC Voltage Test Points 24VAC Input Gate Drive Connections J8, J9 &...

  • Page 49: Maintenance

    DO NOT place any stress on the bus structure! The bottom of the The standard Frick running coolant is pink in color and con- IGBT module will be wet. Ensure that the coolant does...

  • Page 50: Replacement Of The Vyper Harmonic Filter Module

    On the Remote-mounted Vyper compressor drive, what ™ is the dV/dt “snubber” filter for? The combination of long runs of wire between the Frick Vyper and the compressor motor with the fast rise time of ™ the output voltage of the Vyper ™...

  • Page 51: Addendum

    Pressing any key on ant does not necessarily indicate a problem. Most colorless the keypad will clear the flashing backlight alarm. The FRICK samples test above 1000 PPM nitrite, which is normal. There VYPER ™...

  • Page 52: Frick Vyper ™ Fault Codes

    Harmonic Filter Input Frequency Out of Range Quantum LX: “VSD Interface Board to Panel Comms Loss” * 437 HP drives only This fault occurs when the Frick Interface Board loses com- At power-up, all the boards go through a process called ini- munications from the Quantum ™...
  • Page 53 (15 or 30 min demand)”. In the filter option • If the Harmonic Filter option is included, make sure the supplied by Frick, the displayed TDD is the total RMS value Harmonic Filter Logic board is not in continuous reset.
  • Page 54 Quantum LX: “VSD Phase B Gate Driver Fault” constant horsepower. This is a common problem when a second chiller is started. Contact Frick factory service if this Same comments as Fault 21 except applying to Phase B is confirmed to be a problem.
  • Page 55 VYPER VARIABLE SPEED DRIVE 100-200 IOM (FEB 09) ™ MAINTENANCE Page 55 down. The single-phase control uses circuitry to detect the the Vyper was removed. If this was not the case, check the ™ loss of any one of the three input phases. The trigger board DC voltage test points on the Vyper ™...
  • Page 56 ™ a 5-second timer will begin. If the missing run command is were lost from the Frick Interface Board to the Vyper . If this ™ not received within the 5-second window, the Vyper will shut ™...
  • Page 57 Quantum LX: “VSD Precharge DC Bus Voltage Imbalance” Filter Logic board and the Frick Interface board is disrupted. Also check J8 on the filter logic board and J9 on the Frick The 1/2 DC link voltage magnitude will remain within Interface board.
  • Page 58 100-200 IOM (FEB 09) VYPER VARIABLE SPEED DRIVE ™ Page 58 MAINTENANCE Fault 54: Harmonic Filter Phase locked loop Fault 50: Harmonic Filter High DC Bus Voltage Message Message Quantum: “Fault 54” Quantum: “Fault 50” Quantum LX: “Harmonic Filter Phase Locked Loop Fault” Quantum LX: “Harmonic Filter High DC Bus Voltage Fault”...
  • Page 59 VYPER VARIABLE SPEED DRIVE 100-200 IOM (FEB 09) ™ MAINTENANCE Page 59 check the filter precharge relay, filter precharge resistors, shutdown and its accompanying message is generated if the and the wiring between the filter logic board and the filter filter’s DC link voltage drops to a level less than 80 VDC below precharge relay.
  • Page 60 Quantum LX: Interface Board Motor Current Limit Override (Warning Only) This warning is indicated whenever the Frick Interface Board is operating under Current Limit Override. If the Run Com- mand signal is disengaged, any current limit in effect will be cancelled.
  • Page 61 639A0211H71 1. Shaded rows are recommended spare parts. Note: A - If the drive was manufactured after 02-08 or does not use the Frick Interface Board (FIB) replace logic board with 639A0211H10. Note: B - If drives uses the frick interface board (obscolete) replace the Frick Interface and the Control logic Board...
  • Page 62 * Parts Also Used On 305HP Drives 1. Shaded rows are recommended spare parts. Note: A - If the drive was manufactured after 02-08 or does not use the Frick Interface Board (FIB) replace logic board with 639A0211H10. Note: B - If drives uses the Frick interface board (obscolete) replace the Frick Interface and the Control logic Board...
  • Page 63 VYPER VARIABLE SPEED DRIVE 100-200 IOM (FEB 09) ™ MAINTENANCE Page 63 HARMONIC FIlTER SPARE PARTS lISTS MODEl 305 PART DESCRIPTION FRICK PART # BUS ISOLATOR BOARD 639A0211H42 BUS PLATE KIT 639A0211H24 BUS SNUBBER CAPACITOR 639A0211H31 FILTER DC BALANCING RESISTOR...

  • Page 64: Index

    EMI, 11, 12, 28 Flow Rates, 8 EPROMs, 52 Force Unload, 16 exit manifold, 28 FOUNDATION, 4 Frick Interface Board, 47, 56 fuses, 10 FAULT CODES, 51, 58 FVS cabinet, 19 105% Motor Current Overload, 54 DC Bus Voltage Imbalance, 55...
  • Page 65 VYPER VARIABLE SPEED DRIVE 100-200 IOM (FEB 09) ™ INDEX Page 65 jumper configuration, 56 IGBT, 54 IGBT Module, 55 kWh record, 32 IGBT module, 51 IGBT transistor, 55 impedance, 7 liquid-cooled, 12 input fuses, 54 Logic Board, 55 INSTALLATION, 3, 10 Low Condenser Flow, 55 AC line choke, 12 ANALOG BOARD WIRING, 26...
  • Page 66 100-200 IOM (FEB 09) VYPER VARIABLE SPEED DRIVE ™ Page 66 INDEX Applied Motor FLA, 38, 40 RMS input, 59 RMS output, 59 Applied motor FLA, 40 Applied Service Factor, 40 running coolant, 27 Automanual Switch, 34 Average Current, 33 saturation voltage, 54 Baseplate Temperature, 33 SCR, 12, 51, 54, 56, 57...
  • Page 67 VYPER VARIABLE SPEED DRIVE 100-200 IOM (FEB 09) ™ NOTES Page 67...
  • Page 68 Q-NET distributed architecture mean faster, easier, economical installations ™ Q-NET ™ delivers increased operating efficiency and lowers energy costs Available on Frick screw compressors, condensers, evaporators, AcuAir hygienic air handlers, ® and refrigerant vessels. Form 100-200 IoM (2009-02) Johnson Controls Supersedes: 100-200 IOM (2008-11) 100 CV Avenue •...

This manual is also suitable for:

Vyper 254Vyper 437Vyper 362

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