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ROTARY SCREW COMPRESSOR UNITS

ROTARY SCREW COMPRESSOR UNITS

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Published by Rudranath Ramtahal
ROTARY SCREW COMPRESSOR UNITS
ROTARY SCREW COMPRESSOR UNITS

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Published by: Rudranath Ramtahal on May 18, 2012
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Installation - Operation - MaintenanceROTARY SCREW COMPRESSOR UNITS
WITH
MICROPROCESSOR CONTROL
ALL REFRIGERANTS
THIS MANUAL CONTAINS RIGGING, ASSEMBLY, START-UP, ANDMAINTENANCE INSTRUCTIONS. READ THOROUGHLY BEFOREBEGINNING INSTALLATION. FAILURE TO FOLLOW THESE IN-STRUCTIONS COULD RESULT IN DAMAGE OR IMPROPER OPERA-TION OF THE UNIT.
S70-101 IOM/JAN 2000
File:SERVICE MANUAL - Section 70Replaces:S70-101 IOM/APR 96Dist:3, 3a, 3b, 3c
 
RXB PLUS ROTARY SCREW COMPRESSOR UNITSS70-101 IOMPage 2INSTALLATION - OPERATION - MAINTENANCEGENERAL INFORMATION
Preface..............................................................................3Design Limitations............................................................3Job Inspection...................................................................3Transit Damage Claims.....................................................3Compressor/Unit Identification..........................................3
INSTALLATION
Foundation........................................................................4Handling and Moving........................................................4Skid Removal....................................................................5Motor Mounting.................................................................5Compressor/Motor Coupling Installation..........................5Coupling Alignment Procedure.........................................6Hot Alignment of Compressor/Motor................................8Checking Motor/Compressor Rotation..............................8Holding Charge and Storage............................................8Compressor Oil.................................................................8Oil Charge.........................................................................8Oil Heater..........................................................................8Liquid Injection Oil Cooling...............................................9Dual Dip Tube Method.......................................................9Level Control Method........................................................9Water-Cooled Oil Cooling...............................................10Thermosyphon Oil Cooling.............................................10Economizer - High Stage................................................12Electrical.........................................................................13Motor Starter Package....................................................13Current Transformers (CT) Ratios...................................14Minimum Burden Ratings................................................14Battery Backup...............................................................14
OPERATION
General Information........................................................15Microprocessor Control Panel.........................................15Keys and Key Functions.................................................16To Change The Adjustable Setpoints..............................18How To Determine Adjustable Setpoints.........................18Temperature-Pressure Control Program.........................22Lead-Lag (Option)...........................................................24Communications Troubleshooting...................................24How The Microprocessor Works - Summary..................25Multiple Compressor Sequencing...................................26Microprocessor Telecommunications..............................27Communications Protocol Specifications.......................27RXB Compressor............................................................30Compressor Lubrication System.....................................30Full-Lube Oil System......................................................30Compressor Oil Separation System...............................30Compressor Hydraulic System.......................................31Compressor Oil Cooling Systems...................................32Single-Port Liquid Injection.............................................32Dual-Port Liquid Injection................................................33Liquid Injection Adjustment Procedure...........................33Prestart Checklist............................................................34
TABLE OF CONTENTS
Initial Start-up Procedure................................................35Normal Start-up Procedure.............................................35Restarting Unit After Power Failure.................................35
MAINTENANCE
Normal Maintenance Operations....................................36Compressor Shutdown and Start-up..............................36General Instructions For ReplacingCompressor Unit Components....................................36Suction Check Valve Bypass Valve.................................36Oil Filter, Single...............................................................36Oil Filter, Dual.................................................................37Strainer, Oil Return.........................................................37Strainer, Oil Pump (Optional)..........................................37Strainer, Liquid Injection.................................................37Coalescer Filter Element................................................38Changing Oil...................................................................38Recommended Maintenance Program...........................38Vibration Analysis...........................................................39Oil Quality and Analysis..................................................39Motor Bearings...............................................................39Operating Log.................................................................39Maintenance Schedule...................................................40Troubleshooting Guide....................................................41Abnormal Operation Analysis and Correction................41Troubleshooting The Microprocessor..............................42EPROM Memory I/C Chip Replacement........................45SBC Board Replacement................................................45Microprocessor Display Replacement............................45Output Fuse Replacement..............................................45Pressure Transducers - Testing.......................................45Pressure Transducer Conversion Data...........................45Pressure Transducers - Replacement.............................46Volumizer Potentiometer - Replace/Adjust.....................47Temperature/Pressure Adjustment.................................47Bare Compressor Mounting............................................47Troubleshooting The RXB PLUS:Compressor.................................................................48Oil Separator System..................................................48Hydraulic System........................................................48Full-Time Pump Systems............................................49Liquid Injection Oil Cooling.........................................49Thermal Expansion Valves.............................................50Temperature Control Valve..............................................51Wiring Diagrams.............................................................52P and I Diagrams............................................................58
PROPER INSTALLATION OF ELECTRONICEQUIPMENT...............................................................
61
SPARE PARTS LIST.......................................................
64
OPERATING LOG..........................................................
65
 
RXB PLUS ROTARY SCREW COMPRESSOR UNITSS70-101 IOMPage 3
PREFACE
This manual has been prepared to acquaint the owner andserviceman with the INSTALLATION, OPERATION, andMAINTENANCE procedures as recommended by Frick forRXB PLUS Rotary Screw Compressor Units.It is most important that these units be properly applied toan adequately controlled refrigeration system. Your autho-rized Frick representative should be consulted for his ex-pert guidance in this determination.Proper performance and continued satisfaction with theseunits is dependent upon:
CORRECT INSTALLATIONPROPER OPERATIONREGULAR, SYSTEMATIC MAINTENANCE
To ensure correct installation and application, the equipmentmust be properly selected and connected to a properly de-signed and installed system. The Engineering plans, pipinglayouts, etc. must be detailed in accordance with the bestpractices and local codes, such as those outlined in ASHRAEliterature.A refrigeration compressor is a VAPOR PUMP. To be certainthat it is not being subjected to liquid refrigerant carryover, itis necessary that refrigerant controls are carefully selectedand in good operating condition; the piping is properly sizedand traps, if necessary, are correctly arranged; the suctionline has an accumulator or slugging protection; that loadsurges are known and provisions made for control; operat-ing cycles and defrosting periods are reasonable; and thathigh side condensers are sized within system and compres-sor design limits.It is recommended that the entering vapor temperature tothe compressor be superheated to 10
O
F above the refriger-ant saturation temperature. This ensures that all refrigerantat the compressor suction is in the vapor state.
DESIGN LIMITATIONS
The compressor units are designed for operation within thepressure and temperature limits as shown in Frick Pub.E70-100 SED.
JOB INSPECTION
Immediately upon arrival examine all crates, boxes and ex-posed compressor and component surfaces for damage.Unpack all items and check against shipping lists for anypossible shortage. Examine all items for damage in transit.
TRANSIT DAMAGE CLAIMS
All claims must be made by consignee. This is an ICC re-quirement. Request immediate inspection by the agent ofthe carrier and be sure the proper claim forms are execut-ed.Report damage or shortage claims immediately to Frick ,Sales Administration Department, in Waynesboro, PA.
COMPRESSOR and UNIT IDENTIFICATION
Each compressor unit has 2 identification data plates. The
compressor data plate,
containing compressor model andserial number, is mounted on the compressor body. The
unitdata plate,
containing unit model, serial number, and Fricksales order number, is mounted on the side of the motorbase.
NOTE: When inquiring about the compressor or unit, orordering repair parts, provide the MODEL, SERIAL, andFRICK SALES ORDER NUMBERS from these data plates.COMPRESSOR DATA PLATEUNIT DATA PLATEGENERAL INFORMATION

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