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Installation - Operation - Maintenance
ROTARY SCREW COMPRESSOR UNITS
ALL REFRIGERANTS
60 through 480
THIS MANUAL CONTAINS RIGGING, ASSEMBLY, START-UP, AND
MAINTENANCE INSTRUCTIONS. READ THOROUGHLY BEFORE
BEGINNING INSTALLATION. FAILURE TO FOLLOW THESE IN-
STRUCTIONS COULD RESULT IN DAMAGE OR IMPROPER OPERA-
TION OF THE UNIT.
MODELS
S70-200 IOM/AUG 2001
File:
SERVICE MANUAL - Section 70
Replaces:
S70-200 IOM/JAN 2001
Dist:
3, 3a, 3b, 3c
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Table of Contents
Troubleshooting
Related Manuals for Frick RWB II 60
Summary of Contents for Frick RWB II 60
- Page 1 S70-200 IOM/AUG 2001 File: SERVICE MANUAL - Section 70 Replaces: S70-200 IOM/JAN 2001 Dist: 3, 3a, 3b, 3c Installation - Operation - Maintenance ROTARY SCREW COMPRESSOR UNITS ALL REFRIGERANTS MODELS 60 through 480 THIS MANUAL CONTAINS RIGGING, ASSEMBLY, START-UP, AND MAINTENANCE INSTRUCTIONS.
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Page 2: Table Of Contents
S70-200 IOM RWB II ROTARY SCREW COMPRESSOR UNITS Page 2 INSTALLATION - OPERATION - MAINTENANCE Contents PREFACE ................. 3 Maintenance DESIGN LIMITATIONS ............3 GENERAL INFORMATION ..........22 JOB INSPECTION ............3 NORMAL MAINTENANCE OPERATIONS ...... 22 TRANSIT DAMAGE CLAIMS ..........3 GENERAL MAINTENANCE .......... -
Page 3: Preface
The unit panel, communications, specifications, and wiring diagrams, data plate containing unit model, serial number and Frick see S90-010 OM ( Quantum panel) or S70-200 OM (Plus sales order number is mounted on the side of the motor base. -
Page 4: Installation
Use only the certified general customer must be prepared for package vibration and noise arrangement drawings from Frick Co. to determine the mount- ing foot locations and to allow for recommended clearances higher than the values predicted for normal refrigeration duty. -
Page 5: Motor Mounting
RWB II ROTARY SCREW COMPRESSOR UNITS S70-200 IOM INSTALLATION Page 5 CH COUPLING – The T.B. Woods Elastomeric CH Coupling MOTOR MOUNTING is used in most applications up to 600 HP. It consists of two The following procedure is required only when the motor is drive hubs and a loose, gear-type Hytrel Drive Spacer. - Page 6 S70-200 IOM RWB II ROTARY SCREW COMPRESSOR UNITS Page 6 INSTALLATION to the shafts by tightening setscrews. the shaft. 4. Reinstall the eight previously removed bolts and locknuts. 3. Adjust the distance between hub faces, as specified in the Alternately tighten each locknut as you would the lug nuts Series 52 Coupling Data Table, by sliding the hubs.
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Page 7: Coupling Alignment Procedure
(HOT) alignment has been made and found to be satisfac- tory for approximately one week, the motor may be dowelled to maintain alignment. NOTE: Frick recommends cold aligning the motor .005" high. This cold misalignment compensates for thermal growth when the unit is at operating temperature. - Page 8 S70-200 IOM RWB II ROTARY SCREW COMPRESSOR UNITS Page 8 INSTALLATION PARALLEL ALIGNMENT 6. To check parallel alignment, as shown in Figure 4, reposi- tion dial indicator so the stem is in contact with the rim of the compressor hub, as shown in Figure 5. Check the dial indicator to be sure that the indicator stem is slightly loaded so as to allow movement in both directions.
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Page 9: Hot Alignment Of Compressor/Motor
Using a pressure-type pump and the recommended the Frick factory and then thoroughly evacuated and charged Frick oil, open the charging valve and pump oil into the sepa- with dry nitrogen to ensure the integrity of the unit during rator. -
Page 10: Thermosyphon Oil Cooling
The density of the refrigerant Use of filter elements other than Frick must be approved in writing liquid/vapor mixture in the return line is considerably less than the density of the liquid in the supply line. This imbalance pro-... -
Page 11: Liquid Injection Oil Cooling (Optional)
RWB II ROTARY SCREW COMPRESSOR UNITS S70-200 IOM INSTALLATION Page 11 SYSTEM CONDENSER VAPOR SAFETY STATIC HEAD VALVE TO OVERCOME CONDENSER THERMOSYPHON PRESSURE DROP RECEIVER LIQUID LIQUID OVERFLOW LEVEL DRAIN TO RECEIVER OPT. OIL TEMP CONTROL VALVE 6 Ft. Min. COOL REFRIGERANT COOL... -
Page 12: Water-Cooled Oil Cooling (Optional)
* Based on 100 foot liquid line. For longer runs, increase line down the compression process on the screw compressor. size accordingly. ** For models 60 and 76, contact Frick engineering. As the screw compressor unloads, the economizer port will drop in pressure level, eventually being fully open to suction. - Page 13 RWB II ROTARY SCREW COMPRESSOR UNITS S70-200 IOM INSTALLATION Page 13 Due to the tendency of the port pressure to fall with de- For refrigeration plants employing multiple compressors on creasing compressor capacity, a back-pressure regulator a common economizing vessel, regardless of economizer valve (BPR) is generally required on a flash economizer sys- type, each compressor must have a back-pressure regulat- tem (Figure 13) in order to maintain some preset pressure...
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Page 14: Electrical
Starter 5. For customer-supplied across-the-line starters, a shunt- Wiring Diagram, Figure 15. All Frick motor starter pack- ing device must be installed across the Current Transformer ages have the timer relay as standard. -
Page 15: Current Transformer (Ct) Ratios
400:5 300:5 100:5 50:5 120/240 V. IN, 120 V. OUT SOLA #63-23-112-4, 120 VA, 60 HZ 1000:5 1000:5 600:5 500:5 400:5 100:5 50:5 SHOWN HERE- CONSULT FRICK 1000:5 800:5 500:5 500:5 100:5 100:5 FOR OTHER VOLTAGES/HZ 800:5 600:5 500:5 200:5... -
Page 16: Operation
OPERATION and START-UP INSTRUCTIONS CLOCKWISE WHEN FACING THE COMPRESSOR DRIVE SHAFT. THE The Frick RWB II Rotary Screw Compressor Unit is an inte- grated system consisting of six major subsystems: COMPRESSOR SHOULD NEVER BE OPERATED IN RE- VERSE ROTATION AS BEARING DAMAGE WILL RESULT. -
Page 17: Demand Pump Oil System
DO NOT ATTEMPT TO SERVICE THE COLD START VALVE. PLEASE CONTACT THE FRICK SERVICE DEPARTMENT. During the period from start-up to normal operation the oil pressure alarm and oil pressure cutout setpoints will vary... -
Page 18: Compressor Hydraulic System
S70-200 IOM RWB II ROTARY SCREW COMPRESSOR UNITS Page 18 OPERATION NOTE: High Stage Operation: An alternative piping ar- COMPRESSOR HYDRAULIC SYSTEM rangement has been provided to increase slide valve response time during high stage operation. The compressor hydraulic system moves the movable slide valve (MSV) to load and unload the compressor. -
Page 19: Compressor Oil Cooling Systems
(PDCV) to prevent migration of high pres- 4. Monitor the oil temperature of the compressor. If the oil sure gas during shutdown. A Frick-installed timer limits the temperature rises above 150°F, open back-pressure bleed high pressure gas to only thirty seconds duration, since in- valve (V4) a very small amount. -
Page 20: Suction Check Valve
Frick provides a power assist kit consisting of a mounted If multiple compressors are operated with a common econo- and wired solenoid valve and timer on all RWB II booster mizer vessel, it is necessary to install a back-pressure regu- compressors. -
Page 21: Initial Start-Up
FRICK authorized start-up representative to prevent voiding the compressor warranty. Prior to the start-up, the prestart Frick provides a power assist kit consisting of a mounted check (see list in FORMS section) must be accomplished. and wired solenoid valve and timer on all RDB booster com- pressors. -
Page 22: Maintenance
S70-200 IOM RWB II ROTARY SCREW COMPRESSOR UNITS Page 22 MAINTENANCE GENERAL INFORMATION This section provides instructions for normal maintenance, 1. IF UNIT IS RUNNING, PRESS STOP KEY. a recommended maintenance program, troubleshooting and correction guides, and typical P and I diagrams. For typical 2. -
Page 23: General Instructions For Replacing Compressor Unit Components
The separa- 5. Flush the canister with clean Frick refrigeration oil; wipe tor MUST be equalized to atmospheric pressure. dry with a clean, lint-free cloth; and replace the plug. -
Page 24: Strainer - Liquid Injection
The separa- COALESCER FILTER ELEMENT(S) tor MUST be equalized to atmospheric pressure. Use of filter elements other than Frick must be approved Oil entrained refrigerant may vapor- in writing by Frick engineering or warranty claim may be ize, causing a separator pressure denied. -
Page 25: Demand Pump Disassembly
Using a ing and between rotor teeth to keep shaft from turning. Turn pressure-type oil pump and recommended Frick oil, open the locknut counterclockwise and remove locknut. See Fig- the charging valve and fill the separator until the oil level is ure 22 or 23. - Page 26 S70-200 IOM RWB II ROTARY SCREW COMPRESSOR UNITS Page 26 MAINTENANCE Clean all parts thoroughly and examine for wear or damage. sary, protect seal face with a clean cardboard disc and gen- Check lip seals, ball bearings, bushing, and idler pin and tly tap it in place with a piece of wood.
- Page 27 RWB II ROTARY SCREW COMPRESSOR UNITS S70-200 IOM MAINTENANCE Page 27 13. Pack lubrication chamber between inner ball bearing BUSHINGS and double-row ball bearing in the thrust-bearing assembly approximately one-half full of multipurpose grease, NLGI #2. When installing carbon graphite bushings, extreme care must The thrust-bearing assembly will take the remaining space.
- Page 28 S70-200 IOM RWB II ROTARY SCREW COMPRESSOR UNITS Page 28 MAINTENANCE 2. Low reading would indicate - c. Check alignment. a. Air leak in suction line. d. May have a bent shaft or rotor tooth. Straighten or b. End of pipe not in liquid. replace.
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Page 29: Recommended Maintenance Program
Frick for your application. 2. Use vibration readings taken from the new unit at start-up as the base line reference. 2. Only use Frick oil filters or those approved by Frick for your application. 3. Evaluate vibration readings carefully as the instrument range and function used can vary. -
Page 30: Operating Log
S70-200 IOM RWB II ROTARY SCREW COMPRESSOR UNITS Page 30 MAINTENANCE OPERATING LOG The use of an operating log as included in this manual (see Table of Contents) permits thorough analysis of the operation of a refrigeration system by those responsible for its maintenance and servicing. Continual recording of gauge pressures, tempera- tures, and other pertinent information, enables the observer and serviceman to be constantly familiar with the operation of the system and to recognize immediately any deviations from normal operating conditions. -
Page 31: Troubleshooting Guide
THE COLD START VALVE. PLEASE Lowering the equalizing pressure on the thermal expansion CONTACT THE FRICK SERVICE DE- valve would increase the refrigerant feed and the oil tem- PARTMENT. perature should drop. -
Page 32: Pressure Transducers - Replacement
S70-200 IOM RWB II ROTARY SCREW COMPRESSOR UNITS Page 32 MAINTENANCE 0.10 VDC to read between 1.38 VDC and 1.62 VDC. PRESSURE TRANSDUCER CONVERSION DATA 200 psi 500 psi 5. Isolate the oil pressure transducer PE-1 from the package Sensor Range - PSI Range - PSIG* and open it to atmosphere. -
Page 33: Position Potentiometer Replacement And Adjustment
RWB II ROTARY SCREW COMPRESSOR UNITS S70-200 IOM MAINTENANCE Page 33 Completely load the slide valve. The display at this time should SV POSITION POTENTIOMETER indicate 100%. If the display is less than 100%, adjust poten- REPLACEMENT AND ADJUSTMENT tiometer POT #3 on the SBC until 100% is indicated. The Slide Valve Position potentiometer is located on the end Repeat this sequence until the slide valve indicates 0% fully of the compressor unloader cylinder (see Figure 28). -
Page 34: Temperature And/Or Pressure Adjustment
S70-200 IOM RWB II ROTARY SCREW COMPRESSOR UNITS Page 34 MAINTENANCE TEMPERATURE and/or PRESSURE ADJUSTMENT All temperature and pressure sensors are factory set. If cali- bration is required, refer to Analog Calibration for tempera- ture or pressure in S90-010 O ( Quantum panel) or Analog Offset Display in S70-200 OM (Plus panel). -
Page 35: Troubleshooting Rwb Ii Compressor
Unloader piston stuck. Contact Frick Factor or Frick for assistance. Slipper seals worn out or damaged. Contact Frick Factor or Frick for assistance. NOTE: Troubleshooting the compressor is limited to identifying the probable cause. If a mechanical problem is suspected, contact the Frick Service Department. -
Page 36: Hydraulic System
SLIDE STOP WILL NOT FUNCTION Solenoid coils may be burned out, replace. EITHER DIRECTION Solenoid service valves may be closed, open. Manually actuate solenoid. If slide stop will not move mechanical problems are indicated. Consult Frick factor or Frick. -
Page 37: Liquid Injection Oil Cooling System
RWB II ROTARY SCREW COMPRESSOR UNITS S70-200 IOM MAINTENANCE Page 37 TROUBLESHOOTING THE LIQUID INJECTION OIL COOLING SYSTEM SYMPTOM PROBABLE CAUSES and CORRECTIONS HIGH OIL TEMPERATURE Insufficient liquid supply, check receiver level and pressure drop at injection solenoid. Equalizer pressure too high, lower (through 480 only). Suction superheat too high, correct system problem. -
Page 38: Demand Pump System
S70-200 IOM RWB II ROTARY SCREW COMPRESSOR UNITS Page 38 MAINTENANCE TROUBLESHOOTING THE DEMAND PUMP SYSTEM SYMPTOM PROBABLE CAUSES and CORRECTIONS PUMP WILL NOT PRODUCE Check pump rotation. ENOUGH OIL PRESSURE TO START COMPRESSOR Check that service valves are open. Filter cartridges may be blocked. -
Page 39: Thermal Expansion Valves
RWB II ROTARY SCREW COMPRESSOR UNITS S70-200 IOM MAINTENANCE Page 39 THERMAL EXPANSION VALVES In situations where system load conditions increase or de- crease over extended periods of time and the liquid injection thermal expansion valve is not adequate for the new condi- tions, an improvement in valve performance may be achieved by increasing or decreasing discharge tube size. -
Page 40: Jordan Temperature Regulator Valve
S70-200 IOM RWB II ROTARY SCREW COMPRESSOR UNITS Page 40 MAINTENANCE If the hole in the valve plate is to the left and the slot in the JORDAN valve disc is on the top this valve is set for Direct Acting (see TEMPERATURE REGULATOR VALVE figure 37). -
Page 41: Bare Compressor Mounting
The recom- PRESSURE (HIGH STAGE and BOOSTER) mended oil temperatures are 130°F for ammonia and 140°F for R-22. Check with Frick service for recommended oil tem- The compressor must not operate with incorrect oil peratures for other refrigerants. -
Page 42: P & I Diagram
S70-200 IOM RWB II ROTARY SCREW COMPRESSOR UNITS Page 42 MAINTENANCE P & I DIAGRAM... - Page 43 RWB II ROTARY SCREW COMPRESSOR UNITS S70-200 IOM MAINTENANCE Page 43 P & I DIAGRAM - OPTIONAL DUAL OIL FILTERS, DEMAND OIL PUMP, THERMAL CONTROL VALVE SEPARATOR TO COMPRESSOR PALL TAHH OPTIONAL CV-2 DEMAND STR-2 OIL PUMP PM-1 CV-1 PDAH OF-1 OPTIONAL THERMAL...
- Page 44 S70-200 IOM RWB II ROTARY SCREW COMPRESSOR UNITS Page 44 MAINTENANCE P & I DIAGRAM, LIQUID INJECTION – SINGLE PORT P & I DIAGRAM, LIQUID INJECTION – DUAL PORT...
- Page 45 RWB II ROTARY SCREW COMPRESSOR UNITS S70-200 IOM MAINTENANCE Page 45 P & I DIAGRAM, LIQUID INJECTION – BOOSTER...
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Page 46: Proper Installation Of Electronic Equipment In An Industrial Environment
S70-200 IOM RWB II ROTARY SCREW COMPRESSOR UNITS Page 46 PROPER INSTALLATION OF ELECTRONIC EQUIPMENT PROPER INSTALLATION OF ELECTRONIC EQUIPMENT IN AN INDUSTRIAL ENVIRONMENT to provide a “clean” separate source voltage in order to pre- In today’s refrigeration plants, electronic controls have found vent EMI, from other equipment in the plant, from interfering their way into almost every aspect of refrigeration control. - Page 47 RWB II ROTARY SCREW COMPRESSOR UNITS S70-200 IOM PROPER INSTALLATION OF ELECTRONIC EQUIPMENT Page 47 Never run any wires through an electronic control panel GROUNDING that do not relate to the function of the panel. Electronic control panels should never be used as a junction box. Grounding is the most important factor for successful opera- These wires may be carrying large transients that will inter- tion and is also the most overlooked.
- Page 48 S70-200 IOM RWB II ROTARY SCREW COMPRESSOR UNITS Page 48 PROPER INSTALLATION OF ELECTRONIC EQUIPMENT PLANT SUPPLY Never add relays, starters, timers, transformers, etc. in- TRANSFORMER side an electronic control panel without first contacting 3-PHASE the manufacturer. Contact arcing and EMI emitted from these devices can interfere with the electronics.
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Page 49: Forms
RWB II PLUS ROTARY SCREW COMPRESSOR UNITS S70-200 IOM FORMS Page 49 OPERATING LOG SHEET... -
Page 50: 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 the IOM. Certain items on this checklist will be reverified by the Frick Field Service Supervisor prior to the actual start-up. -
Page 51: Start-Up Report
H.P. _________ RPM ________ Serial # _________________________ Service Factor ______ Voltage _______ Hz __________ FLA ________ Design ______ Code _____ Starter Size ____ Special Options DX Economizer Frick Supplied Starter PC Control System Other Prestart Checks Position of all valves... - Page 52 S70-200 IOM RWB II PLUS ROTARY SCREW COMPRESSOR UNITS Page 52 FORMS Adjustable Safety Setpoints High Discharge Pressure Stop Load _____ Force Unload _____ Alarm ______ Delay _____ Shutdown ____ Delay ____ High Discharge Temp. Stop Load _____ Force Unload _____ Alarm ______ Delay _____ Shutdown ____ Delay ____ Motor Amps _____ Volts _____ Service Factor _______ Horsepower _______ CT Factor ______ Recycle Delay ______...
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Page 53: Vibration Data Sheet
RWB II PLUS ROTARY SCREW COMPRESSOR UNITS S70-200 IOM FORMS Page 53 VIBRATION DATA SHEET Date: _________________________________________ Sales Order Number: ____________________________ End User: _____________________________________ Installing Contractor: _____________________________ Address: ______________________________________ Service Technician: ______________________________ Final Hot Alignment Equipment ID (As in Microlog): _____________________ Compressor Serial Number: _______________________ Unit Serial Number: ______________________________ National Board Number: __________________________... -
Page 54: Recommended Spare Parts
S70-200 IOM RWB II ROTARY SCREW COMPRESSOR UNITS Page 54 MAINTENANCE RECOMMENDED SPARE PARTS - CURRENT DESIGN ITEM DESCRIPTION QTY. MODELS ITEM NUMBER QUANTUM CONTROL: Assembly, VGA Display, Sharp (Display only, 333Q0001581) 640C0021G01 Inverter, Sharp 333Q0001582 Power Supply 640C0022G01 Battery, 3V 333Q0001193 Switch, Power 333Q0001194... - Page 55 RWB II ROTARY SCREW COMPRESSOR UNITS S70-200 IOM NOTES Page 55...
- Page 56 Frick Controls at 717-762-2121 or visit our ® website (www.frickcold.com) for a complete listing of Frick sales offices and Frick Factor Distributors. ® T a k e f u l l a d v a n t a g e o f Q - N E T t e c h n o l o g y w i t h a l l F r i c k...
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