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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 BE FORE BE-
GINNING INSTALLATION. FAILURE TO FOLLOW THESE IN STRUC -
TIONS COULD RESULT IN DAMAGE OR IM PROP ER OP ER A TION
OF THE UNIT.
MODELS
S70-200 IOM/OCT 2004
File:
SERVICE MANUAL - Section 70
Replaces:
S70-200 IOM/AUG 2001
Dist:
3, 3a, 3b, 3c
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Table of Contents
Troubleshooting
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Summary of Contents for Frick RWB II
- Page 1 S70-200 IOM/OCT 2004 File: SERVICE MANUAL - Section 70 Replaces: S70-200 IOM/AUG 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
SHUTDOWN DUE TO IMPROPER OIL PRESSURE ..42 SINGLE-PORT LIQUID INJECTION ....... 20 GREASE COMPATIBILITY ..........42 RWB II BOOSTER OR SWING DUTY APPLICATION ..20 NLGI Grease Compatibility Chart ........42 DUAL-PORT LIQUID INJECTION ........20 P & I DIAGRAMS ............43 LIQUID INJECTION ADJUSTMENT PROCEDURE .. -
Page 3: Preface
It is most important that these units be properly applied to an plates. adequately controlled refrigeration system. Your authori zed Frick representative should be con sulted for expert guid ance in this determination. Proper performance and continued satisfaction with these... -
Page 4: Installation
Use only the certifi ed When applying screw compressors at high pressures, the general ar range ment draw ings from Frick Co. to determine customer must be pre pared for package vibration and noise the mount ing foot locations and to allow for recommended higher than the values predicted for normal refrigeration duty. -
Page 5: Motor Mounting
RWB II units are arranged for direct motor drive and require to the compres sor bear ings that could re sult in pre ma ture a fl... - Page 6 S70-200 IOM RWB II ROTARY SCREW COMPRESSOR UNITS Page 6 INSTALLATION 3. Adjust the distance between hub faces as specifi ed in the SPOT HEAT THE HUB as it may cause distortion. Heat in DBZ-B Data Table by sliding the hubs. Key and secure hubs water, oil, or use a SOFT open fl...
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Page 7: Coupling Alignment Procedure
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, re po - si tion dial indicator so the stem is in contact with the rim of the compressor hub, as shown in Figure 5.
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Page 9: Hot Alignment Of Compressor/Motor
Frick. The heat ers are en er gized only when the unit is not in op er a tion. -
Page 10: Oil Filter(S)
S70-200 IOM RWB II ROTARY SCREW COMPRESSOR UNITS Page 10 INSTALLATION OIL FILTER(S) Hot oil (above the liquid tem per a ture) fl owing through the cool er will cause some of the re frig er ant to boil and va por ize. -
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. -
Page 12: Liquid Line Sizes/Receiver Volume
* Based on 100 foot liquid line. For longer runs, increase line down the compres sion 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 suc- WATER-COOLED OIL COOLING (Optional) tion. - 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 com pres sors on creasing compressor capacity, a back-pressure regulator a com mon econ o miz ing vessel, regardless of econ o miz er valve (BPR) is generally required on a fl...
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Page 14: Electrical
Elec tronic Equip ment in an Industrial Environment”. con trol panel as shown in Starter RWB II units are supplied with a QUANTUM control system. Wir ing Diagram, Figure 15. All Frick mo tor starter pack- Care must be taken that the controls are not ex posed to ag es have the tim er re lay as stan dard. -
Page 15: Mini Mum Burden Ratings
100:5 be done to ensure that suffi cient starting torque is avail- 300:5 200:5 200:5 100:5 100:5 able, par tic u lar ly in booster applica tions. Contact FRICK 300:5 300:5 200:5 200:5 100:5 if as sis tance is required. -
Page 16: Control Power Regulator
S70-200 IOM RWB II ROTARY SCREW COMPRESSOR UNITS Page 16 INSTALLATION CONTROL POWER REGULATOR Compressor units that will be used in areas that suffer brown- outs and other signifi cant power fl uctuations can be sup plied with a control power regulator. See the following il lus tra tion, Rec om mend ed Regulator Installation. -
Page 17: Operation
C O M P R E S S O R R O TA T I O N I S CLOCK WISE WHEN FAC ING THE The Frick RWB II Rotary Screw Compressor Unit is an in te - COMPRESSOR DRIVE SHAFT. THE... -
Page 18: Demand Pump Oil System
When the differential pres sure reaches and exceeds 30 psi, the piston fully over comes the The RWB II is an oil fl ooded screw compressor. Most of the spring force and powers the valve fully open for very low oil discharged by the compressor separates from the gas fl... -
Page 19: Compressor Hydraulic System
RWB II ROTARY SCREW COMPRESSOR UNITS S70-200 IOM OPERATION Page 19 COMPRESSOR HYDRAULIC SYSTEM NOTE: High Stage Operation: An alternative piping ar- range ment has been provided to increase slide valve The compressor hydraulic system moves the movable slide response time during high stage operation. -
Page 20: Compressor Oil Cooling Systems
The dual-port system contains all the com ponents of the sin gle-port system with the addition of a double acting so- The RWB II unit can be equipped with one of several sys tems le noid valve SV7 and operates as outlined. -
Page 21: Quantum™ Ez-Cool
RWB II ROTARY SCREW COMPRESSOR UNITS S70-200 IOM OPERATION Page 21 Next, adjust the pressure regulating valve to approximately Liquid Injection Oil Cooling - Halocarbon 30 psig by turning the adjustment ring inside the top of the To tell if the unit you are starting has a low or high temperature valve with a 5/16”... -
Page 22: Suction Check Valve
The ACTUAL value should be reading the current dis- Frick provides a power assist kit consisting of a mounted charge temperature. and wired so le noid valve and tim er on all RWB II booster • The Output should be reading 0% with the machine compressors. -
Page 23: Suction Check Valve Bypass
Frick provides a power assist kit consisting of a mounted Also it is important to close HV-2, if the oil pump is to be run and wired so le noid valve and tim er on all RDB booster for long periods of time with the compressor stopped, to avoid com pres sors. -
Page 24: Initial Start-Up
INITIAL START-UP Initial start-up must be performed under the super vision of a FRICK authorized start-up representative to prevent void ing the compressor warranty. Prior to the start-up, the prestart check (see list in FORMS section) must be accomplish ed. -
Page 25: Maintenance
RWB II ROTARY SCREW COMPRESSOR UNITS S70-200 IOM MAINTENANCE Page 25 GENERAL INFORMATION This section provides instructions for normal main tenance, a recommended maintenance program, troubleshooting and 1. IF UNIT IS RUNNING, PRESS STOP KEY. correction guides, and typical P and I diagrams. For typical 2. -
Page 26: General Instructions For Replacing Compressor Unit Components
To clean the full-lube oil pump strainer, the unit must be shut down. The procedure is as follows: RWB II compressor units are fur nished with one (1) main oil fi lter (OF-1). A sec ond oil fi lter (OF-2) is in stalled as optional 1. -
Page 27: Strainer - Liquid Injection
RWB II ROTARY SCREW COMPRESSOR UNITS S70-200 IOM MAINTENANCE Page 27 STRAINER - LIQUID INJECTION Seat el e ment in center of locating tabs on separator bulk head. To clean the liquid injection strainer the unit must be shut 6. Replace coalescer fi lter retainer and nut. Torque nut to 21 down. -
Page 28: Demand Pump Disassembly
Us ing ing and between rotor teeth to keep shaft from turning. Turn a pressure-type oil pump and recommended Frick oil, open the locknut coun ter clock wise and remove locknut. See Fig ure the charging valve and fi... - Page 29 RWB II ROTARY SCREW COMPRESSOR UNITS S70-200 IOM MAINTENANCE Page 29 Clean all parts thoroughly and examine for wear or dam age. gen tly tap it in place with a piece of wood. Be sure seal seat Check lip seals, ball bearings, bushing, and idler pin and is com plete ly seated in the bore.
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Page 30: Troubleshooting The Demand Pump
S70-200 IOM RWB II ROTARY SCREW COMPRESSOR UNITS Page 30 MAINTENANCE 13. Pack lubrication chamber between inner ball bearing IN STAL LA TION OF CARBON GRAPHITE and double-row ball bearing in the thrust-bearing as sem bly BUSH INGS ap prox i mate ly one-half full of multipurpose grease, NLGI #2. - Page 31 RWB II ROTARY SCREW COMPRESSOR UNITS S70-200 IOM MAINTENANCE Page 31 Pressure Gauge - Discharge Port 4. Pump not up to capacity a. Starving or cavitating - increase suction pipe size or 1. High reading would indicate: reduce length. a. High viscosity and small and/or long discharge line.
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Page 32: Recommended Maintenance Program
1. Al ways take vi bra tion read ings from ex act ly the same plac es and at ex act ly the same per cent age of load. 1. Only use Frick refrigeration oil or high qual i ty refrigera tion oil approved by Frick for your application. -
Page 33: Operating Log
RWB II ROTARY SCREW COMPRESSOR UNITS S70-200 IOM MAINTENANCE Page 33 OPERATING LOG The use of an operating log, as included in this manual, permits thorough analysis of the operation of a refrigeration system by those responsible for its maintenance and servicing. Continual recording of gauge pressures, tem per a 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 34: Troubleshooting Guide
The following list of abnormal system conditions can cause the readings must be made by subtracting ap prox i mate ly 0.02 abnormal operation of the RWB II compressor unit: VDC per 1000 feet of elevation above sea level. There fore, if PE-4 is measured at 5000 feet elevation under rel a tive ly 1. -
Page 35: Pressure Transducers - Replacement
RWB II ROTARY SCREW COMPRESSOR UNITS S70-200 IOM MAINTENANCE Page 35 5. Isolate the oil pressure transducer PE-1 from the pack age PRESSURE TRANSDUCER CONVERSION DATA and open it to atmosphere. 200 psi 500 psi Sensor Range - PSI Range - PSIG* 6. -
Page 36: Position Potentiometer Replacement And Adjust Ment
S70-200 IOM RWB II ROTARY SCREW COMPRESSOR UNITS Page 36 MAINTENANCE SV POSITION POTENTIOMETER Completely load the slide valve. The display at this time should indicate 100%. If the display is less than 100%, ad just REPLACEMENT AND ADJUST MENT po ten ti om e ter POT #3 on the SBC until 100% is in di cat ed. -
Page 37: Temperature And/Or Pressure Adjustment
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... -
Page 38: Oil Separation System
S70-200 IOM RWB II ROTARY SCREW COMPRESSOR UNITS Page 38 MAINTENANCE TROUBLESHOOTING THE OIL SEPARATION SYSTEM SYMPTOM PROBABLE CAUSES and CORRECTIONS GRADUAL OIL LOSS WITH AN OIL Maintaining too high an oil level, lower level. LEVEL IN THE COALESCER SECTION SIGHT GLASS Refrigerant carryover or liquid injection overfeed ing, correct operation. -
Page 39: Liquid Injection Oil Cooling System
RWB II ROTARY SCREW COMPRESSOR UNITS S70-200 IOM MAINTENANCE Page 39 TROUBLESHOOTING THE LIQUID INJECTION OIL COOLING SYSTEM SYMPTOM PROBABLE CAUSES and CORRECTIONS HIGH OIL TEMPERATURE Insuffi cient liquid supply, check receiver level and pressure drop at injection solenoid. Equalizer pressure too high, lower. -
Page 40: Thermal Expansion Valves
S70-200 IOM RWB II ROTARY SCREW COMPRESSOR UNITS Page 40 MAINTENANCE THERMAL EXPANSION VALVES In situations where system load conditions increase or de- crease over extended periods of time and the liquid in jec tion thermal expansion valve is not adequate for the new con di - tions, an improvement in valve perfor mance may be achieved by increasing or decreasing discharge tube size. -
Page 41: Jordantemperature Regulator Valve
RWB II ROTARY SCREW COMPRESSOR UNITS S70-200 IOM MAINTENANCE Page 41 JORDAN If the hole in the valve plate is to the left and the slot in the valve disc is on the top this valve is set for Direct Acting (see TEMPERATURE REGULATOR VALVE fi... -
Page 42: Bare Compressor Mounting
PRESSURE (HIGH STAGE and BOOSTER) om mend ed oil temperatures are 130°F for ammonia and 140°F for R-22. Check with Frick ser vice for rec om mend ed The compressor must not operate with incorrect oil oil tem per a tures for other re frig er ants. -
Page 43: P & I Diagrams
RWB II ROTARY SCREW COMPRESSOR UNITS S70-200 IOM MAINTENANCE Page 43 P & I DIAGRAM... - Page 44 S70-200 IOM RWB II ROTARY SCREW COMPRESSOR UNITS Page 44 MAINTENANCE 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...
- Page 45 RWB II ROTARY SCREW COMPRESSOR UNITS S70-200 IOM MAINTENANCE Page 45 P & I DIAGRAM, LIQUID INJECTION – SINGLE PORT P & I DIAGRAM, LIQUID INJECTION – DUAL PORT...
- Page 46 S70-200 IOM RWB II ROTARY SCREW COMPRESSOR UNITS Page 46 MAINTENANCE P & I DIAGRAM, LIQUID INJECTION – BOOSTER...
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Page 47: Proper Installation Of Electronic Equip- Ment In An Industrial Environment
RWB II ROTARY SCREW COMPRESSOR UNITS S70-200 IOM PROPER IN STAL LA TION OF ELECTRONIC EQUIPMENT Page 47 PROPER INSTALLATION OF ELECTRONIC EQUIPMENT IN AN IN DUS TRI AL ENVIRONMENT VOLTAGE SOURCE In today’s refrigeration plants, electronic controls have found their way into almost every aspect of refrigeration control. - Page 48 S70-200 IOM RWB II ROTARY SCREW COMPRESSOR UNITS Page 48 PROPER IN STAL LA TION OF ELECTRONIC EQUIPMENT GROUNDING Never run any wires through an elec tron ic control pan el that do not relate to the function of the panel. Elec tron ic control panels should nev er be used as a junc tion box.
- Page 49 RWB II ROTARY SCREW COMPRESSOR UNITS S70-200 IOM PROPER IN STAL LA TION OF ELECTRONIC EQUIPMENT Page 49 Never add relays, starters, timers, transformers, etc. in- PLANT SUPPLY side an electronic control panel without fi rst con tact ing TRANSFORMER the man u fac tur er.
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Page 50: Forms
S70-200 IOM RWB II PLUS ROTARY SCREW COMPRESSOR UNITS Page 50 FORMS OPERATING LOG SHEET... -
Page 51: Compressor Prestart Checklist
Page 51 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 reverifi... -
Page 52: Start-Up Report
S70-200 IOM RWB II PLUS ROTARY SCREW COMPRESSOR UNITS Page 52 FORMS START-UP REPORT Sold To: _____________________________________ Contact Name: _______________________ Date: ________________ End User: ___________________________________ Contact Name: _______________________ Phone: ______________ End User Address: _________________________________________________________________ Fax No: ______________ City, State, Zip: ________________________________________________ Start-up Rep. _____________________________... - Page 53 RWB II PLUS ROTARY SCREW COMPRESSOR UNITS S70-200 IOM FORMS Page 53 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 _____...
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Page 54: Vibration Data Sheet
S70-200 IOM RWB II PLUS ROTARY SCREW COMPRESSOR UNITS Page 54 FORMS VIBRATION DATA SHEET Date: ______________________________________ Sales Order Number: _____________________________ End User: ___________________________________ Installing Contractor: _____________________________ Address: ______________________________________ Service Technician: ______________________________ Final Hot Alignment Equipment ID (As in Microlog):... -
Page 55: Recommended Spare Parts
RWB II ROTARY SCREW COMPRESSOR UNITS S70-200 IOM MAINTENANCE Page 55 RECOMMENDED SPARE PARTS - CURRENT DE SIGN ITEM DESCRIPTION QTY. MODELS ITEM NUMBER QUANTUM ™ CONTROL: Assembly, VGA Display, Phillips (Display only, 649C1078H01) 640C0052G01 Assembly, Digital Board #1 640C0024G01... - Page 56 ™ Q-NET delivers increased operating effi ciency and lowers energy costs ™ Now available on Frick’s ACUair hygienic air handlers, condensers, ® screw com pres sors, evaporators, and refrigerant vessels, too. Take full advantage of Q-NET...
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