Johnson Controls Frick 408L, Installation Operation & Maintenance

Page 1: ... COMPRESSOR MODELS 408S 408L 408XL THIS MANUAL CONTAINS RIGGING ASSEMBLY START UP AND MAINTENANCE INSTRUCTIONS READ THOROUGHLY BEFORE BEGINNING INSTALLATION FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR DEATH DAMAGE TO THE UNIT OR IMPROPER OPERATION Please check www jci com frick for the latest version of this publication ...

Page 2: ...UP INSTRUCTIONS 16 COMPRESSOR HYDRAULIC SYSTEM 16 VOLUMIZER VOLUME RATIO CONTROL 16 LOW AMBIENT OPERATION 16 INITIAL START UP 16 INITIAL START UP PROCEDURE 17 NORMAL START UP PROCEDURE 17 MAINTENANCE GENERAL INFORMATION 18 NORMAL MAINTENANCE OPERATIONS 18 GENERAL MAINTENANCE 18 CHANGING OIL 18 RECOMMENDED MAINTENANCE PROGRAM 18 VIBRATION ANALYSIS 18 OIL QUALITY and ANALYSIS 19 OPERATING LOG 19 TRO...

Page 3: ...ion of any moisture in the compressor and oil separator DESIGN LIMITATIONS Frick 408 mm compressors are designed for operation within the pressure and temperature limits which are specified by Johnson Controls Frick and our COOLWARE selection software They are primarily used for compressing refrigerant gas and most hydrocarbon gasses If your application is for sour gas there are special requiremen...

Page 4: ...ermstorageofequipmentmayleadtothedeterioration of components over the period of time Synthetic components in the compressor may deteriorate over time even if they are kept flooded with oil A warm and dry environment is essential to minimize environmental and corrosion damage Long term storage of the affected equipment at a customer s site may involve additional requirements and interested parties ...

Page 5: ...ing is designed to maintain operating pressure on seal well below discharge pressure for increased seal life 9 Oil injected into the rotors to maintain good volumetric and adiabatic efficiency even at very high compression ratios 10 Shaft rotation clockwise facing compressor suitable for all types of drives SEE FOLLOWING WARNING WARNING Compressor rotation is clockwise when facing the compressor d...

Page 6: ...son Controls Frick Sales for additional information Rotors The rotors are machined from AISI 1141 steel to the exacting tolerances of the latest Frick profile The five lobed male rotor is directly connected to the driver The seven lobed female rotor is driven by the male on a thin oil film Bearings Antifriction bearings are used for reduced frictional horsepower and superior rotor positioning resu...

Page 7: ...e models is provided below Please see CoolWare to determine the limits for a specific application The rotor and bearing design set limitations of the 408 mm compressors must not be exceeded See CoolWare Refer to Johnson Controls Frick Compressor Control Panel instruction 090 040 O for additional information on setpoint limits OUTLINE DIMENSIONS Drawings for reference only can be found on the follo...

Page 8: ...070 250 IOM APR 11 Page 8 408 MM ROTARY SCREW COMPRESSOR INSTALLATION COMPRESSOR PORT LOCATIONS 408 MM A B A C C B SC 1 SC 3 SC 5 SC 7 SM 1 SC 9 SV 1 SC 9 ST 2 SC 6 ST 1 SC 10 SC 11 VIEW C C ...

Page 9: ...500 B C MODEL PSI MAX P A B PSI MAX T V Hz Amps Hydraulic Valve Division Elyria Ohio 44036 2026 USA MODEL PSI MAX P A B PSI MAX T V Hz Hydraulic Valve Division Elyria Ohio 44036 2026 USA CAUTION REFER TO INSTALLATION OPERATION AND MAINTENANCE MANUAL FOR ADDITIONAL INFORMATION THIS EQUIPMENT HAS BEEN PRESSURIZED WITH NITROGEN GAS TEMPORARY VALVES AND GAUGES HAVE BEEN INSTALLED ESCAPING GAS MAY CAUS...

Page 10: ...R 11 Page 10 408 MM ROTARY SCREW COMPRESSOR INSTALLATION COMPRESSOR PORT LOCATIONS 408 MM SL 2 SL 1 SC 3 SC 2 SC 14 SC 13 VIEW D D DISCHARGE 12 300 ANSI FLANGE 1 7 UNC 2B x 3 00 DP 16X ON 17 750 B C D D SC 4 SC 2 BP ...

Page 11: ...M 12 UN 2B STRAIGHT THREAD 980A0012K72 CLOSED THREAD PRESSURE SC 10 1B 12 UN 2B STRAIGHT THREAD 980A0012K71 SLIDE VALVE TOOL DISCH PRESSURE SC 11 1B 12 UN 2B STRAIGHT THREAD 980A0012K71 DRAIN DISCHARGE PRESSURE SC 12 3 4 16 UNF 2B STRAIGHT THREAD 980A0012K62 DRAIN SUCTION PRESSURE SC 13 3 4 16 UNF 2B STRAIGHT THREAD 980A0012K62 CYLINDER OIL PRESSURE SC 14 3 4 16 UNF 2B STRAIGHT THREAD 980A0012K62 ...

Page 12: ...roper spacing for servicing see Dimensional Outline Drawing The first requirement of the compressor foundation is that it must be able to support the weight 408S 13 960 lb 408L 15 580 lb 408XL 16 615 lb NOTICE Weights are for standard compressor in Ductile Iron Contact factory for weights of optional models Screw compressors are capable of converting large quantities of shaft power into gas compre...

Page 13: ... MOTOR COUPLING REQUIREMENTS Frick 408 mm compressors are arranged for direct motor drive and require a flexible drive coupling to connect the compressor to the motor If you are using the Johnson Controls Frick motor mount the mount is machined to ensure that motor to compressor alignment is in specification see the above MOTOR MOUNTING section for mounting details With a foot mounted motor it is ...

Page 14: ...Valve off the vacuum pump and hold vacuum for one hour Pass Vacuum cannot rise more than 500 microns during one hour hold period Fail Vacuum rise is more than 500 microns during one hour hold period Identify and repair any system leaks Repeat vacuum test until requirements are met ELECTRICAL INSTALLATION SLIDE STOP TRANSMITTER The slide stop transmitter Figure 5 measures the position of the slide ...

Page 15: ...irectional control valves Solenoids YY1 YY2 YY3 and YY4 must be wired to give the correct function A description of their function is given in the OPERATION chapter For control system information refer to Frick Compressor Control Panel 090 020 O See wiring diagram in Figure 9 Figure 9 Directional Control Valve Wiring Diagram ...

Page 16: ... energized and oil flows from the oil manifold through valve ports P and A to cylinder port SC1 and enters the unload side of the cylinder Simultaneously gas on the load side of the cylinder is vented through port SC2 and valve BP to compressor suction NOTICE To control the rate of loading and unloading throttle the needle valve at SC1 port DOUBLE ACTING MODE Booster low differential Open valve at...

Page 17: ...1 to 3 hours of operation adjust oil cooling system 3 Pull and clean suction strainer after 24 hours of operation If it is excessively dirty repeat every 24 hours until system is clean Otherwise follow the normal maintenance schedule 4 Perform vibration analysis if equipment is available Figure 11 Hydraulic Schematic SC4 BP SC2 SC3 SC1 SC3 2 SC4 SC3 SC13 1 2 SC2 SC1 2 SC2 1 1 2 A B 1 P T BP B A T ...

Page 18: ...or is used to avoid dumping liquid into compressor suction 5 Protect the compressor during long periods of shutdown If the compressor will be sitting for long periods without running it is advisable to evacuate to low pressure and charge with dry nitrogen or oil This is particularly true on systems known to contain water vapor 6 Preventive maintenance inspection is recommended any time a compresso...

Page 19: ...recording of gauge pressures temperatures 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 It is recommended that readings be taken at least daily TROUBLESHOOTING GUIDE Successful problem solving requires an organized approach to define the prob...

Page 20: ...13 Volumizer Transmitter The linear transmitter with hermetic enclosure is based on the inductive measuring principle It features removable electronics from the sensor well eliminating the need to evacuate the compressor for replacement This type of transmitter is dedicated to volume ratio control and has no user adjustments 1 Shut off control power 2 Remove DIN connector plug from transmitter 3 L...

Page 21: ...ere is power to the coil Check coil Solenoid may be actuated mechanically by inserting a piece of 3 16 rod against armature pin and pushing spool to opposite end Push A side to confirm unload capability If valve works problem is electrical SLIDE VALVE WILL LOAD BUT WILL NOT UNLOAD A side solenoid coil may be burned out Replace Dirt inside solenoid valve preventing valve from operating both ways Cl...

Page 22: ...out Repair or replace OIL PRESSURE RAPIDLY DROPS OFF WHEN COMPRESSOR STARTS Main oil injection throttling valve too wide open or oil pressure regulating valve improperly adjusted Readjust both valves NOISE and VIBRATION Pump strainer blocked Clean Pump worn out Repair or replace OIL PRESSURE DROPS AS HEAD PRESSURE INCREASES Normal behavior Set main oil injection and oil pressure for maximum head p...

Page 23: ...ompressor Motor Magnetic Center Checked Marked N A Compressor Coupling Hub Runout____________ Motor Coupling Hub Runout_ ____________ Initial Cold Alignment Initial Hot Alignment Final Hot Alignment Operating Log Sheet Date Time Hour Meter Reading Equip Room Temp Suction Pressure Suction Temperature Suction Superheat Discharge Pressure Discharge Temperature Corresponding Temperature Oil Pressure O...

Page 24: ...__________________________ Motor Serial Number _ ________________________________ RPM _________ Frame Size ____________ H P ___________ Refrigerant Ambient Room Temperature _ ____________ F Operating Conditions VIBRATION DATA SHEET Final Hot Alignment SUCTION DISCHARGE OIL SEPARATOR Slide Valve Position Press Press Press Temp F Vi Ratio Temp F Temp F Temp F F L A Total Thickness of Shims Added Fac...

Page 25: ... female rotor 6 Foundation 12 G gaskets 20 gas load 19 H hermetic enclosur 20 hermetic enclosure 20 Holding Charge 12 hydraulic cylinder 5 16 hydrocarbon gasses 3 I identification data plate 3 Installation 7 insulated 16 L lifting rings 12 linear transmitter 20 load surges 3 Long term storage 4 lubrication system 5 M maintenance 18 Maintenance Maintenance Schedule 19 male rotor 6 male rotor shaft ...

Page 26: ...r 17 18 system piping 19 T thermal stability 6 transmitter unit 20 traps 3 troubleshooting 18 Troubleshooting 21 Filter cartridges 22 hydraulic control valve 21 Oil Pressure 22 Oil pressure regulator 22 Piston Seals 21 pressure regulating valve 22 Pump 22 Pump strainer 22 service valves 22 Slide Stop 21 Slide stop indicator rod 21 Slide Valve 21 Solenoid coils 21 Solenoid spool 21 Strainer 22 Unlo...

Page 27: ...070 250 IOM APR 11 Page 27 408 MM ROTARY SCREW COMPRESSOR INSTALLATION OPERATION MAINTENANCE ...

Page 28: ...ION MAINTENANCE Johnson Controls 100 CV Avenue Waynesboro PA 17268 1206 USA Phone 717 762 2121 FAX 717 762 8624 www jci com frick Form 070 250 IOM 2011 04 Supersedes NOTHING Subject to change without notice Published in USA 0714 PDF 2014 Johnson Controls Inc ALL RIGHTS RESERVED ...