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ROTARY SCREW COMPRESSOR UNITS
MICROPROCESSOR CONTROL
ALL REFRIGERANTS
THIS MANUAL CONTAINS RIGGING, ASSEMBLY, START-UP, AND
MAINTENANCE INSTRUCTIONS. READ THOROUGHLY BEFORE BE-
GINNING INSTALLATION. FAILURE TO FOLLOW THESE INSTRUC-
TIONS COULD RESULT IN DAMAGE OR IMPROPER OPERATION
OF THE UNIT.
Form S70-101 IOM (JAN 2000)
INSTALLATION - OPERATION - MAINTENANCE
File:
SERVICE MANUAL - Section 70
Replaces:
S70-101 IOM (APR 96)
Dist:
3, 3a, 3b, 3c
WITH
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Summary of Contents for Frick RXB Plus
- Page 1 Form S70-101 IOM (JAN 2000) INSTALLATION - OPERATION - MAINTENANCE File: SERVICE MANUAL - Section 70 Replaces: S70-101 IOM (APR 96) Dist: 3, 3a, 3b, 3c ROTARY SCREW COMPRESSOR UNITS WITH MICROPROCESSOR CONTROL ALL REFRIGERANTS THIS MANUAL CONTAINS RIGGING, ASSEMBLY, START-UP, AND MAINTENANCE INSTRUCTIONS.
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Page 2: Table Of Contents
S70-101 IOM RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 2 INSTALLATION - OPERATION - MAINTENANCE TABLE OF CONTENTS GENERAL INFORMATION Prestart Checklist ............34 Preface ................3 Initial Start-up Procedure ..........35 Design Limitations ............. 3 Normal Start-up Procedure ..........35 Job Inspection .............. -
Page 3: Preface
RXB PLUS Rotary Screw Compres sor Units. The unit data plate, containing unit model, serial number, and Frick sales order number, is mounted on the side of the It is most important that these units be properly applied to an motor base. -
Page 4: Installation
LAT. AXIAL VERT. LAT. Each RXB PLUS Rotary Screw Compressor Unit is shipped mounted on a wood skid which must be removed prior to unit installation. CAUTION: Allow space for servicing both ends 1.25 of the unit. A minimum of 24 inches is recommended. -
Page 5: Skid Removal
COMPRESSOR/MOTOR COUPLING INSTALLATION RXB PLUS units are arranged for direct motor drive and require a fl exible drive coupling to connect the compressor to the motor. Before installing, perform the following: FIG. 3 - COUPLING/SHAFT KEYS INSTALLATION... -
Page 6: Coupling Alignment Procedure
After fi nal (HOT) alignment has been made and found to be satisfac tory for approximately one week, the motor may be dowelled to maintain align ment. NOTE: Frick recommends cold aligning the motor .005” high. This cold misalignment compensates for thermal growth when the unit is at operating temperature. - Page 7 RXB PLUS ROTARY SCREW COMPRESSOR UNITS S70-101 IOM INSTALLATION Page 7 PARALLEL ALIGNMENT 6. To check parallel alignment, as shown in Fig. 4, reposition dial indicator so the stem is in contact with the rim of the compressor hub, as shown in Fig. 5.
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Page 8: Hot Alignment Of Compressor/Motor
Add oil by attaching the end of a suitable pressure type hose to the oil charging valve, located on the top of the oil Each compressor unit is pressure and leak tested at the Frick separator on the compressor end of the separator. Using a... -
Page 9: Liquid Injection Oil Cooling
SINGLE PORT TEMP USAGE (LOW Vi) R-717 R-22 R-717 & R-22 75°F +10°F +5°F -23°F 85°F +25°F +15°F -17°F 95°F +35°F +25°F -11°F 105°F +40°F +35°F - 4°F * Dual Injection Kit will be shipped by Frick below these temperatures. -
Page 10: Water-Cooled Oil Cooling
S70-101 IOM RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 10 INSTALLATION Liquid line sizes and the additional receiver volume (quantity NOTE: The water regulating valve shipped with the unit of refrigerant required for 5 minutes of liquid injection oil will be sized to the specifi c fl ow for the unit. - Page 11 4. Frick recommends the installation of an angle valve in the piping before the thermosyphon oil cooler to balance the The component and piping arrangement shown below is thermosyphon system.
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Page 12: Economizer - High Stage
S70-101 IOM RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 12 INSTALLATION ECONOMIZER - HIGH STAGE (OPTIONAL) outlet pressure regulator to the fl ash vessel outlet to avoid overpressurizing the economizer port, which could result in motor overload. Example: A system feeding liquid to the The economizer option provides an increase in system ca- fl... -
Page 13: Electrical
Elec tronic Equip ment in an Industrial Environment”. are desired, a motor/compressor torque analysis must RXB PLUS units are supplied with a SBC (single-board be done to ensure that suffi cient starting torque is avail- computer) microprocessor control system. Care must be able, particularly in booster applica tions. -
Page 14: Current Transformers (Ct) Ratios
In addition to the starter package interlocks shown on the starter package diagram, the following optional interlocks are on the typical RXB PLUS Screw Compressor unit with the SBC Microprocessor Control System wiring diagram: 1. Remote LOAD, UNLOAD, and RUN interlocks in case the customer desires to operate the unit from a remote control device. -
Page 15: Operation
OPERATION and START-UP INSTRUCTIONS GENERAL INFORMATION The information in this section of the manual provides the The Frick RXB PLUS Rotary Screw Compressor Unit is an logical step-by-step instructions to properly start up and integrated system consisting of six major subsystems: operate the RXB PLUS Rotary Screw Compressor Unit. -
Page 16: Keys And Key Functions
S70-101 IOM RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 16 OPERATION KEYS AND KEY FUNCTIONS 1. Operating displays NOTE: The microprocessor will automatically return to 2. Setpoints displays the main operating display after 60 seconds of keybo ard 3. Annunciator displays nonactivity. - Page 17 RXB PLUS ROTARY SCREW COMPRESSOR UNITS S70-101 IOM OPERATION Page 17 pressed, automatic (AUTO MODE) when Auto Cycle has been activated, remote (RMT MODE) when the [REMOTE] SETPOINTS PAGE 1B key has been pressed, or off (OFF MODE). Dead Band--[/./#] Prop.
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Page 18: To Change The Adjustable Setpoints
S70-101 IOM RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 18 OPERATION SETPOINTS DISPLAY, Page 1B: AUX 1 and AUX 2 - May be confi gured for either an alarm or shutdown and with either a normally closed (NC) or normally Dead Band - This is a + (plus) or - (minus) value above or open (NO) contact. - Page 19 RXB PLUS ROTARY SCREW COMPRESSOR UNITS S70-101 IOM OPERATION Page 19 The High Discharge Pressure Cutout should be set at 90% ANNUNCIATOR DISPLAY * of the setting of the lowest high side relief valve. The High Discharge Pressure Alarm should be set 10 PSIG lower than ANNUNCIATOR: PG-01 Thu 03-01-89 15:33:36 the Cutout.
- Page 20 S70-101 IOM RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 20 OPERATION Compressor Differential Cutout - The differential cutout has been lowered from 55 lb to 25 lb. Cutout will occur after SHUTDOWN RECORD P2 Thu 03-01-89 15:33:36 fi ve minutes. To allow operation at low differential pressures,...
- Page 21 RXB PLUS ROTARY SCREW COMPRESSOR UNITS S70-101 IOM OPERATION Page 21 The [F2] function key will call up the Security display. The AUTO CYCLE DISPLAY * Security display allows the operator to either enable or dis- able the microprocessor’s keyboard and, thereby, prevent AUTO CYCLE Compressor Start ---[20.0 g ]...
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Page 22: Temperature-Pressure Control Program
Baud-[19200] the Temperature-Pressure Control Program option has Sep Cond-Alarm-10F-no Recycle--[30] been ordered with the RXB Plus Rotary Screw Compres- sor Unit. The new setpoints provided on this display allow monitoring of SETPOINTS DISPLAY, Page 1 * compressor superheat and condensing in the separator. The... - Page 23 RXB PLUS ROTARY SCREW COMPRESSOR UNITS S70-101 IOM OPERATION Page 23 TEMPERATURE-PRESSURE CONTROL MIN SV - Minimum Slide Valve Posi tion, shown as a per- centage, will limit the slide valve position to the displayed PROGRAM (OPTION) (continued) setpoint. PRESS SETPOINT - The capacity-control setpoint is used ACTIVE - Indicates whether Auto Cycle is active or not.
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Page 24: Lead-Lag Option
With ONE Compressor Running This information is either “0” or “1” and represents what is be- If the load rises: ing sent from the other compressor. Consult Frick Company The lag compressor will start when its “START” setpoint if additional information is required. -
Page 25: How The Microprocessor Works - Summary
The microprocessor receives information that the oil tempera- ture is below 49°F, the Low Oil Temperature Cutout setpoint, The Frick microprocessor has 4 major components and a va- and and shuts down the unit. The micropro cessor will prevent riety of sensors. The major components are the SBC (single the compressor package from running. -
Page 26: Multiple Compressor Sequencing
The customer may supply his own master sequencer panel (usually a programmable control- ler) or Frick, can supply this sequencer if desired (contact Frick for pricing). OUTPUT NO. -
Page 27: Microprocessor Telecommunications
MICROPROCESSOR OUTPUT DATA CODE A 3.5 KOHM, 10 watt resistor (RES) must be fi eld installed, as shown below, when the 120 VAC outputs of the RXB PLUS are driving 120 VAC solid state input devices such as programmable controllers. - Page 28 S70-101 IOM RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 28 OPERATION COMPRESSOR DISPLAY SCREENS COMMAND: #01DXNN CHANGE SETPOINTS COMMAND: #01C # Start command sequence. Start command sequence. 01 Compressor ID code. Compressor ID code. D Compressor control com mand. Change setpoint command.
- Page 29 RXB PLUS ROTARY SCREW COMPRESSOR UNITS S70-101 IOM OPERATION Page 29 READ INPUT/OUTPUT COMMAND READ FAILURES COMMAND: #01F #01X Start command sequence. Start command sequence. Compressor ID Code. Compressor ID Code. Read Failures command. Read Input/Output(s) command. Returned Answer: Returned Answer:...
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Page 30: Rxb Compressor
8. Shaft seal design to maintain operating pressure on seal well below discharge pressure for increased seal life. The RXB PLUS is an oil fl ooded screw compressor. Most of the oil discharged by the compressor separates from the 9. Oil injected into the rotors to maintain good volumetric and gas fl... -
Page 31: Compressor Hydraulic System
RXB PLUS ROTARY SCREW COMPRESSOR UNITS S70-101 IOM OPERATION Page 31 COMPRESSOR HYDRAULIC SYSTEM FUNCTIONAL CHECK OF THE COMPRESSOR VOLUME RATIO CONTROL (Vi) OPERATION The compressor hydraulic system moves the movable slide valve (MSV) to load and unload the compressor. It also moves 1. -
Page 32: Compressor Oil Cooling Systems
OPERATION COMPRESSOR OIL COOLING SYSTEMS SINGLE-PORT LIQUID INJECTION The RXB PLUS unit can be equipped with one of several The single-port liquid injection system is designed to permit systems for controlling the compressor oil tempera ture. They liquid refrigerant injection into one port on the compressor are single or dual-port liquid injection, thermo syphon or at any given moment and operate as outlined. -
Page 33: Dual-Port Liquid Injection
RXB PLUS ROTARY SCREW COMPRESSOR UNITS S70-101 IOM OPERATION Page 33 DUAL-PORT LIQUID INJECTION LIQUID INJECTION ADJUSTMENT PROCEDURE The dual-port liquid injection system is designed to obtain the most effi cient compressor performance at high and low 1. Close vent valve (V4). -
Page 34: Prestart Checklist
Ammonia Units: Only refrigerant grade Ammonia as specifi ed by International Institute of Ammonia Refrigeration (IIAR) Bulletin # 110, Section 3.3 should be used with FRICK equipment. Unit pressure test. Close suction and discharge service valves, and isolation valve to low pressure transducer. -
Page 35: Initial Start-Up Procedure
RXB PLUS ROTARY SCREW COMPRESSOR UNITS S70-101 IOM OPERATION Page 35 INITIAL START-UP PROCEDURE Having performed the checkpoints on the prestart check list, the compressor unit is ready for start-up. It is impor tant that an adequate refrigerant load be available to load test the unit at normal operating conditions. -
Page 36: Maintenance
S70-101 IOM RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 36 MAINTENANCE MAINTENANCE This section provides instructions for normal maintenance, 3. Open suction, discharge, and liquid injection service valves a recommended maintenance program, troubleshooting and remove tags. and correction guides, typical wiring diagrams, and typical 4. -
Page 37: Oil Filter, Dual
Isolate and equalize unit to atmospheric pressure (See General Instructions for Replacing Compressor Unit 4. Flush the canister with clean Frick refrigeration oil; wipe Components). dry with a clean, lint-free cloth; and replace the plug. 2. Close the inlet service valve. -
Page 38: Coalescer Filter Element
Using a 5. Install the new coalescer fi lter element. pressure-type oil pump and recommended Frick oil, open Seat the element in center of locat- the charging valve and fi ll separator until oil level is midway ing tabs on separator bulkhead. -
Page 39: Vibration Analysis
VIBRATION ANALYSIS 1. Only use Frick refrigeration oil as recommended by Frick Periodic vibration analysis can be useful in detecting bear- for your application. ing wear and other mechanical failures. If vibration analysis 2. -
Page 40: Maintenance Schedule
S70-101 IOM RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 40 MAINTENANCE MAINTENANCE SCHEDULE This schedule should be followed to ensure trouble-free operation of the compressor unit. HOURS OPERATION (MAXIMUM) MAINTENANCE CHANGE OIL As directed by oil analysis OIL ANALYSIS Then every 6 months... -
Page 41: Troubleshooting Guide
RXB PLUS ROTARY SCREW COMPRESSOR UNITS S70-101 IOM MAINTENANCE Page 41 TROUBLESHOOTING GUIDE 3. Excessively high suction superheat. 4. Excessively high discharge pressure. Successful problem solving requires an organ ized ap proach to defi ne the problem, identify the cause, and make the 5. -
Page 42: Troubleshooting The Microprocessor
SBC (single board com puter) and one cuits of the RXB PLUS unit. The section is composed of display screen. four parts: a general information section, a trouble shoot ing... - Page 43 The current transducer is used to convert the AC motor amps to a DC voltage signal for the (FORCED UNLOAD) OCCURS micropro cessor. If the %FLA reading from the Operating display is incorrect, consult Frick Co. AT HIGH MOTOR AMPS PRESSURES ON THE TEST 1 - Shut down the compressor and allow pressures to equalize.
- Page 44 S70-101 IOM RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 44 MAINTENANCE TROUBLESHOOTING FRICK SBC MICROPROC ESSOR SYSTEM (Continued) SYMPTOM PROBABLE CAUSES and CORRECTIONS DISPLAY SCREENS DISPLAY A loose or improper connection between the displays and the SBC is indicated. Remove fuse SCRAMBLED PATTERN OR (2FU, 10 amp) for 15 seconds, then restore to reset the displays.
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Page 45: Eprom Memory I/C Chip Replacement
RXB PLUS ROTARY SCREW COMPRESSOR UNITS S70-101 IOM MAINTENANCE Page 45 EPROM MEMORY I/C CHIP REPLACEMENT OUTPUT FUSE REPLACEMENT Microprocessor EPROM memory I/C chips are located inside 1. Shut off control power. the microprocessor console on the SBC board. A special 2. -
Page 46: Pressure Transducers - Replacement
S70-101 IOM RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 46 MAINTENANCE 2. Isolate suction transducer PE-4 from the unit and open PRESSURE TRANSDUCERS - it to atmosphere using valves provided at the transducer REPLACEMENT manifold.Close the applicable transducer isolation valve. -
Page 47: Volumizer Potentiometer - Replace/Adjust
RXB PLUS ROTARY SCREW COMPRESSOR UNITS S70-101 IOM MAINTENANCE Page 47 SLIDE VALVE POSITION POTENTIOMETER BARE COMPRESSOR MOUNTING REPLACEMENT AND ADJUSTMENT The following procedure is required only when a bare com- pressor is replaced in the fi eld. The slide valve potentiometer is located under a cover on the right side of the compressor (facing shaft) at the inlet end. -
Page 48: Troubleshooting The Rxb Plus: Compressor
SYMPTOM PROBABLE CAUSES and CORRECTIONS EXCESSIVE NOISE and VIBRATION Bearing damage or excessive wear. CONTACT Frick Factor or Frick. Coupling loose on shaft. Tighten coupling. Replace if damaged. Misalignment between motor and compressor. Realign motor and compressor. Refrigerant fl ood-back. Correct system problem. -
Page 49: Full-Time Pump Systems
RXB PLUS ROTARY SCREW COMPRESSOR UNITS S70-101 IOM MAINTENANCE Page 49 TROUBLESHOOTING THE OIL PUMP SYSTEM SYMPTOM PROBABLE CAUSES and CORRECTIONS PUMP WILL NOT PRODUCE Filter cartridge may be blocked. Check PSID across fi lter. Replace fi lter. ENOUGH OIL PRESSURE TO START COMPRESSOR Strainer may be blocked. -
Page 50: Thermal Expansion Valves
S70-101 IOM RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 50 MAINTENANCE THERMAL EXPANSION VALVES JORDAN TEMPERATURE REGULATOR VALVE (For low differential pressure applications) In situations where system load conditions increase or de- crease over extended periods of time and the liquid injection... -
Page 51: Temperature Control Valve
RXB PLUS ROTARY SCREW COMPRESSOR UNITS S70-101 IOM MAINTENANCE Page 51 TYPE M THERMAL EXPANSION VALVE (12 TO 34 TONS) R-22 TX VALVE SIZES R-22 TX VALVE MODE FPT CONNECTION HVE - 2-/1/2 HVE - 5-1/2 HVE - 11 HVE - 16... -
Page 52: Wiring Diagrams
S70-101 IOM RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 52 MAINTENANCE MICRO COMPONENT PLACEMENT DIAGRAM... - Page 53 RXB PLUS ROTARY SCREW COMPRESSOR UNITS S70-101 IOM MAINTENANCE Page 53 SBC WIRING DIAGRAM RXB PLUS TELECOMMUNICATIONS COMPUTER TO MICROPROCESSOR WIRING DIAGRAM COMPUTER COMPRESSOR #1 COMPRESSOR #2 COMMUNICATIONS PORT: AC-422 PORT #1 PORT #1...
- Page 54 POWER SOURCE -ISOLATED AND SEPARATED FROM OTHER INDUCTIVE LOADS SUCH AS LIGHTING CIRCUITS ALL NEUTRALS ENTERING -OR FROM FRICK SUPPLIED OR SPECIFIED STARTER, USE MINIMUM #12 AWG FOR FEED THIS ENCLOSURE SHALL NEUTRAL IF SEPARATE FEED FOR HEATER CIRCUIT IS DESIRED, BE TIED TOGETHER AT REMOVE JUMPERS 1 TO 1A &...
- Page 55 MICRO PANEL ASSEMBLY WIRING DIAGRAM RXBELD2 NOTE A: IF COMPR. MOTOR STARTER IS A FRICK SUPPLIED STARTER OR CONFORMS TO FRICK STARTER SPECS, WIRE AS SHOWN ON LINE 60 ONLY. JUMP TERM 6 TO 36. IF 2CR IS USED AS A ISOLATED CONTACT, WIRE AS SHOWN BETWEEN THE HOT &...
- Page 56 S70-101 IOM RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 56 MAINTENANCE MICRO PANEL ASSEMBLY WIRING DIAGRAM C.T. MOUNTED IN STARTER OR MOTOR JUNCT. BOX (BY OTHERS) MOTOR CHANNEL 12 0-5 AMP AC AMPS SECONDARY 0-5 AMP AC MOTOR AMPS ONE PHASE...
- Page 57 RXB PLUS ROTARY SCREW COMPRESSOR UNITS S70-101 IOM MAINTENANCE Page 57 MICRO PANEL ASSEMBLY WIRING DIAGRAM TEMPERATURE SENSOR WIRING TO BE #8760 BELDEN CABLE OR EQUAL. GROUND DRAIN WIRE AT PANEL GROUND ONLY. INSULATE AT PROBE END NOTE 2A: SPECIFICATIONS FOR TEMP . CAPACITY CONTROL OF.
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Page 58: P And I Diagrams
S70-101 IOM RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 58 MAINTENANCE P & I DIAGRAM, Models 12, 15, & 19 w/Full-Lube Oil Pump LEGEND (Covers P & I diagrams pages 58 – 60) See page 59 for additional notes AUTO CYCLE... - Page 59 RXB PLUS ROTARY SCREW COMPRESSOR UNITS S70-101 IOM MAINTENANCE Page 59 P & I DIAGRAM, Models 24, 30, 39, & 50 w/Full-Lube Oil Pump SUCTION GAS TO THE COMPRESSOR LPCO SHIPPED LOOSE HPCO 1 MLC 2 MLC DTCO OIL CHARGE...
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Page 60: Proper Installation Of Electronic Equipment
S70-101 IOM RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 60 MAINTENANCE P & I DIAGRAM, All Models WATER-COOLED OIL COOLER THERMOSYPHON OIL COOLER 1" AMOT VALVE (REMOVE TEMP. TO OIL ELEMENT BEFORE WELDING, REINSTALL SEPARATOR ELEMENT W/SENSING BULB IN "A" PORT) - Page 61 RXB PLUS ROTARY SCREW COMPRESSOR UNITS S70-101 IOM MAINTENANCE Page 61 (EMI). EMI fl ows on the wires that are common to a circuit. a ground stake at the electronic control will cause additional EMI cannot travel easily through transformers and therefore problems since other equipment in the plant on the same can be isolated from selected circuits.
- Page 62 S70-101 IOM RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 62 MAINTENANCE Then clean all of the remaining chips from the panel before It is very important to read the installation instructions removing the protective plastic. It would be a good idea to thoroughly before beginning the project.
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Page 63: Operating Log
RXB PLUS ROTARY SCREW COMPRESSOR UNITS S70-101 IOM MAINTENANCE Page 63 OPERATING LOG SHEET... - Page 64 ™ 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 Control ! ™...
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