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Maintenance ROTARY SCREW COMPRESSOR UNITS

1. 15 Temperature Pressure Adjustment 47 Keys and Key Functions 16 Bare Compressor Mounting 47 To Change The Adjustable Setpoints 18 Troubleshooting The RXB PLUS How To Determine Adjustable Setpoints 18 COMDICSSOR ittm THEE 48 Temperature Pressure Control Program 22 Oil Separator System 48 aee dee 24 Hydraulic SySlelty case d Za 48 Communications Troubleshooting 24 Full Time Pump Systems 49 How Microprocessor Works Summary 25 Liquid Injection Oil Cooling 49 Multiple Compressor Sequencing 26 Thermal Expansion Valves 50 Microprocessor Telecommunications 27 Temperature Control Valve 51 Communications Protocol Specifications 27 Wiring Diagrams 52 Compressor
2. SLIDE STOP SLIDE VALVE COMPRESSOR FUNCTION AUTO AUTO RUN RMT F1 P MANUAL MANUAL STOP 5 0 Vi LOAD F2 a MANUAL MANUAL REMOTE 3 5 Vi UNLOAD START N MANUAL ALARM 2 2 Vi SILENCE SETPOINT ENTRY CHANGE STEP ENTER A gt V V J V EMERGENCY STOP RXBELD7 The RXB PLUS compressor is controlled by a state of the art microprocessor control system The microprocessor continuously monitors the compressor unit s condition and operation The microprocessor also directs instructions to the various compressor unit subsystems The microprocessor has a membrane switch keyboard Pressing the keyboard in the area outlined as a key will cause that function to be recognized by the microprocessor The keyboard has 32 membrane type keys In addition to the keyboard there is an emergency stop but ton Pushing the emergency stop will bypass the computer and remove all power from the outputs This will shut down the compressor motor and all high voltage to the compres sor auxiliary systems such as the oil pump and liquid injec tion solenoid THE EMERGENCY STOP BUTTON IS FOR EMERGENCY SHUTDOWN SITUATIONS ONLY and MUST NOT BE USED TO ROUTINELY SHUT OFF THE COMPRESSOR The microprocessor continuously monitors the state of the battery which maintains setpoints and various other data If the battery voltage is low the message LOW will flash in the lower right hand corner o
3. VIVO 9 O ve T LVI oO e N 9 4 GSE juvdS T Ace Se 7 229 NS 135 110 gt 929 6 E iL se s gt H31V3H co i 1 mi ol vels 1 H3MOd 2 eee e WHVTV d vt 9 pies tke q O3u 4 H3ZINONOO3 4 5 2 pez fhe Jl ON IA IH O c S tie SR Eko 0 089 4 NOLLO3fNI AINON O e Ese 015 y aeg 9 Ste jSv3HONI 4015 0 reis QVOTNh IMYA 301116 N yeo ZL GVO13ATVA 30S 88 9 YIMOd 2149 98 1 LHVLS 3 9 29 2 ote p ME 026 XNV L gt OPi 86 MSIS W Zok e oz HH 2 66 e xnv HOSS3HdWOO 5 46 891 7 cm 5 4 9 e qavo1Nn 35 22 ss 9 avoiaioWau y 29 8 nny 3LlOWd3H c Tt kes ee HOLIMS 13437 110 gt Z S A CC sone wid 8 L 3L L T3NNVHO 9 8 2 31 2 TANNVHO m S m FR 8 8 2 31 TANNVHO dW3L e CC gt lt rar T3NNVHO LL 19 9 31 s TANNVHO 8 Std Y alo 218 Z TANNVHO 9rT dqag S 1 Saud Mall 8 TANNVHO HOSIG sH s T 1916
4. 30 P and l Diagrams 58 Compressor Lubrication System 30 Full Lube Oil Systemi 30 PROPER INSTALLATION OF ELECTRONIC Compressor Oil Separation System 30 EQUIPMENT iieri a UE ce E Hexe ceu es 61 Compressor Hydraulic System 31 Compressor Oil Cooling Systems 32 SPARE PARISLISTu Z z L u 64 Single Port Liquid Injection 32 Dual Port Liquid Injection 33 OPERATING LOG 65 Liquid Injection Adjustment Procedure 33 Prestart 34 Frick PREFACE This manual has been prepared to acquaint the owner and serviceman with the INSTALLATION OPERATION and MAINTENANCE procedures as recommended by Frick for RXB PLUS Rotary Screw Compressor Units It is most important that these units be properly applied to an 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 these units is dependent upon CORRECT INSTALLA
5. 570 101 IOM JAN 2000 p ICK File SERVICE MANUAL Section 70 Replaces 570 101 IOWAPR 96 Dist 3 3a 3b 3c Installation Operation Maintenance HX ROTARY SCREW COMPRESSOR UNITS WITH MICROPROCESSOR CONTROL ALL REFRIGERANTS 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 S70 101 IOM RXB PLUS ROTARY SCREW COMPRESSOR UNITS Frick Page 2 INSTALLATION OPERATION MAINTENANCE Frick TABLE OF CONTENTS GENERAL INFORMATION Initial Start up Procedure 35 Nile 3 Normal Start up Procedure 35 Design Limitations 3 Restarting Unit After Power Failure 35 JOD NSPECUON 3 Transit Damage 3 MAINTENANCE Compressor Unit Identification 3 Normal Maintenance Operations 36 Compressor Shutdown and Start up 36 INSTALLATION General Instructions For Replacing uku aman 4 Compressor Unit Components 36 Handling and
6. 3 Evaluate vibration readings carefully as the instrument range and function used can vary Findings can be easily misinterpreted RXB PLUS ROTARY SCREW COMPRESSOR UNITS MAINTENANCE Page 39 570 101 IOM 4 Vibration readings can be influenced by other equipment operating in the vicinity or connected to the same piping as the unit OIL QUALITY and ANALYSIS High quality refrigeration oil is necessary to ensure compres sor longevity and reliability Oil quality will rapidly deterio rate in refrigeration systems containing moisture and air or other contaminants In order to ensure the quality of the refrigeration oil in the compressor unit follow these recommendations 1 Only use Frick refrigeration oil as recommended by Frick Company for your application 2 Participate in a regular periodic oil analysis program to help maintain oil and system integrity MOTOR BEARINGS Follow the motor manufacturer s maintenance recommen dations Lubricate the motor bearings prop CAUTION erly before start up Maintain sub sequent lubrication as recom mended by the motor manufacturer LUBRICATION SCHEDULE INSTRUCTIONS SYNC FRAME SERVICE CYCLE BALL BEARING LUBRICATE BEARINGS WITH POWER IN THE OFF CONDITION RPM SERIES 8 HR DAY OPERATION 24 HR DAY OPERATION CLEAR AND CLEAN THE GREASE FITTINGS AND SURROUNDING AREA 3600 360 5800 150 DAYS 1200 HRS 50 DAYS 1200 HRS
7. ET Sk T Frick Never run any wires through an electronic control panel that do not relate to the function of the panel Elec tronic control panels should never be used as a junc tion box These wires may be carrying large transients that will interfere with the operation of the control An extreme example of this would be to run the 480 volts from a motor starter through the control panel to the motor When running conduit to an electronic control panel take notice of the access holes knockouts provided by the manu facturer These holes are strategically placed so that the field wiring does not interfere with the electronics in the panel Never allow field wiring to come in close proximity with the controller boards since this will almost always cause problems Do not drill a control panel to locate conduit connec tions You are probably not entering the panel where the manufacturer would like you to since most manufacturers recommend or provide prepunched conduit connections Drilling can cause metal chips to land in the electronics and create a short circuit If you must drill the panel take the following precautions First cover the electronics with plas tic and tape it to the board with masking or electrical tape Second place masking tape or duct tape on the inside of the panel where you are going to drill The tape will catch most of the chips Then clean all of the remaining chips from the panel before removing the protec
8. JUMPER 0 36 SEENOTEB 42 18 HOT WIRING IF ISOLATED 3CR CONTACT IS USED JUMP TO 6 SEE NOTE A IF REQ D Sars INDICATES FURNISHED OR REQUIRED WITH OIL PUMP ONLY Tee INDICATES DEVICES SUPPLIED ONLY WHEN OPTIONAL OR REQUIRED Pepe ers WIRING BY OTHERS ALL WIRING ENTERING CONTROL CENTER INCLUDING GROUND amp NEUTRAL TO BE 14 AWG STRANDED WIRES UNLESS SPECIFIED OTHERWISE 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 amp NEUTRAL LINES ON LINE 60 IF 2CR IS USED AS A ISOLATED CONTACT WIRE AS SHOWN BETWEEN THE HOT amp NEUTRAL LINES ON LINE 60 SAME NOTES APPLY TO OIL PUMP STARTER CIRCUIT ON LINE 63 NOTE B FOR OPTIONAL ALARMS amp SHUTDOWNS HIGH LEVEL SHUTDOWN ETC WHEN REFERENCING MICRO POWER TO OPERATE COMPR MOTOR STARTER PARAGRAPH 1 NOTE A REMOVE JUMPER 36 TO 42 amp INSERT ISOLATED CONTACT S JUMP 42 TO EITHER 29 OR 30 AUX 1 OR AUX 2 PROGRAM AUX TO SHUTDOWN NORMALLY CLOSED WHEN USING 2CR AS A ISOLATED CONTACT PARAGRAPH 2 NOTE A REMOVE JUMPER 36 TO 42 amp INSERT ISOLATED CONTACT S A SEPARATE ISOLATED CONTACT SHO
9. O ME alko SUCTION VALVE SHIPPED LOOSE DXO 1 1 SAE OF 1 N s 1 XXH PIPE ADAPTER TO RESTRICT OIL t FLOW AT START UP TE C TAHH 300 PSIG DISCHARGE GAS LSLY LSLN FROM UNIT 1 X Qe Um 5 ae Co HTRH TE TALNTALN i AUD ET C I a gt STR l RXF12PNI TO OIL COOLER FROM OIL COOLER AC CG DTA DTCO HPA HPCO HTA HTCO HTR HV LICO LLCO LPA LPCO LSL LTA AUTO CYCLE COMPRESSOR CAPACITY CONTROL HIGH DISCHARGE TEMPERATURE ALARM HIGH DISCHARGE TEMPERATURE CUTOUT FILTER HIGH DISCHARGE PRESSURE ALARM HIGH DISCHARGE PRESSURE CUTOUT HIGH OIL TEMPERATURE ALARM HIGH OIL TEMPERATURE CUTOUT HEATER HAND VALVE LIQUID INUECTION REFRIGERANT CUTOUT LOW OIL SEPARATOR LEVEL CUTOUT LOW SUCTION PRESSURE ALARM LOW SUCTION PRESSURE CUTOUT LEVEL SWITCH LOW OIL TEMPERATURE ALARM LTCO M MLC NV OF OHTR OPA OPCO P PE PM PSV SG STR 5 TW V LOW OIL TEMPERATURE CUTOUT MOTOR MOTOR LOAD CONTROLLER NEEDLE VALVE OIL FILTER OIL HEATER TEMPERATURE SWITCH LOW OIL PRESSURE ALARM LOW OIL PRESSURE CUTOUT PUMP PRESSURE INDICATOR PUMP MOTOR
10. P Page 52 MAINTENANCE Frick MICRO COMPONENT PLACEMENT DIAGRAM FRONT PANEL REAR VIEW 3 CONTRAST 26 COND DISPLAY i e 12 COND GREEN WIRE B CSA ONLY WARNING AVERTISSEMENT O 3 U5 U4 POWER BAT ce ON SUPPLY gt AL BATTERY PORT F1 1 Pi5 P10 115 F P13 230 F2 P12 P11 1 FRICK REV D P9 RXB RDB ANALOG EXPANSION DIGITAL INPUT DIGITAL OUTPUT POT POT MODULES MODULES 3 4 FUSES FU1 FU1 SPAN ZERO Estee TERM ANALOGTERMS DIG I O TERMS 5 4 1 16 17 P2 34 35 1 48 ANALOG WIRING 1 5 Q Q amp SBC POWER SUPPLY WIRING WIREWAY AC WIRING ONLY 1A FU SP FU 8e IF REQ D u E E 5 TOROID I ERE 1 SE 2A cuu Laa gt GP o em 25
11. tam 6 TANNVHO lOd io 838 7 3ATVA 3qI1S o eee OL NvdS ANWA 8 lOd NOILISOd e1io4 JAVA gars TANNVHO SONS s D glo 88 te ay e Zk TANNVHO z Oa Frick RXBELD6 COMPRESSOR 2 PORT 1 PORT 1 COMPRESSOR 1 RXB PLUS TELECOMMUNICATIONS COMPUTER TO MICROPROCESSOR WIRING DIAGRAM COMPUTER COMMUNICATIONS PORT AC 422 S70 101 IOM Page 54 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 MAINTENANCE RXB PLUS ROTARY SCREW COMPRESSOR UNITS eae k Ee Frick MICRO PANEL ASSEMBLY WIRING DIAGRAM CUSTOMER SUPPLIED 120 VAC CONTROL TRANSFORMER POWER SOURCE IS REQUIRED EARTH BUSBAR AT HOT ALL POWER SOURCES SHALL BE GROUNDED ON ONE SIDE i dm POWER SOURCE lt ISOLATED AND SEPARATED FROM OTHER INDUCTIVE LOADS SUCH AS LIGHTING CIRCUITS es ye OR FROM FRICK SUPPLIED OR SPECIFIED STARTER USE MINIMUM 1
12. tion with the economizer turned on Please note however that shell and coil and DX economizers can be used at low compressor capacities in cases where efficiency is not as important as ensuring that the liquid supply is subcooled In such cases the economizer liquid solenoid can be pro grammed to be left open whenever the compressor is run ning Due to the tendency of the port pressure to fall with de creasing compressor capacity a back pressure regulator valve BPR is generally required on a flash economizer system FIG 3 in order to maintain some preset pressure difference between the subcooled liquid in the flash vessel and the evaporators If the back pressure regulator valve is not used on a flash economizer it is possible that no pres sure difference will exist to drive liquid from the flash vessel to the evaporators since the flash vessel will be at suction pressure In cases where wide swings in pressure are an SUCTION INTERMEDIATE PRESSURE GAS TO COMPRESSOR Sy ECONOMIZER STR VCK COOLER HIGH PRESSURE SUBCOOLED LIQUID HIGH PRESSURE 77 LIQUID TO lt EVAPORATOR v ECON1 Se lt lt FIG 1 SHELL and COIL ECONOMIZER SYSTEM INTERMEDIATE PRESSURE GAS TO COMPRESSOR HIGH PRESSURE LIQUID TA STR VCK lt SUBCOOLED 4 W
13. CONTACT Frick Factor or Frick Co Coupling loose on shaft Tighten coupling Replace if damaged Misalignment between motor and compressor Realign motor and compressor Refrigerant flood back Correct system problem TROUBLESHOOTING THE OIL SEPARATOR 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 overfeeding Correct operation Contaminated oil damaged or not seated coalescer filter elements Replace oil charge and coalescers Oil return valve closed Open return valve Return oil strainer blocked Clean strainer RAPID LOSS WITH NO OIL LEVEL Compressor unit suction check valve did not close on shutdown Repair valve IN THE COALESCER SECTION SIGHT GLASS Bypass open around check valve if field installed Close bypass Economizer check valve if applicable failed Coalescer not seated Reseal TROUBLESHOOTING THE HYDRAULIC SYSTEM SYMPTOM PROBABLE CAUSES and CORRECTIONS SLIDE VALVE WILL NOT LOAD OR Solenoid coil may be burned out Replace UNLOAD Hydraulic service valve may be closed Open valve Solenoid spool may be stuck or centering spring broken Free spool or replace spring Solenoid may be mechanically actuated by inserting a piece of 3 16 rod against armature pin and pushing spool to opposite end If valve is mounted on compressor push A side to conf
14. Em ilie LICO F 1 LTCO FROM OIL OHTR T ASA RELIEF VALVE ON OIL COOLER OPTIONAL m PIPING OPA mox CYCLING OPCO WITH NO de lt m OIL OIL vU Wi E ORIFICE TO Y 1 RESTRICT OIL d x FLOW AT MN START UP FROM OIL TO OIL COOLER COOLER OR OR FILTER SEPARATOR Gg DH CONNECTION DESCRIPTION NOTES 1 MAIN OIL SUPPLY PRESSURE TRANSDUCER INDICATE 2 SLIDE VALVE POSITION PE1 OIL PRESSURE MAINIFOLD 3 LOW Vi LIQUID INJECTION DISCHARGE PRESSURE 4 HIGH Vi LIQUID INJECTION PE4 SUCTION PRESSURE 5 ECONOMIZER TEMPERATURE PROBES INDICATE 7 SUCTION PRESSURE TE1 SUCTION GAS TEMPERATURE 8 CLOSED THREAD TE2 DISCHARGE GAS TEMPERATURE 10 DISCHARGE PRESSURE LUBE OIL TEMPERATURE 11 LIQUID INJECTION BLEED LINE TE4 SEPARATOR OIL TEMPERATURE 12 COALESCER BLEED LINE SOLENOID VALVE FUNCTION 15 VENT UNLOADING SV1 ENERGIZE UNLOAD SLIDE VALVE 16 THERMO WELL SV2 ENERGIZE LOAD SLIDE VALVE 18 OIL INJECTION SV3 ENERGIZE INCREASE VOLUME RATIO 19 SUCTION PRESSURE SV4 ENERGIZE DECREASE VOLUME RATIO 20 SEAL WEEPAGE eae k Ee S70 101 IOM RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 60 MAINTENANCE Frick P amp DIAGRAM All Models WATER COOLED OIL COOLER THERMOSYPHON OI
15. F1 To Exit Stop 25 0 9 Timer 01 min Min SV 50 Lead Yes Active No Suct Press 35 5 g The software includes user adjustable setpoints on the Auto Cycle setpoints screen F4 on Main Menu for the following START The suction pressure must be greater than or equal to the START setpoint in order to start the compressor This setpoint works in conjunction with the Timer setpoint located to the right of it on the Auto Cycle setpoints screen Start TIMER This is a time delay used to start the com pressor The timer only accumulates time whenever the pres sure rises to or above the START setpoint and will reset if the pressure drops below the START setpoint STOP The suction pressure must be less than or equal to the STOP setpoint in order to stop the compressor This setpoint works in conjunction with the Timer setpoint lo cated to the right of it on the Auto Cycle setpoints screen Stop TIMER This is a time delay used to stop the com pressor The timer only accumulates time whenever the pres sure drops to or below the STOP setpoint and will reset if the pressure rises above the STOP setpoint MIN SV This setpoint is the minimum slide valve position and is shown as a percentage It will limit the slide valve position to the displayed setpoint LEAD This setpoint assigns the compressor as the lead or the lag unit Press the CHANGE key while at this setpoint to change
16. HIGH PRESSURE SAFETY VALVE SIGHT GLASS STRAINER SOLENOID VALVE TEMPERATURE ELEMENT THERMOWELL VESSEL a RXB PLUS ROTARY SCREW COMPRESSOR UNITS 670 101 IOM Frick MAINTENANCE Page 59 P amp 1 DIAGRAM Models 24 30 39 amp 50 w Full Lube Oil Pump SUCTIONGASTO N THE COMPRESSOR AC LPA PE Bu s LPCO 4 m OC SHIPPED LOOSE INF D 16 HPA HPCO CF C4 37 1 PE 11 3 12 SV C ieee e NC 5 4 1 8 2 O 1 MLC Q 2 MLC d 5 O p MSIE 10 116 DTA DTCO OIL CHARGE DISCHARGE GAS 00 2 PSV 42 FROM THE UNIT 2 1 gt STOP CHECK VALVE n Cts NOTE THIS vave d UA E INCLUDES INTERNAL i CHECK VALVE j E i A v m HTR Pj 1 i D p D 1 LLCO D 1 lt ES L TE HTA 4 Ks 87
17. PROM and will remain in memory if power to the microprocessor is interrupted SETPOINTS DISPLAY Page 3 OIL HEATER The Oil Heater setpoint reported in degrees Fahrenheit turns on the oil separator heater s when the oil temperature equals or falls below this setpoint whenever the compressor is NOT running LIQ INJ CON The Liquid Injection Control reported in de grees Fahrenheit will shut off the liquid refrigerant supply to the compressor if the oil temperature equals or falls below this setpoint HI DISCH CUT The High Discharge Temperature Cutout re ported in degrees Fahrenheit will shut down the compressor if the discharge temperature equals or exceeds this setpoint HI DISCH ALARM The High Discharge Temperature Alarm reported in degrees Fahrenheit will trigger a prealarm if the discharge temperature equals or exceeds this setpoint SETPOINTS DISPLAY Fixed Page 4 OIL TEMP CUTOUT The High Oil Temperature Cutout reported in degrees Fahrenheit will shut down the compres sor if the oil temperature equals or exceeds this setpoint HI OIL TEMP ALARM The High Oil Temperature Alarm reported in degrees Fahrenheit will trigger a prealarm if the oil temperature equals or exceeds this setpoint LOW OIL TEMP CUTOUT The Low Cil Temperature Cutout reported in degrees Fahrenheit will shut down the compres sor if the oil temperature equals or falls below this setpoint LOW OIL TEMP ALARM The Low Ci
18. common to a circuit EMI cannot travel easily through trans formers and therefore can be isolated from selected circuits Use a control transformer to isolate the electronic con trol panel from other equipment in the plant that gener ate EMI Figure 1 J GROUND CONTROL TRANSFORMER ISOLATED m CIRCUIT ELECTRONIC CONTROL CORRECT ART1T J GROUND CONTROL TRANSFORMER NONISOLATED CIRCUIT px 2 Q A ELECTRONIC CONTROL i INCORRECT ARTIB Figure 1 S70 101 IOM GROUNDING Grounding is the most important factor for successful op eration and is also the most overlooked The NEC states that control equipment may be grounded by using the rigid conduit as a conductor This worked for the earlier relay systems but it is not acceptable for electronic control equip ment Conduit is made of steel and is a poor conductor rela tive to a copper wire Electronic equipment reacts to very small currents and must have a good ground in order to operate properly therefore copper grounds are required for proper operation Note aluminum may be used for the large three phase ground wire The ground wire must be sized the same size as the supply wires or one size smaller as a minimum The three phase power brought into the plant must also have a ground wire making a total of four wires In many instal lations that are having electronic control problems this es sential wire
19. if the rim at 0 and 180 readings indicates that the motor rises 005 between its hot and cold state 005 of shims should be removed from under the motor After the initial hot alignment adjustment is made restart unit and bring to operating temperature Shut down and re check hot alignment Repeat procedure unit hot alignment is within specified tolerance INSTALL COUPLING GUARD BE CAUTION FORE OPERATING COMPRES SOR CHECKING MOTOR COMPRESSOR ROTATION COMPRESSOR ROTATION IS CLOCKWISE WHEN FAC ING THE END OF THE COMPRESSOR SHAFT Under NO conditions should the motor rotation be checked with the coupling center installed as damage to the compressor may result COMPRESSOR MM Deep HOLDING CHARGE AND STORAGE Each compressor unit is pressure and leak tested at the Frick factory and then thoroughly evacuated and charged with dry nitrogen to ensure the integrity of the unit during shipping and short term storage prior to installation NOTE Care must be taken when entering the unit to ensure that the nitrogen charge is safely released All units must be kept in a clean dry location to prevent corrosion damage Reasonable consideration must be given to proper care for the solid state components of the micro processor Unit which will be stored for more than two months must have the nitrogen charge checked peri odically RXB PLUS ROTARY SCRE
20. inch gauge g and inches of mercury hg The RUN STOP and REMOTE START keys control the starting and stopping of the compressor unit The ALARM SILENCE key will de energize the alarm horn output The AUTO REMOTE and MANUAL keys control the operation of the compressor slide valve The AUTO MANUAL 2 2 MANUAL 3 5 and MANUAL 5 0 keys control the operation of the compressor slide stop The F1 function key will return the operator to the main operating display This function may be invoked at any time even during setpoint entry The F2 function key will call up the Security display NOTE Press the F2 key as prompted by the display to return to the previously selected display The F3 function key will call up the Setback display NOTE To exit the Setback display press the F1 key as prompted by the display The F4 function key will call up the Auto Cycle display NOTE To exit the Auto Cycle display press the F1 key as prompted by the display The microprocessor has two liquid crystal displays in an 8 line by 40 character format for a total of 320 characters When power is first applied to the control panel the unit will be in the Operating display mode To change to a different display mode press the CHANGE key The display modes in their order of rotation are Display for illustrative purposes only RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 16 OPERATION eae k Ee
21. 2 COVERS THAT MAY HAVE BEEN REMOVED TO ACCESS THE MOTOR OPERATING LOG The use of an operating log as shown on the inside back cover permits thorough analysis of the operation of a refrigeration system by those responsible for its maintenance and servicing Continual recording of gauge pressures tem peratures 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 every four hours S70 101 IOM RXB PLUS ROTARY SCREW COMPRESSOR UNITS p Page 40 MAINTENANCE Frick MAINTENANCE SCHEDULE This schedule should be followed to ensure trouble free operation of the compressor unit HOURS OPERATION MAXIMUM e e e O O O O O O O N m LO co T CHANGE OIL As directed by oil analysis OIL ANALYSIS CHANGE FILTERS E _ Then every 6 months jm m m __ _ o Then every months ______ m m CLEAN OIL Seanno m jw m m m m m m owe L L L LL L L L TL Lim ww pw m p a m m w w w ml m m Tm m ml imi VIBRATION ANALYSIS Every 6 months more frequently if levels increase REPLACE SEAL When leak rate exceeds 7 8 drops per minute
22. CHECK AND CLEAN SUCTION SCREEN Frick TROUBLESHOOTING GUIDE Successful problem solving requires an organized approach to define the problem identify the cause and make the proper correction ABNORMAL OPERATION ANALYSIS and CORRECTION Four logical steps are required to analyze an operational problem effectively and make the necessary corrections 1 Define the problem and its limits 2 Identify all possible causes 3 Test each cause until the source of the problem is found 4 Make the necessary corrections The first step in effective problem solving is to define the limits of the problem If for example the compressor peri odically experiences high oil temperatures do not rely on this observation alone to help identify the problem On the basis of this information the apparent corrective measure would appear to be a readjustment of the liquid injection system Lowering the equalizing pressure on the thermal expansion valve would increase the refrigerant feed and the oil temperature should drop If the high oil temperature was the result of high suction superheat however and not just a matter of improper liquid injection adjustment increasing the liquid feed could lead to other problems Under low load conditions the liquid in jection system may have a tendency to overfeed The high suction superheat condition moreover may only be tempor ary When system conditions return to normal the unit s lig u
23. COOLING SYSTEM SYMPTOM PROBABLE CAUSES and CORRECTIONS HIGH OIL TEMPERATURE LOW OIL TEMPERATURE OIL TEMPERATURE FLUCTUATES Insufficient liquid supply Check receiver level Check strainer Equalizer pressure too high Lower pressure Suction superheat too high Correct system problem Thermal valve power head lost charge Replace Liquid strainer blocked Clean Liquid supply line not sized properly Install larger line Operating conditions significantlydifferent from design Equalizing pressure too low Raise Suction superheat too low or refrigerant flood back on compressor Correct system problem Low load conditions Valve oversized increase load or use smaller thermovalve Operating conditions significantlydifferent from design System conditions rapidly fluctuate causing liquid injection system to overrespond Stabilize system operation S70 101 IOM THERMAL EXPANSION VALVES In situations where system load conditions increase or de crease over extended periods of time and the liquid injec tion thermal expansion valve is not adequate for the new conditions an improvement in valve performance may be achieved by increasing or decreasing discharge tube size NOTE DO NOT ATTEMPTTO ADJUST SUPERHEAT AD JUSTMENT STEMON BOTTOM OF VALVE INAN EFFORT TO CHANGE THE VALVE S THIS AD JUSTMENTIS PRESET ATTHE FACTORY ONLY ADJUST 1 4 BLEED VALVE ON EQUALIZING LINE TYPE D THERMAL EXPANSION V
24. Frick 1 Operating displays 2 Setpoints displays 3 Annunciator displays 4 Shutdown Record displays 5 Freeze displays F1 Operating display F2 Security display F3 Setback display F4 Auto Cycle display NOTE On initial powering of the microprocessor and any time power has been removed from the micropro cessor only the Operating Setpoints Annunciator and Shutdown displays will display information The Freeze display will appear as a dark screen The Freeze display will only be present after a compressor unit cutout OPERATING DISPLAY Pages 1 and 2 OP DISPLAY PAGE 1 Thu 03 01 89 15 33 36 Suction Disch Oil Compressor 14 3hg 0240 060g Man Mode 0409F 1359F 1359F Running OP DISPLAY PAGE 2 Thu 03 01 89 15 33 36 V Ratio SV Pos Pump FLA Sep 132 F 2 2 070 on 096 HTR off Auto Auto U OPERATING DISPLAY Page 1 The Operating display is continuously updated and provides a variety of information in regard to the current status of the compressor s condition and performance The information furnished by the Operating display is as fol lows The DAY DATE and TIME are displayed at the top right of the display NOTE To set day date and time see TO CHANGE THE ADJUSTABLE SETPOINTS SUCTION Suction Pressure and Temperature are mea sured at the compressor inlet and are respectively displayed in pounds per square inch gauge g or inches of mercury hg and degrees Fahrenheit DISCH Discha
25. HANDLING AND MOVING THIS UNIT MAY BE TOP HEAVY CAUTION USE CARE WHILE HANDLING Spreader bars should be used on both the length and width of the package to prevent bending of oil lines and damage to the package The unit can be moved with rigging using a crane or forklift The recommended method is to insert lengths of 2 pipe through the lifting holes in the vertical supports see FIG 1 Alternatively hooks may be used in rigging inserting them in the lifting holes see FIG 2 Use CAUTION in locating the lifting ring If no motor is mounted the lifting ring should be moved off center to the compressor side of the unit because 60 percent of the weight is toward the compressor end If a motor is mounted ap propriate adjustment in the lifting point should be made to compensate for motor weight Adjustment of the lifting point must also be made for any additions to the standard pack age such as an external oil cooler etc as the center of balance will be affected yt 1 Y gs T f j he n IN 2 1 2 DIA HOLES IN VERTICAL STAND oe EJ INSERT HOOKS 2 2 m o FIG 2 ALTERNATIVE LIFTING METHOD The unit can be moved with a forklift by forking under the skid or it can be skidded into place with pinch bars by push ing against the skid NEVER MOVE THE UNIT BY PUSH ING OR FORKING AGAINST THE SEPARATOR SHELL OR ITS MOUNTING SUPPORTS
26. MAINTENANCE Page 45 570 101 IOM OUTPUT FUSE REPLACEMENT 1 Shut off control power 2 Remove the microprocessor console cover 3 Identify the faulty fuse 4 Use a voltmeter to verify that no voltage is present on either side of the fuse 5 Remove the faulty fuse using a fuse puller or screwdriver 6 Install a new plug type fuse PRESSURE TRANSDUCERS TESTING Pressure transducers are located below the microproces sor console Test Procedure 1 Shut down the compressor and allow pressures to equal ize PRESSURE TRANSDUCER CONVERSION DATA PROBE Low High Low High 0 2 3 4 5 6 E 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 4 4 4 AA E CE Below 0 PSIG measured inches of At zero psig S70 101 IOM 2 Isolate suction transducer 4 from the unit and open it to atmosphere using valves provided at the transducer manifold Close the applicable transducer isolation valve NOTE To change the discharge pressure transducer PE 3 it will be necessary to depressurize the entire compressor package Follow General Instructions For Replacing Compressor Unit Components p 36 before going to step 3 3 Measure the voltage of PE 4 on connector P4 terminals WHT and BLK on the SBC with a d
27. Moving 4 Suction Check Valve Bypass Valve 36 Skid 3 a aun 5 engl 36 Motor MOUNUNG Nen m 5 e S IMBRE TIMES 37 Compressor Motor Coupling Installation 5 Sirainer Oll Fett ces coro pite o e v nee tese 37 Coupling Alignment Procedure 6 Strainer Oil Pump Optional 37 Hot Alignment of Compressor Motor 8 Strainer Liquid Injection 37 Checking Motor Compressor Rotation 8 Coalescer Filter Element 38 Holding Charge and Storage 8 Changing mc 38 Compressor Qillu uyu tun 8 Recommended Maintenance Program 38 enema D 8 Vibration Analysis 39 eir umu amma ene eter a 8 Oil Quality and Analysis 39 Liquid Injection Oil Cooling 9 Motor B ari gS sucre omues ope qo 39 Dual Dip Tube Method 9 ODperaling Eogu cc ow 39 Level Control Method 9 Maintenance
28. Schedule 40 Water Cooled Oil Cooling 10 Troubleshooting Guide 41 Thermosyphon Oil Cooling 10 Abnormal Operation Analysis and Correction 41 Economizer High Stage 12 Troubleshooting The Microprocessor 42 MERERI 13 EPROM Memory Chip Replacement 45 Motor Starter Package 13 SBC Board 45 Current Transformers CT Ratios 14 Microprocessor Display Replacement 45 Minimum Burden Ratings 14 Output Fuse Replacement 45 Battery Backup uuu u q 14 Pressure Transducers Testing 45 Pressure Transducer Conversion Data 45 OPERATION Pressure Transducers Replacement 46 General Information 15 Volumizer Potentiometer Replace Adjust 47 Microprocessor Control
29. adjust slide valve travel time preventing ex cessive slide valve hunting NV2 should be adjusted to restrict oil flow to compressor port so that slide valve travel time from full load to full unload or vice versa is a minimum of 30 seconds NOTE A change in operating conditions may require readjustment of Slide Valve travel time NV VOLUMIZERSGII Vi CONTROL Solenoid valves 3 and 4 control the Vi Ratio Oil is internally ported to move the Movable Slide Stop NL SOL 3 TOP SOL 4 BOTTOM Energized Energized Energized De energized De energized De energized CAPACITY CONTROL VALVE MOUNTED ON BASE TO COMPRESSOR SUCTION COIL COIL OIL PRESSURE N S VLRTCONT RXB PLUS ROTARY SCREW COMPRESSOR UNITS OPERATION Page 31 570 101 IOM FUNCTIONAL CHECK OF THE COMPRESSOR VOLUME RATIO CONTROL Vi OPERATION 1 Remove the slide valve potentiometer cover located on the outlet end of the compressor and secured by 4 cap SCrews 2 Push the Slide Stop Manual 2 2 Vi key on the micro keypad 3 Push Manual Load on the Slide Valve Control and hold in the depressed position until the compressor is fully loaded 4 Remove the Capacity Position Potentiometer which is secured by 2 bolts This will expose the indicator rod which protrudes from the indicator rod guide 5 In the 2 2 Vi position the rod should extend from the guide the am
30. ainssald 9 T m oJnjeueduue 1 u B HO Iy gt UC 4 dv doiq einsseug jepnno a e1njeJeduue 1 u PEPPY IO ejduexe A oJnjeJeduue JUIOdJAS 041002 Ayoedeyn uiu sdoJp abeyes7 eas V d CTA ones euinjoA 9o UONISOd 9A EA pl lS dV sseJg 4 IO oJnjeJeduue 5 eJnje1eduue eDJeuosiq jen y eJnjeJeduje Buipuodseui05 oJnsseJg eDJeuosiq jeeuJedng uonong oJnjeJeduje uonong oJnssoeJg uonong das OPERATING LOG SHEET RXB PLUS ROTARY SCREW COMPRESSOR UNITS JossaJduJo duie 1ueuudinb3 JnoH ojeq uoneoo jun ON jeeus ON J9pJQO J24 YOSSSYdNOD 95 a Frick S70 101 IOM Page 66 RXB PLUS ROTARY SCREW COMPRESSOR UNITS Pd ir d Frick m Refrigeration Frick Printed in U S A amp 100 CV Avenue P O Box 997 Waynesboro Pennsylvania USA 17268 0997 Phone 717 762 2121 Fax 717 762 8624 Subject To Change Without Notice
31. automatic operation at two sepa rate suction conditions on a preset time schedule Having entered the desired Setback setpoint enter the start and stop time or times and select Active Yes or No NOTE To change the Setback setpoints refer to TO CHANGE THE ADJUSTABLE SETPOINTS RXB PLUS ROTARY SCREW COMPRESSOR UNITS OPERATION Page 21 570 101 IOM AUTO CYCLE DISPLAY AUTO CYCLE Compressor Start 20 0 g Compressor Stop 18 0 hg F1 To Exit Suct Press Min Cap Control 050 03 5 g Auto Cycle Active No The Auto Cycle display is accessed by pressing F4 The Auto Cycle display provides for independently adjustable setpoints to turn the compressor on and off in response to the suction pressure or as an adjustable setpoint to limit the minimum slide valve position NOTE To change the Auto Cycle setpoints refer to TO CHANGE THE ADJUSTABLE SETPOINTS SUCT PRESS Constantly monitors and displays the suc tion pressure in pounds per square inch gauge g or inches of mercury hg COMPRESSOR START Compressor Start up will bring the compressor back on line when the suction pressure rises to the displayed setpoint COMPRESSOR STOP Compressor Stop will shut down the unit if the suction pressure drops to or below the dis played setpoint limit NOTE This limit must be set higher than Low Suction Pressure Cutout and the Low Suction Pressure Alarm setpoints MIN CAP CONTROL Mini
32. board com puter microprocessor control system Care must be taken that the controls are not exposed to physical damage dur ing handling storage and installation The microprocessor enclosure cover must be kept tightly closed to prevent entry of moisture and foreign matter Customer control power connec A CAUTION tions are made at the BOTTOM of the microprocessor enclosure Consult local ordinances before installation Current transformer wiring should be kept separate Extreme care should be taken that metal filings or other foreign material is not left in the microprocessor enclosure Use seal tight conduit fittings to prevent moisture entry into the microprocessor enclosure This is the ONLY electri cal enclosure that should be opened during installation and it should be kept tightly closed whenever work is not being performed in it GROUND 3 PHASE LINE Uv dude 2 o Sg CIRCUIT BREAKER DISCONNECT e AES e COMPRESSOR COMPR e STARTER MOTOR 3 TR ATL SS AT YD OR PW CURRENT YD OR PW ONLY 4 TRANSFORMER m 2M OL VOLTAGE 4 Xo OIL MONITOR o X o PUMP PROTECTOR Sp MOTOR NOTE WHEN MOTOR VOLTAGE IS DIFFERENT FROM OIL PUMP MOTOR VOLTAGE SUPPLY CIRCUIT BREAKER DISCONNECT FOR SEPARATE FEED AN IN LIEU OF FUSES _ AD
33. bration is not required NOTE Refer to page 22 for description on microproces sor offset adjustment for temperature and or pressure RXB PLUS ROTARY SCREW COMPRESSOR UNITS MAINTENANCE Page 47 570 101 IOM BARE COMPRESSOR MOUNTING The following procedure is required only when a bare com pressor is replaced in the field 1 Thoroughly clean the compressor feet and mounting pads of burrs and other foreign matter to ensure firm seating of the compressor 2 Clean the discharge flange surfaces on the compressor and separator 3 Install a gasket on the compressor discharge connection of the separator 4 Set the compressor on its base and tighten the discharge flange bolts The feet of the compressor should lift off the mounting base If the compressor feet do not raise off the mounting base install a thicker discharge gasket and reinstall the discharge flange bolts Check the clear ance between the feet and the base with a feeler gauge Shim the compressor feet gauge reading plus 002 5 Tighten compressor hold down bolts 6 Complete compressor motor coupling alignment see IN STALLATION section 7 Complete tubing piping and wiring per the P amp and wir ing diagrams S70 101 IOM RXB PLUS ROTARY SCREW COMPRESSOR UNITS 48 MAINTENANCE Frick TROUBLESHOOTING THE RWB II PLUS COMPRESSOR SYMPTOM PROBABLE CAUSES and CORRECTIONS EXCESSIVE NOISE and VIBRATION Bearing damage or excessive wear
34. changed to 110 and the returned answer is A110 followed by a Carriage return line feed If the command sent was 01C0520002 the returned answer is BAD followed by the ID number and a carriage return line feed RETURN PRESSURES COMMAND 01PX Start command sequence Compressor ID code Return pressures command Return suction pressure PSIA Return discharge pressure g hg Return oil pressure 9 Return filter differential pressure Return all pressures VOH If the command was 01PS then the microprocessor would dump the suction pressure RETURNED ANSWER XXX 3 characters followed by a carriage return line feed If using the A command then the returned data would be XXXXXXXXXXXX 12 characters followed by a carriage return line feed Frick READ INPUT OUTPUT COMMAND 01X Start command sequence 01 Compressor ID Code X Read Input Output s command Returned Answer A1000001 1000000000100000001 Character Description Position Acknowledge of command sent Oil Level Input 1 Remote Run Input 2 Remote Load Input 3 Remote Unload Input 4 Compressor Aux Input 5 Oil Pump Aux 6 Aux 1 Input 7 Aux 2 Input 8 Compressor Run Output 1 Slide Valve Load Output 2 Slide Valve Unload Output 3 Slide Stop Increase Output 4 Slide Stop Decrease Output 5 Liquid Injection Output 6 High Vi Liquid Injection Output 7 Economizer Output 8 Alarm Output 9 Oil Heate
35. closed loop fluids be analyzed and maintained regularly and as necessary to prevent corrosion of heat exchanger surfaces The oxygen content of river water and some other cooling water sources will oxidize steel tubes and cause premature failure Careful attention to water treatment is essential to ensure adequate life of steel cooler tubes if cooling tower water is used The condition of heat exchanger tubes should be checked semiannually to prevent hazard OIL COOLER DATA TABLE WATER FLOW COOLER WATER CONN RANGE GPM 5 Foot Lengths 6 DIA 1 NPT 10 23 8 DIA 1 1 4 NPT 35 60 RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 10 INSTALLATION Frick NOTE The water regulating valve shipped with the unit will be sized to the specific flow for the unit THERMOSYPHON OIL COOLING OPTIONAL Thermosyphon oil cooling is an economical effective method for cooling oil on screw compressor units Thermosyphon cooling utilizes liquid refrigerant at condenser pressure and temperature which is partially vaporized at the condenser temperature in a shell and tube or plate type vessel cool ing the oil to within 159F of that temperature The vapor at condensing pressure is vented to the condenser inlet and reliquified This method is the most cost effective of all cur rently applied cooling systems since no compressor capac ity is lost or compressor power penalties incurred The va por from the cooler need only be co
36. compressor Consult Frick Com pany if additional information is required Display for illustrative purposes only Frick LEAD LAG OPTION continued TYPICAL LEAD LAG WIRING OPTIONAL WIRING FOR LEAD LAG SEQUENCING DE 9P DE 9P RX 4 GN E 4 SBC RX 5 AN bp 5 RX RS422 8 O RED g it 8422 1 1 TX A a OS s 28 UNIT B COM 3 Q WHT NOT USED BLK USE BELDEN 8777 OR EQUAL 3 TWISTED PAIRS COLOR CODING SHOWN IS BELDEN 8777 RS 422 WIRING SHALL BE SEPARATE FROM ALL OTHER WIRING CONNECTORS DE 9P MALE WITH DBCH 9 HOOD 2 THUS JUMPER PIN 1 TO6 AND 2 TO 7 ON BOTH CONNECTORS WIRED AT FRICK IF BOTH UNITS ARE ON THE SAME SKID NOTE WHEN USING THE RS422 PORTS FOR LEAD LAG THEY CANNOT BE USED FOR ANY OTHER COMMUNICATIONS HOW THE MICROPROCESSOR WORKS SUMMARY The Frick microprocessor has 4 major components and a variety of sensors The major components are the 5 single board computer two display screens and the key board The SBC can be considered the brain of the microproces sor control console The SBC contains the logic center which provides the rules by which the microprocessor will oper ate the integrated circuit chips which store the burned in memory of how the compressor unit is to behave an analog input to convert VDC from the vari
37. cover on the right side of the compressor facing shaft at the inlet end 1 Shut off control power 2 Remove the potentiometer cover and gasket 3 Remove the potentiometer and mounting bracket 4 Install new potentiometer and bracket GASKET gt N gt N SUPPORT ay SLIDE VALVE PUSHROD POTENTIOMETER POTENTIOMETER PUSHROD 103 2 F am Li RED WHT BLK POTENTIOMETER TERMINALS POT RXB 5 ADJUSTMENT must be made with the slide valve fully unloaded and the compressor running The Operating dis play at this time should indicate a slide valve position of 0 If the display is greater than 0 adjust potentiometer POT 4 on the SBC until 0 is indicated If 0 is not attainable get as close as possible and then proceed to the next step The adjustments of POT 4 and POT 8 are interactive and POT 3 may require adjustment to allow POT 4 to come into range Completely load the slide valve at 2 2 Vi The display at this time should indicate 100 If the display is less than 100 adjust potentiometer POT 3 on the SBC until 100 is indi cated Repeat this sequence until the slide valve indicates 0 fully unloaded and 100 fully loaded TEMPERATURE and or PRESSURE ADJUSTMENT All temperature and pressure sensors are factory set cali
38. is not found when the LED for Output 8 is on check the fuse FU8 NOTE The economizer output should only on when the slide valve is at or above the 90 position Output 9 controls the Alarm Circuit The Alarm should turn on only when there is a prealarm or shutdown If the Alarm does not sound when these conditions are found check for 120VAC across Wires 10 and 2 If 120VAC is not found check the fuse FU9 Inputs 2 through 4 can be used to operate the compressor from a remote location NOTE Check the Operating display to verify that the compressor and the Slide Valve are in the REMOTE MODE If 120VAC is found across Wires 21 and 2 22 and 2 and 23 and 2 and the input does not turn on consult Frick Company The current transducer is used to convert the AC motor amps to a DC voltage signal for the microprocessor If the FLA reading from the Operating display is incorrect consult Frick Co TEST 1 Shut down the compressor and allow pressures to equalize Discharge pressure and oil pressure should have the same reading TEST 2 If either oil pressure or discharge pressure read different pressures one or both transducers are at fault Valve off the suction transducer from the unit and open the vent valve on transducer manifold to atmosphere If the suction transducer reads atmospheric pressure then the suction transducer is correct NOTE A 1 tolerance is allowed for all transducers Verify that the AUTO key has b
39. key is pushed while A CAUTION the unit is in Recycle Delay the compressor will start at the end of the delay period OPERATING DISPLAY Page 2 V RATIO Volume Ratio is the ratio selected by the micro processor to provide the highest efficiency at any given suc tion and discharge pressure condition Immediately below this an information space has been provided to indicate whether V ratio is in the automatic AUTO or the manual MAN mode SV POS Slide valve position is displayed as a percentage This percentage reflects the mechanical position of the slide valve and does not reflect the percentage of full load opera tion Immediately below this information space has been provided to indicate whether SV Pos is in the automatic AUTO manual MAN or remote RMT mode The micro processor will control this function in the automatic mode To the right of the mode indicator two other messages may appear L Indicates Slide Valve loading U Indicates Slide Valve unloading PUMP Optional Pump displays the current status of the oil pump The display will read ON or OFF whenever the HAND OFF AUTO switch is selected to AUTO and the com pressor is running FLA Percent Full Load Amps displays the percentage of the drive motor full load amperage rating that the motor is currently using SEP Separator displays the oil separator temperature in degrees Fahrenheit HTR Heater displays the condition of the oil sepa
40. mounting and support of suction and discharge lines is also very important Rub ber or spring pipe supports may be required to avoid excit ing the building structure at any pipe supports close to the compressor package It is best to employ a vibration expert in the design of a proper mounting arrangement In any screw compressor installation suction and discharge lines should be supported in pipe hangers preferably within 2 ft of vertical pipe run so that the lines won t move if disconnected from the compressor See table for Allowable Flange Loads A licensed architect should be consulted to determine the proper foundation requirements for any large engine or tur bine drive RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 4 INSTALLATION EE gt Eee Frick ALLOWABLE FLANGE LOADS NOZ MOMENTS ft Ibf LOAD Ibf PS AXIAL VERT AXIAL VERT D Mee m PY 25 25 25 50 50 50 When applying screw compressors at high pressures the customer must be prepared for package vibration and noise higher than the values predicted for normal refrigeration duty Proper foundations and proper installation methods are vi tal and even then sound attenuation or noise curtains may be required to reduce noise to desired levels For more detailed information on Screw Compressor Foun dations please request Frick publication 570 210 IB SPREADER BAR 2 in PIPE x 6 ft MINIMUM LENGTH FIG 1 RECOMMENDED LIFTING METHOD
41. new board from its packing and place both on an antistatic sur face 3 Remove the program chip s from the defective board and install them in the replacement board Pay particular attention to the ori A CAUTION entation of the notch es on the end of the chip s Install the chip s on the replacement board in exactly the same position as they were on the defective board 4 IMPORTANT Before installing the new board determine if there are gray yellow wires from P15 see page 14 for lo cation on the old board If they are present the display is the old style and the new board can be installed without modification 5 If the gray yellow wires are not present on the old SBC the machine is equipped with a new style display Resistor R6 must be removed from the new board by cutting the wire leads on either side of the resistor 6 Then install the modified replacement board in the panel MICROPROCESSOR DISPLAY REPLACEMENT The procedure to replace the microprocessor display is out lined below 1 Shut off control power 2 Remove the defective display s 3 Install the new display s 4 If present remove the grey yellow wires from P15 on the SBC see page 14 for location to the display s as they are no longer needed 5 If resistor R6 is present on the SBC cut off the wire leads on both sides see page 14 for location and remove it This resistor is no longer needed RXB PLUS ROTARY SCREW COMPRESSOR UNITS
42. of the control system If the wire is loaded to its maxi mum capacity the voltage dips are much larger and the potential of a malfunction is very high If the wire is sized one size larger than required the voltage dips are smaller than in a fully loaded supply wire and the potential for mal function is much lower The NEC code book calls for spe cific wire sizes to be used based on current draw An ex ample of this would be to use 14 gauge wire for circuits up to 15 amp or 12 gauge wire for circuits of up to 20 amp Therefore when connecting the power feed circuit to an elec tronic industrial control use 12 gauge wire for a maximum current draw of 15 amp and 10 wire for a maximum current draw of 20 amp Use this rule of thumb to minimize voltage dips at the electronic control VOLTAGE SOURCE Selecting the voltage source is extremely important for proper operation of electronic equipment in an industrial en vironment Standard procedure for electronic instrumenta tion is to provide a clean separate source voltage in order to prevent EMI from other equipment in the plant from in terfering with the operation of the electronic equipment Con necting electronic equipment to a breaker panel also known as lighting panels and fuse panels subjects the electronic equipment to noise generated by other devices connected to the breaker panel This noise is known as electromag netic interference EMI EMI flows on the wires that are
43. single port application TABLE EVAPORATOR TEMPERATURE with SINGLE PORT LIQUID INJECTION MAXIMUM MINIMUM EVAPORATOR EVAP TEMP CONDENS TEMPERATURE FOR FOR ING LIQUID INJECTION SINGLE PORT TEMP USAGE LOW Vi Rc E ERE Dual Injection Kit will be shipped by Frick below these temperatures RXB PLUS ROTARY SCREW COMPRESSOR UNITS INSTALLATION Page 9 570 101 IOM Where low compression ratios low condensing pressures are anticipated thermosyphon or water cooled oil cooling should be used It is IMPERATIVE that an uninterrupted supply of high pressure liquid refrigerant be provided to the injection system at all times Two items of EXTREME IM PORTANCE are the design of the receiver liquid injection supply and the size of the liquid line It is recommended that the receiver be oversized sufficiently to retain a 5 minute supply of refrigerant for oil cooling The evaporator supply must be secondary to this consideration Two methods of accomplishing this are shown DUAL DIP TUBE METHOD The dual dip tube method uses two dip tubes in the receiv er The liquid injection tube is below the evaporator tube to ensure continued oil cooling when the receiver level is low K TO EVAPORATOR COMPRESSOR FROM CONDENSER Aces Um RECEIVER LOCATE TO PROVIDE 5 MIN LIQUID SUPPLY LIOC1 LEVEL CONTROL METHOD The level control method utilizes a float level control on the receiver to close a soleno
44. the nut securing the coalescer filter retainer 4 Remove the retainer coalescer filter element and 2 O rings Discard the filter element 5 Install the new coalescer filter element Seat the element in center of lo CAUTION cating tabs on separator bulkhead 6 Replace the coalescer filter retainer and nut DO NOT OVERTIGHTEN THE NUT Torque values for nut are 15 ft Ib for models 12 and 15 17 ft lb for 19 and 24 and 21 ft lb for 30 50 Install jam nut T Install a new head gasket and replace the coalescer head 8 Tighten the head bolts NOTE WHEN THE COMPRES SOR UNIT IS REPRESSURIZED RETIGHTENTHE HEAD BOLTS TO PREVENT THEM FROM LOOSENING 9 Refer to CHANGING OIL Steps 9 thru 14 CHANGING OIL DO NOT MIX OILS of different AWARNING brands manufacturers or types Mixing of oils may cause excessive oil foaming nuisance oil level cutouts oil pressure loss gas or oil leakage and catastrophic compressor failure Use of oils other than Frick Oil in A CAUTION Frick compressors must be ap RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 38 MAINTENANCE k Frick proved in writing by Frick engineering or warranty claim may be denied Shut down the unit when changing oil At the same time all oil filter cartridges must be changed and all oil strainer ele ments removed and cleaned The procedure is as follows 1 Push STOP key to shut down the unit 2 Open the disconnect switch for th
45. your elec tronic equipment RXB PLUS ROTARY SCREW COMPRESSOR UNITS PROPER INSTALLATION OF ELECTRONIC EQUIPMENT Page 63 570 101 PLANT SUPPLY TRANSFORMER a CEU 3 PHASE Da L BUS lt lt G ELECTRONIC ELECTRONIC ELECTRONIC CONTROL CONTROL CONTROL ART4T CORRECT PLANT SUPPLY TRANSFORMER 3 PHASE BUS GROUND BUS il ELECTRONIC ELECTRONIC ELECTRONIC CONTROL CONTROL CONTROL INCORRECT Figure 4 S70 101 IOM RXB PLUS ROTARY SCREW COMPRESSOR UNITS m Page 64 MAINTENANCE Frick RECOMMENDED SPARE PARTS Current Design ITEM DESCRIPTION MODELS NUMBER Fuse 10 AMP Shaft Seal Assy Kit Shaft Seal Assy Kit Oil Heater 500 Watt 110 Volt Oil Heater 500 Watt 240 Volt Oil Filter Cartridge Oil Filter Gasket End Cover Oil Filter Gasket Clamping Plate Cap Control Sol Valve amp Coil 120 110 Volt Coil Only for C C Sol Valve 120 110 Volt Cap Control Sol Valve amp Coil 240 220 Volt Coil Only for C C Sol Valve 240 220 Volt Slide Valve Potentiometer Slide Valve Potentiometer Bracket Vi Control Sol Valve Less Coil Coil Only for Vi Solenoid Microprocessor Cover and Keypad Gasket for 640D0012H01 Display Output Module Input Module SBC Board 2 PDT Relay IDEC Type Base for 333Q0000194 3 PDT Relay IDEC Type Base for 333Q0000206 Fuse 5 AMP Cable Assy 26 Conductor SBC to Display Cable Assy 12 Conductor SBC to Keypad Suppre
46. 1 Shut down the unit and open the disconnect switches for the compressor and if applicable the oil pump motor start ers Isolate and equalize unit to atmospheric pressure See General Instructions for Replacing Compressor Unit Com ponents 2 Close the inlet service valve 3 Open the drain valve located in the strainer cover and drain the oil into a container 4 Remove the capscrews securing the strainer cover strainer cover gasket and element Retain the gasket 5 Wash the element in solvent and blow it clean with air 6 Wipe the strainer body cavity clean with a lint free clean cloth 7 Replace the cleaned element and gasket then reattach the cover using the retained capscrews 8 Close the drain valve and open the strainer inlet service valve 9 Check for leakage 10 Open suction and discharge valves and readjust suc tion check valve bypass if required Close the disconnect switches for the compressor and if applicable the oil pump motor starters 11 Start the unit LIQUID INJECTION STRAINER To clean the liquid injection strainer the unit must be shut down The procedure is as follows 1 Shut down unit and open the disconnect switches for the compressor and if applicable oil pump motor starters 150 late and equalize unit to atmospheric pressure See Gen eral Instructions for Replacing Compressor Unit Compo nents 2 Close the liquid supply service valve located before the liquid soleno
47. 2 AWG FOR FEED ALL NEUTRALS ENTERING nom NEUTRAL THIS ENCLOSURE SHALL IF SEPARATE FEED FOR HEATER CIRCUIT IS DESIRED BE TIED TOGETHER AT REMOVE JUMPERS 1 1 amp 2 2 8 CONNECT 9 L SOURCE NOT IN THIS SEPARATE 120 VAC SOURCE TO 1A amp 2A ENCLOSURE WIRE 1 FU amp NUMBER 25 SOURCE 1F 1CR Ds HEATER GROUND BAR IN MICRO 1 1A gt s 26 2N 2 FU ICR SEPARATOR OIL HEATER S II Wo el EE 5 KW HTR S ADD 1A FU FOR 115V 1KW ALL HEATER WIRING 14 AWG ALL NEUTRAL EXP 2 amp 2 id 2 FU OIL PUMP WIRING TO BE WHITE ERGEN HAND AUTO EXCEPT WHERE NOTED Q 5 6 s SBC TERMINALS FOR DIGITAL I O dx A PROGRAMMABLE CONTROL 47 31 DATA CODE BIT 3 FU1 Gi PROGRAMMABLE CONTROL 32 DATA CODE BIT 2 FU14 gt PROGRAMMABLE CONTROL 33 DATA CODE BIT 1 FU13 o a PROGRAMMABLE CONTROL 84 DATA CODE BIT 0 FU12 40X12 e SPARE gt 185 ow 73 _ OIL Pu START RUN 35 Y 39 CR 63 FUI0 TO LN 30 OO 1 OIL HEATER 35 9 CR 3 4 FUS ALARM PRE amp CUTOUT 10 RELAY amp OR LAMP OPTIONAL FU8 oo 31 719 ECONOMIZER IF REQ D FU7 E oro HIVI LIQ INJ IF REQ D FU6 p qe LIQUID INJECTION IF REQ D FU5 E
48. 2 BLACK Mi nid w CHANNEL 12 0 5 AMP 5 SEE IOM MANUAL FOR WIRE SIZING CHANNEL 11 SLIDE VALVE CHANNEL 10 1 5 VDC ECON PRESS CHANNEL 9 1 5 VDC SUCT PRESS CHANNEL 8 1 5 VDC DISCH PRESS CHANNEL 7 1 5 VDC FILTER PRESS IF OPTIONAL OR REQ D CHANNEL 6 1 5 VDC OIL PRESS CHANNEL 5 SPARE TEMP REMOTE TEMPERATURE CAPACITY CONTROL OPTIONAL WIRING BY OTHERS SEE NOTE 2A CHANNEL 4 SEP TEMP CHANNEL 3 OIL TEMP CHANNEL 2 DISCH TEMP CHANNEL 1 SUCT TEMP RXBELD3 pa _________ Frick 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 RXB PLUS ROTARY SCREW COMPRESSOR UNITS 570 101 IOM MAINTENANCE Page 57 Revised 1 97 MICRO PANEL ASSEMBLY WIRING DIAGRAM 2 FRONT PANEL 1 11 DISPLAY 1 26 COND RIBBON CABLE 1 SEG NO CONNECTION ON 230 FOR GROUNDED CIRCUITS KEY 1 1 P10 PAD 12 COND RIBBON CABLE Bis 8 2 2 115 230 STUD S E STUD SI EE WIRES G GREEN SET SW1 TO CORRECT VOLTAGE REV D SBC ONLY WRAP WIRES THROUGH TOROID TWO 2 Se TIMES ALL INTHE SAME DIRECTION RING e 2 TEMPERATURE SEN
49. A PLATE S70 101 IOM FOUNDATION 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 of the unit minimum of 24 inches is recommended The first requirement of the compressor foundation is that it must be able to support the weight of the compressor pack age including coolers oil and refrigerant charge Screw compressors are capable of converting large quantities of shaft power into gas compression in a relatively small space and a mass is required to effectively dampen these rela tively high frequency vibrations Firmly anchoring the compressor package to a suitable foun dation by proper application of grout and elimination of pip ing stress imposed on the compressor is the best insurance for a trouble free installation Use only the certified general arrangement drawings from Frick to determine the mount ing foot locations and to allow for recommended clearances around the unit for ease of operation and servicing Foun dations must be in compliance with local building codes and materials should be of industrial quality The floor should be a minimum of 6 inches of reinforced crete and housekeeping pads are recommended Anchor bolts are required to firmly tie the unit to the floor Once the unit is rigged into place See HANDLING and MOVING the feet must then be shimmed in order to level the unit Th
50. ALVE 1 15 TONS R 717 7 WE SSS gt F m s Z SSS 555 ZZ 4 WN 22 S Sa pent wes sS W WT ts IIS CETT 2 a R 717 p NNNNNS RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 50 MAINTENANCE Frick JORDAN TEMPERATURE REGULATOR VALVE For low differential pressure applications TYPE H THERMAL EXPANSION VALVE 2 1 2 TO 16 TONS R 22 Cr A n c 55 N Va A IN 9 y N 2 0 d P N N Zh Frick TYPEMTHERMAL EXPANSION VALVE 12 TO 34 TONS R 22 ZZ NZ THU n ilii Sera N aoe gt a R 22 Sse TAY RXB PLUS ROTARY SCREW COMPRESSOR UNITS MAINTENANCE Page 51 570 101 R 22 TX VALVE SIZES TX VALVE MODE FPT CONNECTION 2 1 2 1 2 5 1 2 1 2 11 1 2 16 1 2 MVE 12 MVE 21 MVE 34 VVE 52 VVE 70 VVE 100 JORDAN TEMPERATURE REGULATOR VALVE To increase or decrease the discharge temperature oil tem perature adjust the knurled nut located on the actuator stem of the Jordan Temperature regulator valve The tempera ture is allowed to increase as the nut is turned higher on the stem and decreases as the nut is turned lower S70 101 IOM RXB PLUS ROTARY SCREW COMPRESSOR UNITS
51. All check points in the following list must be completed before placing the compressor unit in operation Only when the checklist is completed will the unit be ready for initial start up CHECKPOINT Ammonia Units Only refrigerant grade Ammonia as specified by International Institute of Ammonia Refrigeration 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 Introduce pressure to unit and check for leaks CAUTION Do NOT exceed 80 of relief valve and or 10096 of the vessel s design working pressure Charge unit with proper amount and grade of oil Oil level should be between the two sight glasses on the oil separator Evacuate unit and system to 29 88 Hg vacuum 1000 microns to ensure that the system is free of moisture and noncondensable gases Additional information regarding evacuation is detailed in the following publications AMMONIA International Institute Of Ammonia Refrigeration IIAR Bulletin 110 Section 5 4 HALOCARBONS Refrigeration Service Engineering Society RSES Service Application Manual Section 83 Forms 610 57 and 630 46 Confirm that all field wiring is complete With coupling center removed check for proper compressor motor rotation COMPRESSOR ROTATION IS CLOCKWISE WHEN FACING COMPRESSOR SHAFT Check for proper alignment OPEN compressor motor disconnect Replace coupling cen
52. CLOCKWISE WHEN FACING COMPRESSOR SHAFT see CHECKING MO TOR COMPRESSOR ROTATION page 8 After verifica tion install gear or disk drive spacer as applicable 15 Install the coupling guard before operating the compres sor When installing drive spacer make A CAUTION sure that hub spacing is within lim its shown on the Coupling Data Table applicable to the coupling being installed and that the clamping bolt s are properly torqued RXB PLUS ROTARY SCREW COMPRESSOR UNITS INSTALLATION Page 7 570 101 FIG 4 PARALLEL MISALIGNMENT PLAN AS VIEWED FROM ABOVE FIG 5 DIAL INDICATOR ATTACHED AT 9 O CLOCK PLAN AS VIEWED FROM ABOVE FIG 6 DIAL INDICATOR AT 3 O CLOCK S70 101 IOM HOT ALIGNMENT OF COMPRESSOR MOTOR Hot alignments can only be made after the unit has oper ated for several hours and all components are at operating temperatures Shut down the unit and quickly affix dial indicator to cou pling motor hub then take readings of both the face and rim of the compressor hub If these readings are within toler ance record reading attach coupling guard and restart unit However if the reading is not within limits compare the hot reading with the cold alignment and adjust for this differ ence i e
53. CV see LIQUID INJECTION ADJUSTMENT PROCEDURE The differential pressure control valve uses discharge gas to maintain downstream pressure The gas downstream of the differential pressure control valve is bled off to the compressor suction to ensure steady and con stant operation of the valve BOOSTER APPLICATION Discharge gas from the high stage compressor is required to assist the differential pres sure control valve PDCV in providing the temperature con trol valve TCV with a constant back pressure A solenoid valve SV6 is installed before the differential pres sure control valve PDCV to prevent migration of high pres sure gas during shut down LICO r gt lt lt _ lt S X X 77 X LIQUID gt pkey 4 REFRIGERANT SG FROM X RECEIVER ud Y v X 0 FIELD 1 X CONNECTION TO HIGH X PRESSURE REFRIGERANT AV GAS SUPPLY 11 TO PORT 4 X 40 PDQV G X lt _ lt RXBBSTAP Frick DUAL PORT LIQUID INJECTION The dual port liquid injection system is designed to obtain the most efficient compressor performance at high and low compression ratios by permitting injection of liquid refriger ant into one of two ports on the compressor The dual port system con
54. D TIMER FOR ACROSS Pr THE LINE STARTERS ONLY 120 VOLT N GRD S STARTING CURRENT VOLTAGE MONITOR 10 SEC SHUNT TIMER CONTACT 1M OL ON DELAY 18 V COMPRESSOR 2M STARTER 19 OR INTERPOSING 5 RELAY 1M AUX 20 2M OL OIL PUMP STARTER SUPP 2 e 0103 02 NOTE Customer ground required see Micro Panel As sembly Wiring Diagram MOTOR STARTER PACKAGE Motor starter and interlock wiring requirements are shown in the wiring diagram above All the equipment shown is supplied by the installer unless a starter package is pur chased from Frick Starter packages should consist of NOTE When compressor motor voltage is different from oil pump motor voltage supply a circuit breaker discon nect for separate feed in lieu of fuses RXB PLUS ROTARY SCREW COMPRESSOR UNITS INSTALLATION Page 13 570 101 IOM 1 The compressor motor starter of the specified HP and voltage for the starting method specified across the line autotransformer wye delta or solid state NOTE If starting methods other than across the line are desired a motor compressor torque analysis must be done to ensure that sufficient starting torque is avail able particularly in booster applications Contact FRICK Company if assistance is required 2 If specified the starter package can be supplied as a combinati
55. EDURE SEE MMIB NO 4 11 10 7 SEE 640D0024 FOR STANDARD CONTROL CENTER ASSEMBLY S70 101 IOM Page 56 01 02 03 04 05 06 07 08 09 10 11 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 RXB PLUS ROTARY SCREW COMPRESSOR UNITS MAINTENANCE eae k Ee Frick MICRO PANEL ASSEMBLY WIRING DIAGRAM C T MOUNTED IN STARTER OR MOTOR JUNCT BOX BY OTHERS R MOTOR 2 9 5 AMP 4 5 SECONDARY e ONE PHASE 3 OF MOTOR RED SLIDE VALVE al Wee TA m POSITION w POTENTIOMETER 4 BLACK li u Os mi CABLE 11 O O s on a RED EE 4 s WHITE BLACK Ss O E CABLE 9 DO NOT GROUND DRAIN AT PANELCABLE TYPICAL r RED amp Q PES neg WB H 8 BLACK M 17 d CABLE 48 RED FUSCE P u C PE 2 alh WHITE Nu sg BLACK i zm 5 7 i it PE 1 s WHITE 07 g BLACK M l CABLE 6 20 AWG TWISTED PAIR 2000 FT MAX DISTANCE 5 2 CABLE 5 saa BLACK M COLOR MAY VARY TYPICAL WHITE a 4 2 x CABLE 4 BLACK BLACK WHITE b CABLE DES 2 BLACK BLACK x WHITE Gs TE 2 2 CABLE 2 BLACK BLACK or 4 WHITE on TES
56. HAND OFF AUTO switch in the starter package as this would bypass the compressor safety devices S70 101 IOM CURRENT TRANSFORMER CT RATIOS The CT ratio for various motor sizes with a 5 amp second ary is given in the following table VOLTAGE 200 230 380 460 575 2300 MINIMUM BURDEN RATINGS The following table gives the minimum CT burden ratings This is a function of the distance between the motor starting package and the compressor unit RATING FRICK PANEL USING USING USING B 0 1 2 5 15 ft 25 ft 40 ft B 0 2 5 35 ft 55 ft 88 ft B 0 5 12 5 93 ft 148 ft 236 ft 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 2 Alarm Horn output 3 Control solenoid valve for the economizer option For customer control options consult FRICK Company NOTE The microprocessor will not operate without EPROM chips installed When EPROM chips are not in stalled the microprocessor display will typically indi cate two dark lines across both the upper and lower dis play screens RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 14 INSTALLATION s Frick BATTERY BACKUP The battery backup preven
57. IRING Y HIGH PRESSURE lt LIQUID US EVAPORATOR EC ECONOMIZER gt lt gt lt lt ECON2 COOLER FIG 2 DIRECT EXPANSION ECONOMIZER SYSTEM RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 12 INSTALLATION Eee Frick ticipated in the flash economizer vessel it may be neces sary to add an outlet pressure regulator to the flash vessel outlet to avoid overpressurizing the economizer port which could result in motor overload Example A system feeding liquid to the flash vessel in batches The recommended economizer systems are shown below Notice that in all systems there should be a strainer STR and a check valve VCK between the economizer vessel and the economizer port on the compressor The strainer prevents dirt from passing into the compressor and the check valve prevents oil from flowing from the compressor unit to the economizer vessel during shutdown Other than the isolation valve A CAUTION needed for strainer cleaning it is essential that the strainer be the last device in the economizer line before the compres sor Also piston type check valves are recommended for installation in the economizer line as opposed to disc type check valves The latter are more prone to gas pulsation induced failure The isolation and check val ves and strainer should be located as closely as pos sible to the compressor preferably within a few feet For refrigeration plants employing multiple compress
58. ITS Page 26 OPERATION Eee Frick cutout in the Freeze display Information regarding the cut out will also be retained by the Annunciator and the Shut down Record displays NOTE If the operator makes an error by attempting to start the compressor under conditions outside safe normal operating conditions the microprocessor will prevent start up and advise the operator of the fault MULTIPLE COMPRESSOR SEQUENCING FOR RXB COMPRESSOR UNITS WITH MICROPROCESSOR CONTROLS A The standard microprocessor panel includes 1 Remote Run Input 2 Remote Load Input 3 Remote Unload Input The remote run input is only recognized when the remote run mode has been selected by pressing the REMOTE START key on the front panel of the microprocessor The remote load and unload inputs can only be recognized when the REMOTE key in the slide valve column on the front panel of the microprocessor has been pressed B If master sequencing between multiple compressors in parallel on a common suction is desired This output data will permit the compressor microprocessor to be interfaced with a master sequence controller See electrical diagram for details C A master sequence controller must be installed to pro vide the signals to remote start and stop the compressors and remote load and unload the compressors based on the common suction pressure or other parameter and the com pressor status based on the optional microprocess
59. Ib to 25 Ib Cutout will occur after five minutes To allow operation at low differential pressures the micro will take the following steps A Force unload the compressor to 5096 and display an F Unload when the oil pressure is within 10 Ib of the main oil injection port pressure and the slide valve position is greater than 5096 B Prohibit the compressor from loading and display a Ld Inhib message when the differential is within 15 Ib of the main oil injection port pressure Oil Pressure Alarm and cutout Prelube and Cycling Oil Pump version when pump is not running Alarm will occur if oil pressure is 25 Ib below discharge pressure or within 10 lb of suction pressure for 30 seconds Cutout occurs if oil pressure is 30 Ib below discharge pressure or if oil pressure is within 7 lb of suction pressure for 10 seconds and alarm has already been set Full Lube and Cycling Oil Pump version when oil pump is running Alarm occurs if oil pressure is within 10 Ib of dis charge pressure for 30 seconds Cutout occurs when oil pressure is within 5 Ib of discharge pressure for 10 seconds and oil pressure alarm has been set Cycling Oil Pump Control The oil pump will cut off when differential pressure between suction and discharge pres sure is 55 lb or greater Upon pump termination the above cutout logic pump not running is utilized Pump cut in oc curs when the differential pressure between suction and dis charge is 45 lb or less Oil
60. L COOLER 1 AMOT VALVE REMOVE TEMP TO OIL ELEMENT BEFORE WELDING REINSTALL SEPARATOR ELEMENT W SENSING BULB IN A PORT 1 OIL FILTER FROM ONES i SEPARATOR 4 L FROM OIL WATER REGULATING VALVE C SEPARATOR B OIL IE RELIEF y d VALVE C RELIEF UN OPTIONAL RISE F TO OIL L VALVE Y AP SEPARATOR OPTIONAL T _ WCOC 3 jue TSOC I D RXBWCOC RXBTSOC ED Frick RXB PLUS ROTARY SCREW COMPRESSOR UNITS PROPER INSTALLATION OF ELECTRONIC EQUIPMENT Page 61 570 101 PROPER INSTALLATION OF ELECTRONIC EQUIPMENT IN AN INDUSTRIAL ENVIRONMENT In today s refrigeration plants electronic controls have found their way into almost every aspect of refrigeration control Electronic controls have brought to the industry more pre cise control improved energy savings and operator conve niences Electronic control devices have revolutionized the way refrigeration plants operate today The earlier relay systems were virtually immune to radio fre quency interference RFI electromagnetic interference EMI and ground loop currents Therefore installation and wiring were of little consequence and the wiring job con sisted of hooking up the point to point wiring and sizing the wire properly In an electronic system improper installation will cause problems that outweigh the benefits of electronic control Electronic equipment is susceptible to RFI EMI and gr
61. LACEMENT 1 Shut off control power 2 Close the applicable transducer isolation valve NOTE To change the discharge pressure transducers it will be necessary to depressurize the entire compressor pack age Follow General Instructions For Replacing Com pressor Unit Components p 36 before going to step 3 3 Open the microprocessor console door 4 Use the chart to identify transducer terminals of the SBC P amp I TRANSDUCER CONNECTION Oil Pressure PE 1 Discharge Pressure PE 3 Suction Pressure PE 4 5 Disconnect transducer leads by loosening the terminal screws for the transducer to be changed 6 Tape a 3 ft length of pull wire to the leads of the transdu cer to be removed 7 Pull the transducer leads through the conduit until pull wire extends out of the conduit hole in the transducer mani fold Separate the transducer leads from the pull wire 8 Unscrew the transducer using a wrench on the metal hex at the base of the transducer DO NOT ATTEMPT TO LOOSEN OR TIGHTEN TRANSDUCERS BY THEIR TOP CASING 9 Install new transducer and tape leads to the pull wire 10 Pull new transducer leads into the microprocessor con sole and reconnect them to the terminal strip 11 Close the microprocessor console door 12 Reopen the transducer isolation valve 13 Turn on control power Frick SLIDE VALVE POSITION POTENTIOMETER REPLACEMENT AND ADJUSTMENT The slide valve potentiometer is located under a
62. M CONDENSER I Oe OF Ge Ge OF OF Ge 06 0505050505 09 09 Ge 05 Os O O amp Og CO gy O 0 O amp O amp O amp O amp Oy O y O amp OQ amp Og Ou O a O 95 F 95 F 2 5 FT oo FT 120 140 F OIL OUT o 0 28 90 90 99 99 90 00 90 990 99 9 HOT OIL IN FROM SEPARATOR RXB PLUS ROTARY SCREW COMPRESSOR UNITS 670 101 Frick INSTALLATION Page 11 Current thermosyphon systems are using two pass oil cool TSOC ANDWCOC OPTIONAL OIL SIDE SAFETY RELIEF ers and flow rates based on 4 1 overfeed Compressor units which have valves in the oil piping to isolate the oil cooler from the oil separator for servicing The liquid vapor returned from the cooler is separated in the may have factory installed piping to relieve the shell side receiver The vapor is vented to the condenser inlet and need oil side safety valve directly into the oil separator as shown only be reliquified since it is still at condenser pressure in the P amp I diagrams on pages 58 through 60 INSTALLATION The shell and tube type thermosyphon oil This arrangement uses a special UV stamped safety valve cooler with oil side piping and a thermostatically controlled rated for liquid and vapor relief The safety valve is de
63. OMPRESSOR UNITS S70 101 IOM Frick MAINTENANCE Page 49 TROUBLESHOOTING THE OIL PUMP SYSTEM SYMPTOM PROBABLE CAUSES and CORRECTIONS PUMP WILL NOT PRODUCE ENOUGH OIL PRESSURE TO START COMPRESSOR OIL PRESSURE RAPIDLY DROPS OFF WHEN COMPRESSOR STARTS OIL PRESSURE FLUCTUATES NOISE and VIBRATION GREASE LEAKS FROM VENT PORT IN THE SIDE OF THE PUMP BODY MAIN FILTER PSID IS TOO HIGH Filter cartridge may be blocked Check PSID across filter Replace filter Strainer may be blocked Clean Oil pressure regulator set too low or stuck open Readjust or repair Low oil level Add oil Excessive refrigerant in oil Equalize separator to a lower pressure Oil pressure regulating valve improperly adjusted Readjust valve Check manual system Regulator defective Replace Excessive refrigerant in oil Check heaters Liquid injection overfeeding or refrigerant carryover Make necessary adjustments or corrections Dirty oil filter Replace Low oil level Add oil Pump strainer blocked Clean Liquid injection overfeeding Adjust liquid injection Pump worn out Repair or replace Normal leakage which will cease after initial operation Black oil leaking from this vent indicates oil seal wear or failure Replace seal Filters clogged with dirt Replace Oil is too cold Allow oil to warm up and check again Service valve on filter outlet is partially closed Open valve fully TROUBLESHOOTING THE LIQUID INJECTION OIL
64. OR SYSTEM Continued SYMPTOM PROBABLE CAUSES and CORRECTIONS SLIDE VALVE DOES NOT LOAD and or UNLOAD SLIDE STOP DOES NOT INCREASE and or DECREASE LIQUID INJECTION SOLENOID DOES NOT ENERGIZE LICO ONLY HI Vi LIQUID INJECTION PORT ECONOMIZER OPTIONAL SOLENOID DOES NOT ENERGIZE ALARM CIRCUIT DOES NOT ENERGIZE CONTROL PANEL DOES NOT RESPOND TO REMOTE CONTROL SIGNALS MOTOR LOAD CONTROL FORCED UNLOAD OCCURS AT HIGH MOTOR AMPS PRESSURES ON THE OPERATING DISPLAY DO NOT APPEAR CORRECT COMPRESSOR DOES NOT AUTOMATICALLY LOAD OR UNLOAD Verify that the Slide Valve is in the AUTO mode and that capacity control is calling for loading or unloading AUTO L or AUTO U will appear on the Operating display Output 2 controls the Slide Valve Load Solenoid If 120VAC is found across Wires 17 and 2 the Slide Valve Load Solenoid should be energized If not the solenoid is defective If 120VAC is not found when the LED for Output 2 is on check the fuse FU2 Output 3 controls the Slide Valve Unload Solenoid If 120VAC is found across Wires 16 and 2 the Slide Valve Unload Solenoid should be energized If not the solenoid is defective If 120VAC is not found across Wires 16 2 when the LED for Output is on check the fuse FU3 NOTE Verify that the proper setpoint has been programmed into C C Capacity Control on the Adjustable Setpoints display Output 4 controls the Slide Stop 3 5 Vi Solenoid If 120VAC is f
65. R UNITS INSTALLATION Page 5 570 101 IOM 1 Inspect the shaft of the motor and compressor to ensure that no nicks grease or foreign matter is present 2 Inspect the bores in the coupling hubs to make sure that they are free of burrs dirt and grit 3 Check that the keys fit the hubs and shafts properly CH COUPLING The T B Woods Elastomeric CH Coupling is used in most applications It consists of two drive hubs and a loose gear type Hytrel Drive Spacer The split hub is clamped to the shaft by tightening the clamp screws Torque is transmitted from the motor through the elastomeric gear which floats freely between the hubs Install as follows IT IS MANDATORY THAT THE COU AWARNING PLING CENTER BE REMOVED AND THE DIRECTION OF MOTOR ROTATION BE CONFIRMED BEFORE RUNNING THE COMPRESSOR Proper rotation of the compressor shaft is clockwise looking at the end of the compressor shaft FAILURE TO FOLLOW THIS STEP COULD RESULT IN BACKWARD COMPRESSOR ROTATION WHICH CAN CAUSE COMPRESSOR FAILURE OR EXPLOSION OF THE SUCTION HOUSING 1 Slide one hub onto each shaft as far as possible It may be necessary to use a screwdriver as a wedge in the slot to open the bore before the hubs will slide onto the shafts 2 Hold the elastomeric gear between the hubs and slide both hubs onto the gear to fully engage the mating teeth Make sure that the keys on the compressor and motor halves of the coupling are offset 1809 see FIG 3 Ce
66. REMOVE THE PIPE PLUG FROM THE CEN PORT OPPOSITE THE GREASE FITTING 360 390 DAYS 3120 HRS 130 DAYS 3120 HRS USING A LOW PRESSURE GREASE GUN 1800 400 440 270 DAYS 2160 HRS 90 DAYS 2160 HRS APPLY 2 OZS 60 GRAMS OF GREASE AT EACH FITTING DO NOT OVER GREASE WITH THE VENT PORTS OPEN OPERATE 0000 58001 210 DAYS 1680 HRS 70 DAYS 1680 HRS THE MOTOR FOR A MINIMUM OF 15 MINUTES AND UNTIL ANY GREASE FLOW 360 440 390 DAYS 3120 HRS 1200 130 DAYS 3120 HRS HAS CEASED AT THE VENTING PORTS REMOVE POWER 0000 58001 270 DAYS 2160 HRS 90 DAYS 2160 HRS REPLACE THE VENT PIPE PLUGS REPLACE ANY AND ALL GUARDS AND ENVIRONMENTAL EXTREME 1 3 OF THE ABOVE INTERVALS CHEVRON OIL CO SRI 2 EXXON CORP POLYREX SHELL OIL CO DOLIUM R LUBRICATION SCHEDULE FOR SEVERE SERVICE VIBRATION SHOCK AND OR LUBRICATION SCHEDULE FOR ROLLER BEARINGS 1 3 OF THE ABOVE INTERVALS THE FACTORY INSTALLED RECOMMENDED LUBRICANT IS LISTED ON THE MOTOR DATA PLATE THE FOLLOWING PRODUCTS ARE DEEMED SUITABLE LUBRICANTS UNDER NORMAL SERVICE CONDITIONS BUT MAY NOT BE CHEMICALLY COMPATIBLE OR INTERCHANGEABLE ONE TO THE OTHER OR CORRECT FOR ALL AMBIENT OR SERVICE CONDITIONS FOLLOW ALL MANUFACTURER S GUIDELINES WHEN INTRODUCING ALTERNATES WHEN DOUBT EXISTS PURGE THE BEARINGS AS DESCRIBED IN THE INSTRUCTION MANUAL EXXON CORP UNIREX 2 MOBIL OIL CO MOBILUX
67. RY SCREW COMPRESSOR UNITS Page 36 MAINTENANCE Eee Frick 3 Open suction discharge and liquid injection service valves and remove tags 4 Compressor unit is ready for prestart checks Refer to PRESTART CHECKLIST GENERAL INSTRUCTIONS FOR REPLACING COMPRESSOR UNIT COMPONENTS When replacing or repairing components which are exposed to refrigerant proceed as follows 1 Push STOP key to shutdown the unit 2 Open disconnect switches for the compressor motor starter and the oil pump motor starter if applicable 3 Close discharge service valve 4 SLOWLY vent the component to low side system pres sure using suction check valve bypass Then close suction service valve and suction bypass valve NOTE Recover or transfer all refrigerant vapor in accordance with local ordinances before opening to atmosphere The compo nent MUST be equalized to atmospheric pressure be fore opening Oil entrained refrigerant may va CAUTION porize causing a pressure in crease Repeat venting and recov ery procedure if necessary 5 Make replacement or repair 6 Isolate the low pressure transducer PE 4 to prevent dam age during pressurization and leak test T Pressurize the unit and leak test 8 Evacuate the unit to 29 88 Hg 1000 microns 9 Open suction and discharge service valves and the low pressure transducer Readjust suction bypass valve 10 Close disconnect switches for the compressor mo
68. S iil E UA Cay P 26 i M i 27 Und Cond Cond EOS 1 Vale MM P RM a L en he CN EUH E l SPARE ANALOG w GND iin mE SPARE DRAIN WIRES LUG SPARE 3 y 2FU PE CUSTOMER S _____ GND E GROUND WIRE LUG 40 TERMINALS aa o TODOOR amp STUD SCREEN 5 i TR ON FRONT PANEL PANEL 9 THIS STUD NOT REQ D STUD 55 4 3 2 2 2 1 IF GROUNDING WASHER amp STUD ON SIDE ARE USED vv GROUNDING WASHER COPPER CONDUCTORS ONLY T CUSTOMER S 120 CONNECTION INDICATES DEVICES SUPPLIED ONLY WHEN OPTIONAL OR REQUIRED RXBELD5 INDICATES SUPPLIED ONLY WHEN OIL PUMP IS REQUIRED Page 53 S70 101 IOM U5 U4 DIG I O EXPANSION PORT ON BATTERY MAINTENANCE OFF SBC WIRING DIAGRAM P 11 P10 BAT RXB PLUS ROTARY SCREW COMPRESSOR UNITS P15 POWER SUPPLY 115 ee 230 F1 F2 eA Le e lg VIVO Zeo 2 g viva
69. SKID REMOVAL If the unit is rigged into place the skid can be removed by taking off the nuts and bolts that are fastening the unit mount ing supports to the skid before lowering the unit onto the mounting surface If the unit is skidded into place remove the cross members from the skid and remove the nuts anchoring the unit to the skid Using a 5 ton jack under the separator raise the unit at the compressor end until it clears the two mounting bolts Spread the skid to clear the unit mounting support then lower the unit to the surface Repeat procedure on opposite end MOTOR MOUNTING The following procedure is required only when the motor is mounted at the job site 1 Thoroughly clean the motor feet and mounting pads of grease burrs and other foreign matter to ensure firm seat ing of the motor 2 Attach the motor to the base using the bolts and motor raising blocks if required Bolt snugly through the base 3 Weld the four kick bolts into place so that they are posi tioned to allow movement of the motor feet 4 Now that the motor has been set check that the shafts are properly spaced for the coupling being used Refer to the coupling data table for the applicable dimension COMPRESSOR MOTOR COUPLING INSTALLATION RXB PLUS units are arranged for direct motor drive and require a flexible drive coupling to connect the compressor to the motor Before installing perform the following RXB PLUS ROTARY SCREW COMPRESSO
70. SOR 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 SETPOINT RANGE 50 79 906 TEMP PROBE SIZE 188 DIA x 4 LONG 304 S S WITH 2 24 LEADS MOUNTING IN WELL IS DESIRABLE USE HEAT TRANSFER COMPOUND WIRE AS SHOWN IN SEPARATE CONDUIT FROM ALL OTHER WIRING USE BELDEN 8761 CABLE OR EQUAL TEMP PROBE FRICK P N 11100280982 WELL FOR ABOVE 3 4 WELL CONNECTION 1 2 FOR CONNECTION P N 990A0014H01 HEAT TRANSFER COMPOUND P N 11100831807 OPTIONAL WIRING FOR LEAD LAG SEQUENCING EH SBC 4 pal 686 RS422 Ho BLK 727 5422 PORT 1 PORT 1 UNIT A ig UNIT B 9 USE BELDEN 8777 OR EQUAL 3 TWISTED PAIRS COLOR CODING SHOWN IS BELDEN 8777 RS 422 WIRING SHALL BE SEPARATE FROM ALL OTHER WIRING WIRED AT FRICK IF BOTH UNITS ARE ON THE SAME SKID NOTE WHEN USING THE RS422 PORTS FOR LEAD LAG THEY CANNOT BE USED FOR ANY OTHER COMMUNICATIONS RXBELD4 S70 101 IOM Page 58 x MAINTENANCE RXB PLUS ROTARY SCREW COMPRESSOR UNITS SEIN k INN Frick P amp I DIAGRAM Models 12 15 amp 19 w Full Lube Oil Pump SUCTION GAS TO THE COMPR PAL PIC CREO PEE OPTIONAL CHECK VALVE P 2d
71. SUCT CUTOUT The Low Suction Pressure Cutout reported in pounds per square inch gauge g or inches of mercury hg will shut down the compressor if the suction pressure drops to this limit or lower for 90 seconds or longer LO SUCT ALARM The Low Suction Pressure Alarm re ported in pounds per square inch gauge g or inches of mercury hg will trigger a prealarm if the suction pressure drops to this limit or lower ID The ID number is a programmable identification code used in telecommunications to access a specific compressor DATE The Date displays the current date in the following format Month Day Year DAY Day will display the current day of the week TIME The Time displays the current time in the following format Hours Minutes Seconds The time is in 24 00 00 hour clock format BAUD Shows the baud rate of the RS422 communication port Both ports are configured as follows word 8 bit par ity none or even stop 1 bit The communications port is programmable from 300 to 19200 baud RECY DELAY The Recycle Delay displays the current recycle delay setpoint in minutes NOTE Consult the mo tor manufacturer for recommended setpoint S70 101 IOM SETPOINTS DISPLAY Page 1B Dead Band This is a plus or minus value above or below the setpoint at which the compressor will neither load nor unload A dead band of 1 is the default value It is ad justable between 5 Ib to 5 Ib in increme
72. SULT IN BACKWARD COMPRESSOR ROTATION WHICH CAN CAUSE COMPRESSOR FAILURE OR EXPLOSION OF THE SUCTION HOUSING COMPRESSOR LUBRICATION SYSTEM The RXB compressor is designed specifically for operation without an oil pump for high stage service Boosters and some low differential pressure applications will require the full lube pump option The lubrication system on an RXB screw compressor unit performs several functions 1 Lubricates the rotor contact area allowing the male rotor to drive the female rotor on a cushioning film of oil 2 Provides lubrication of the bearings and shaft seal RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 30 OPERATION Eee Frick 3 Serves to remove the heat of compression from the gas keeping discharge temperatures low and minimizing refriger ant or oil breakdown 4 Fills gas leakage paths between or around the rotors with oil thus greatly reducing gas leakage and maintaining good compressor performance even at high compression ratios 5 Provides oil pressure for development of balance load on the balance pistons to reduce bearing loading and increase bearing life FULL LUBE OIL SYSTEM RXB PLUS booster compressors and high stage compres sors that operate with very low differential pressures across the compressor suction and compressor discharge require a full time oil pump to produce the oil flow and pressures required Oil is pumped from the oil separator through the oil f
73. TER when all desired setpoint changes have been made SETBACK DISPLAY SETBACK DISPLAY Mon 04 09 90 01 00 51 Press Setpt 25 3g Temp Setpt 50 0F Mon Start Time Stop Time Active No F1 to Exit The Setback Display is accessed by pressing the F3 key Frick TEMPERATURE PRESSURE CONTROL PROGRAM OPTION continued PRESS SETPOINT The capacity control setpoint is used when in the Setback mode and Pressure is selected as the capacity control desired TEMP SETPOINT The capacity control setpoint is used when in the Setback mode and Temperature is selected as the capacity control desired NOTE To change the Setback setpoints refer to CHANGE THE ADJUSTABLE SETPOINTS ANALOG OFFSET DISPLAY ANALOG OFFSET Suc Disch Oil Sep Filt Spare Econ Temp 0 0 0 0 0 0 Pres 1 0 0 0 0 3 The Analog Offset Display is accessed by pressing key All analog values can be offset or 3 to 10 units depend ing on which value is being adjusted Use the STEP key to step to the desired setpoint Press the CHANGE key to change the value of the offset by 1 The actual analog value will be displayed on the top line of the display The Filt and Econ and channels are displayed but do not pertain to the standard program AUTO CYCLE PRESS CONTROL DISPLAY AUTO CYCLE Start 40 0g Timer 01 min C C Press Stop 25 00 Timer 01 min Min SV 50 Active No f
74. TION PROPER OPERATION REGULAR SYSTEMATIC MAINTENANCE To ensure correct installation and application the equipment must be properly selected and connected to a properly de signed and installed system The Engineering plans piping layouts etc must be detailed in accordance with the best practices and local codes such as those outlined in ASHRAE literature A refrigeration compressor is a VAPOR PUMP To be certain that it is not being subjected to liquid refrigerant carryover it is necessary that refrigerant controls are carefully selected and in good operating condition the piping is properly sized and traps if necessary are correctly arranged the suction line has an accumulator or slugging protection that load surges are known and provisions made for control operat ing cycles and defrosting periods are reasonable and that high side condensers are sized within system and compres sor design limits It is recommended that the entering vapor temperature to the compressor be superheated to 10 F above the refriger ant saturation temperature This ensures that all refrigerant at the compressor suction is in the vapor state DESIGN LIMITATIONS The compressor units are designed for operation within the pressure 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 agai
75. ULD BE INSERTED BETWEEN 5 amp 29 OR 30 PROGRAM AUX AS ABOVE SEE 1 PSH WIRING BELOW FOR EXAMPLE AUX 1 amp AUX 2 CAN BE PROGRAMMED TO ALARM OR SHUTDOWN NOR OPEN OR NOR CLOSED NOTE C A SURGE SUPPRESSOR OR MOV TO BE INSTALLED ACROSS ALL INDUCTIVE LOADS IN CONTROL CENTER SURGE SUPPRESSOR SUPPRESSOR SPECIFICATIONS RC NETWORK CONSISTING OF A 1 MFD CAPACITOR 600 VDC IN SERIES WITH A 47 OHM RESISTOR USE ELECTROCUBE RG2031 3 6 OR EQUAL 5 1 VARISTOR METAL OXIDE VARISTOR MOV SPECIFICATIONS GE V130LA10A OR EQUAL _ 1 PSHWIRING FOR GAUGEBOARD OPTION 1 PSH PROGRAM HPCO AUX 1 AS e O NOR CLOSED 5 30 SHUTDOWN oo oe COMPR MOTOR STARTER IF STARTER CONTAINS MULTIPLE CONTACTORS RELAYS amp TIMERS ADD SUPRESSORS OR VARISTORS AT EACH COIL SEE NOTE C OIL PUMP STARTER SUPRESSOR OR VARISTOR INSTALLED AT OIL PUMP STARTER COIL SEE NOTE C TERMINALS IN CONTROL CENTER NO THREE PHASE WIRING SHALL ENTER OR LEAVE MICRO PANEL NO SINGLE PHASE OVER 300 VOLTS SHALL ENTER OR LEAVE MICRO PANEL FOR PROPER INSTALLATION OF ELECTRONIC EQUIPMENT SEE FRICK PUBLICATION S90 400 SB SERVICE MANUAL ALL CONTROL CENTER WIRING TO BE 16 AWG STRANDED WIRE UNLESS SPECIFIED OTHERWISE FOR RXB PACKAGE MICROPROSSOR TEST PROCEDURE SEE MMIB NO 4 11 10 8 FOR INSTALLATION OF MICROPROCESSOR BOARD AND EPROMS SEE MMIB NO 4 11 10 11 FOR HIGH POT TEST PROC
76. Undefined OU POONDOOAWD 1 RXB PLUS ROTARY SCREW COMPRESSOR UNITS S70 101 IOM Frick OPERATION Page 27 MICROPROCESSOR OUTPUT DATA CODE enc ccu crecer NEUTRAL A 3 5 KOHM 10 watt resistor RES must yo So field installed shown below when a the 120 VAC outputs ofthe RXB PLUS are RECO ME A 5069 PES e aa driving 120 VAC solid state input devices eao i lt RES PROGRAMMABLE CONTROL such as programmable controllers x is prog e 5 MICROPROCESSOR TELECOMMUNICATION The Frick RXB PLUS Microprocessor comes with an on board telecommunication interface The telecommunication feature permits interfacing the microprocessor with a mo dem remote data communications terminal or master com puter via RS 422 protocol In the case of a modem tele phone lines are used for the actual transmission of data permitting communication from a remote location The components necessary to utilize the telecommunica tion feature will vary with the application Information concerning these items may be obtained from Frick Com pany Waynesboro Pa COMMUNICATIONS PROTOCOL SPECIFICATIONS All commands must be in ASCII CAPS to be recognized A compressor with an ID code of 00 is considered dis abled ID Codes from 01 thru 99 are valid and are recog nized by the microprocessor Th
77. W COMPRESSOR UNITS Page 8 INSTALLATION Eee Frick COMPRESSOR UNIT OIL DO NOT MIX OILS of different AWARNING brands manufacturers or types Mixing of oils may cause excessive oil foaming nuisance oil level cutouts oil pressure loss gas or oil leakage and catastrophic compressor failure Use of oils other than Frick Oil must A CAUTION be approved in writing by Frick en gineering or warranty claim may be denied Use of filter elements other than A CAUTION Frick must be approved in writing by Frick engineering or warranty claim may be denied The oil charge shipped with the unit is the best suited lubri cant for the conditions specified at the time of purchase If there is any doubt due to the refrigerant operating pres sures or temperatures refer to Frick Pub E160 802 SPC for guidance OIL CHARGE The normal charging level is midway in the top sight glass located midway along the oil separator shell Normal oper ating level is between the top sight glass and bottom sight glass The following table gives the approximate oil charge quantity TABLE BASIC OIL CHARGE Gal MODEL BASIC CHARGE GAL Add oil volume for external oil cooler according to cooler size selected 6 x 5 TSOC 4 gal 6 x 5 5 gal 8 x 5 TSOC 6 1 2 gal and 8 x 5 WCOC 8 gal Add oil by attaching the end of a suitable pressure type hose to the oil charging valve located on the top of the oil separa
78. ating display Page 1 amp 2 Setpoints display Page 1 amp 2 Setpoints display Page 3 amp 4 Shutdown record display Page 1 amp 2 Freeze display Page 1 amp 2 Autocycle display Security display Setback display Analog offset display ANN Annunciator display page NN gt X gt gt gt gt gt gt gt gt TIT lt X lt O NOTE NN parameter is used to access the annunciator display pages If the command was 01DA10 then the microprocessor would dump the annunciator display page number ten RETURN FULL LOAD AMPS COMMAND 01A Start command sequence 01 Compressor ID code A Return full load amps command If the command was 01A then the microprocessor would dump the full load amps value RETURNED ANSWER XXX 3 characters followed by a carriage return line feed RETURN TEMPERATURES COMMAND 01TX Start command sequence Compressor ID code Return temperature command Return suction temperature Return discharge temperature Return oil temperature Return separator temperature Return all temperatures as a string of data dos I H H H I gt 2000 If the command was 01TS then the microprocessor would dump the suction temperature RETURNED ANSWER XXXX 4 characters followed by a carriage return line feed if suction temperature is requested The first character is or followed by 3 digits XXX 3 characters fol
79. e unit NO Disconnect power from unit before performing any main tenance 3 Wear proper safety equipment when the compressor unit is opened to the atmosphere Ensure adequate ventilation Take necessary safety precautions required for the frigerant being used COMPRESSOR SHUTDOWN and START UP For seasonal or prolonged shutdown the following pro cedure should be used 1 Push STOP key to shutdown the unit 2 Open the disconnect switch for the compressor motor starter and oil pump motor starter if applicable 3 Turn off power 4 Close suction discharge suction check valve bypass and liquid injection service valves Attach CLOSED TAGS 5 Shut off cooling water supply valve to the oil cooler if applicable Attach CLOSED 6 Protect the oil cooler from ambient temperatures below freezing or remove the water heads NOTE The unit should be inspected weekly during shut down Check for leaks or abnormal pressure Manually rotate the compressor Consult motor manufacturer for recommendations To start up after a seasonal or prolonged shutdown the following procedure should be used 1 Perform routine maintenance Change oil and replace fil ters Check strainers 2 Any water necessary for the operation of the system that may have been drained or shut off should be restored or turned on If the oil cooler heads were removed reinstall and remove tags RXB PLUS ROTA
80. e compressor motor starter and if applicable oil pump motor starter 3 Close the discharge and liquid injection if applicable service valves 4 SLOWLY vent the separator to low side system pressure using the suction check valve bypass Close suction valve and suction check valve bypass NOTE Recover or trans fer all refrigerant vapor in accordance with local ordi nances before opening to atmosphere The separator MUST be equalized to atmospheric pressure Oil entrained refrigerant may va A CAUTION porize causing a separator pres sure increase Repeat venting and recovery procedure if necessary 5 Open the drain valve s located on the underside of the separator and drain the oil 6 Drain the oil filter strainers and oil cooler if applicable 7 Remove and install new oil filter cartridge s Inspect check valve in the bottom of the filter housing to ensure that the parts are in good condition 8 Remove clean and reinstall strainer elements in strain ers 9 Evacuate the unit to 29 88 Hg 1000 microns 10 Open the suction service valve and pressurize the unit to system suction pressure Close the suction valve and leak test 11 Add oil by attaching suitable pressure type hose to the oil charging valve located on top of the separator Using a pressure type oil pump and recommended Frick oil open the charging valve and fill separator until oil level is midway in the top sight glass The following table
81. e following is a complete list of available command types COMMAND CODE and DESCRIPTION Returns compressor status information Compressor start command Compressor stop command Compressor capacity control command Compressor display screens command Return Pressures information Return Temperatures information Return full load amps information Enter change setpoints mode R S V p P Te A C The following is a detailed description of each command RETURN COMPRESSOR STATUS INFORMATION 011 Start of command sequence 01 Compressor ID code Return Status information command RETURNED ANSWER ie 090RRRN340 Character Description Positionof returned data 1 2 3 Capacity control position 4 Remote Auto Manual Cap control 5 Delay recycle Running 6 Rem Man Off Auto Compressor mode 7 Cutout Alarm Normal 8 9 10 Suction in PSIA Carriage return line feed COMPRESSOR START COMMAND 01901 Start command sequence Compressor ID code Start compressor command ID code repeated for verification NOTE The compressor must be in the remote start mode for this command to be executed Returned answer 01 Character Description Position of returned data Acknowledgement of command sent 2 3 ID code of compressor Carriage return line feed COMPRESSOR STOP COMMAND 01501 Start command sequence Compressor ID code Stop compressor command ID code repeated for verif
82. e shims should be placed to position the feet roughly one inch above the house keeping pad to allow room for grouting An expansion type epoxy grout must be worked under all areas of the base with no voids and be allowed to settle with a slight outward slope so oil and water can run off of the base When installing on a steel base the following guidelines should be implemented to properly design the system base 1 Use I beams in the skid where the screw compressor will be attached to the system base They should run parallel to the package feet and support the feet for their full length 2 The compressor unit feet should be continuously welded to the system base at all points of contact or bolted 3 The compressor unit should not be mounted on vibration isolators in order to hold down package vibration levels 4 The customer s foundation for the system base should fully support the system base under all areas but most certainly under the that support the compressor package When installing on the upper floors of buildings extra pre cautions should be taken to prevent normal package vibra tion from being transferred to the building structure It may be necessary to use rubber or spring isolators or a combi nation of both to prevent the transmission of compressor vibration directly to the structure However this may increase package vibration levels because the compressor is not in contact with any damping mass The
83. ed in RAM random access memory and are easily changed in the field Adjustable Setpoints are lost if A CAUTION power is interrupted and the bat tery is not fully charged To facili tate reentry we suggest that a list of Adjustable Setpoints be affixed to one end of the microprocessor cabinet for reference NOTE The following procedure also applies to the chang ing of the Security Setback and Auto Cycle display setpoints 1 Press the CHANGE key to rotate the display to the Ad justable Setpoints display 2 Press the STEP key to move or step a set of flashing brackets through the various setpoints A setpoint is selected for change or update when it is enclosed by the flashing brackets NOTE The DAY indicator itself will flash when selected for change or update 3 Having selected the setpoint to be changed the NU MERIC KEYPAD may be used to enter the new setpoint NOTE All digits must be entered including zeros For example 01 0 NOTE The DAY AUX 1 and AUX 2 setpoints once selected are changed or updated by pressing the CHANGE key NOTE Certain setpoints may be reported in either pounds per square inch gauge g or inches of mercury hg To toggle between g and hg having selected the setpoint press the key to toggle between g and hg 4 In the event that an incorrect setpoint is keyed in com pletely or partially press the CLEAR key to restore the original setpoint Pressi
84. een pressed and AUTO appears under SV Pos on the Operating display 4 If the problem persists see the Troubleshooting section SLIDE VALVE DOES NOT LOAD and or UNLOAD S70 101 IOM Page 44 RXB PLUS ROTARY SCREW COMPRESSOR UNITS MAINTENANCE Frick TROUBLESHOOTING FRICK SBC MICROPROCESSOR SYSTEM Continued SYMPTOM PROBABLE CAUSES and CORRECTIONS DISPLAY SCREENS DISPLAY SCRAMBLED PATTERN OR LIST ALPHABET OIL PUMP DOES NOT START Optional OIL PUMP IS RUNNING BUT COMPRESSOR DOES NOT START Optional A loose or improper connection between the displays and the SBC is indicated Remove fuse 2FU 10 amp for 15 seconds then restore to reset the displays Verify that the Oil Pump HAND OFF AUTO switch 155 is in the AUTO position and that the Emergency Stop Button is not depressed Output 11 controls the Oil Pump Starter Relay 3CR when in the AUTO mode If HAND is selected on 155 Output 11 will not have any effect on the operation of the oil pump starter If AUTO has been selected and the oil pump does not start check for 120VAC between Wires 39 and 2 If 120VAC is not found when the LED for Output 11 is on check the fuse FU11 If the problem persists check the control relay The Oil Pump Starter Auxiliary Contact switches voltage to Input 6 Wires 28 and 2 when the auxiliary contacts are closed and the AUTO mode is selected on 1SS If the Input does not turn on and voltage is present at Input 6 consul
85. ever the CC Temperature rises to or above the START setpoint and will reset if the CC Temperature drops below the START setpoint STOP The CC Temperature must be less than or equal to the STOP setpoint in order to stop the compressor This setpoint works in conjunction with the setpoint lo cated to the right of it on the display Stop TIMER The stop TIMER is a time delay used to stop the compressor The timer only accumulates time when ever the CC Temperature drops to or below the STOP setpoint and will reset if the CC Temperature rises above the STOP setpoint MIN SV Minimum Slide Valve Position shown as a per centage will limit the slide valve position to the displayed setpoint ACTIVE It indicates whether Auto Cycle is active or not Press the CHANGE key while at this setpoint to change the status Upon deactivation the compressor will return to the previous mode of operation TELECOMMUNICATIONS COMMANDS ADDED OR CHANGED Command 01DS will send the Adjustable Setpoints pages 1 and 2 01D3 will send the Adjustable Setpoint page 3 01DC will send both Auto Cycle Displays 01D will send the Analog Offset Display Display for illustrative purposes only S70 101 IOM LEAD LAG OPTION The lead lag compressor sequencing option provides the controls for operating two RXB compressors in one system AUTO CYCLE DISPLAY AUTO CYCLE Start 40 0g Timer 01 min
86. f the bottom display see page 14 for description of battery backup The microprocessor hardware contains an output watch dog circuit If the microprocessor should fail this circuit will disable turn off all outputs S70 101 IOM KEYS AND KEY FUNCTIONS NOTE The microprocessor will automatically return to the main operating display after 60 seconds of keybo ard nonactivity The CHANGE key rotates the dual display screen through six display modes The CHANGE key is also used to change the status of various setpoints The STEP key steps or moves a set of flashing brackets through the variable setpoints on the Adjustable setpoints display the Auto cycle display the Security display and the Setback display The setpoint enclosed within the flashing brackets may be changed or updated The STEP key is also used when the Annunciator display is selected to step through the annunciator s four information displays NOTE The key is used to step or move the flashing brackets described above backwards The ENTER key is used to enter new setpoint limits The CLEAR key will reset an alarm or cutout indication on the annunciator screen and will clear the microprocessor to allow continued operation or restarting if all conditions have returned to normal and no other control lockouts are in force The NUMERIC KEYPAD is used to introduce new setpoint limits The key is used to toggle between pounds per square
87. gives approximate oil charge quantities TABLE BASIC OIL CHARGE RXB MODEL BASIC CHARGE Gal 10 Add oil volume for external oil cooler according to cooler size selected 6 x 5 TSOC 4 gal 6 x 5WCOC 5 gal 8 x 5 TSOC 6 1 2 gal and 8 x 5 WCOC 8 gal 12 Open the suction discharge and liquid injection service valves Readjust suction check valve bypass 13 Close the disconnect switch for the compressor motor starter and if applicable oil pump motor starter 14 Start the unit Frick RECOMMENDED MAINTENANCE PROGRAM In order to obtain maximum compressor unit performance and ensure reliable operation a regular maintenance pro gram should be followed The compressor unit should be checked daily for leaks ab normal vibration noise and proper operation A daily log should also be maintained There should be a continued monitoring of oil quality and oil analysis testing In addition an analysis of the unit s vibration should be made periodi cally VIBRATION ANALYSIS Periodic vibration analysis can be useful in detecting bear ing wear and other mechanical failures If vibration analysis is used as a part of your preventive maintenance program take the following guidelines into consideration 1 Always take the vibration reading from exactly the same places and at exactly the same percentage of load 2 Use vibration readings taken from the new unit at start up as the base line reference
88. h high pressure and low pressure applications The compres sor incorporates the following features 1 High capacity roller bearings to carry radial loads at both the inlet and outlet ends of the compressor 2 Heavy duty four point angular contact ball bearings to carry axial loads are mounted at the discharge end of com pressor 3 Moveable slide valve to provide infinite step capacity con trol from 100 to 25 of full load 4 VOLUMIZER adjusts to the most efficient of three vol ume ratios 2 2 3 5 or 5 0 depending upon system require ments 5 A hydraulic unloader cylinder to operate the slide stop and slide valve 6 Compressor housing suitable for 350 PSI pressure Dual compressor casing design for very low airborne noise trans mission T Most bearing and control oil vented to closed thread in the compressor instead of suction port to avoid performance penalties from superheating suction gas 8 Shaft seal design 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 ra tios IT IS MANDATORY THAT THE COU AWARNING PLING CENTER BE REMOVED AND THE DIRECTION OF MOTOR ROTATION BE CONFIRMED BEFORE RUNNING THE COMPRESSOR Proper rotation of the compressor shaft is clockwise looking at the end of the compressor shaft FAILURE TO FOLLOW THIS STEP COULD RE
89. he Freeze display will retain the information generated by a cutout until a new cutout occurs or power is removed from the micro processor Do not confuse the Freeze display A CAUTION with the Operating display In or der to avoid confusion remember that the displayed information on the Operating display is constantly being updated and changed The Freeze display is fixed and FREEZE DISPLAY appears in the upper left hand corner of the display NOTE The Freeze display will appear as a blank screen when power is initially furnished to the unit and it will return to a blank screen anytime power is removed from the microprocessor SECURITY DISPLAY SECURITY DISPLAY Press F2 To Exit Setpoints Access Enabled Keyboard Enter Access Code Display for illustrative purposes only Frick The F2 function key will call up the Security display The Security display allows the operator to either enable or dis able the microprocessors keyboard and thereby prevent unauthorized tampering with the various adjustable setpoints When enabled the microprocessor keyboard is fully opera tive and the security lockout is not in effect When disabled the keyboard is rendered partially nonfunctional All displays will still be accessible through the keyboard If any attempt is made to enter new adjustable setpoints however the mi croprocessor will default to the Security display TO ENABLE THE KEYBOARD pre
90. hen the unit is at operating tempera ture After final HOT alignment has been made and found to be satisfactory 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 Use dial indicators to measure the angular and parallel shaft misalignment Coupling alignment is attained by alternately measuring angular and parallel misalignment and reposi tioning the motor until the misalignment is within specified tolerances The following procedure is recommended MISALIGNMENT MUST NOT EX CAUTION CEED FOR ALL CH COU PLINGS ANGULAR ALIGNMENT 1 To check angular alignment as shown in Fig 1 attach dial indicator rigidly to the motor hub Move indicator stem so it is in contact with the outside face of compressor hub as shown in Fig 2 2 Rotate both coupling hubs several revolutions until they seek their normal axial positions Check the dial indicator to be sure that the indicator stem is slightly loaded so as to allow movement in both directions 3 Set the dial indicator at zero when viewed at the 12 o clock position as shown in Fig 2 4 Rotate both coupling hubs together 180 6 o clock posi tion as shown in Fig 3 At this position the dial indicator will show TOTAL angular misalignment NOTE The use of a mirror is helpful in read
91. ication NOTE The compressor must be in the remote start mode for this command to be executed RETURNED ANSWER A01 Character Description Position of returned data Acknowledgement of command sent 2 3 ID code of compressor Carriage return line feed COMPRESSOR SLIDE VALVE 01VLXX CONTROL COMMANDS 01VUXX 01VS Start command sequence Compressor ID code Compressor control command Load slide valve command Unload slide valve command XX 00 Turns selected output off XX 01 to 15 Turns selected output on for XX seconds XX 99 Turns selected output on Return slide valve position value If the command was 01VLO00 then the load slide valve output on compressor 1 would be turned off If the command was 01VLO5 then the load slide valve output on compres sor 1 would be turned on for 5 seconds and would then automatically turn off NOTE the slide valve must be in the remote mode for this command to be executed RETURNED ANSWER for L or U commands 01 Character Description Position of returned data 1 Acknowledgement of command sent 2 3 ID code of compressor Carriage return line feed RETURNED ANSWER for 5 command ie 090 1 2 3 Slide valve position S70 101 IOM RXB PLUS ROTARY SCREW COMPRESSOR UNITS SEINEN X Frick Page 28 OPERATION COMPRESSOR DISPLAY SCREENS COMMAND 01DXNN Start command sequence 01 Compressor ID code D Compressor control command Oper
92. id 3 Immediately screw in the manual solenoid valve stem to relieve liquid refrigerant pressure trapped between the solenoid and the service valve S70 101 IOM 4 Close the service valve located between the compressor and the liquid injection thermal expansion valve 5 Carefully loosen the capscrews securing the strainer cover to the strainer Allow pressure to relieve slowly 6 When all entrapped refrigerant has been relieved care fully remove the loosened capscrews as liquid refrigerant is sometimes caught in the strainer strainer cover and strainer basket 7 Wash the strainer basket and cover in solvent and blow them clean with air 8 Reassemble the strainer 9 Open the service valve between the compressor and the liquid injection thermal expansion valve and check for leakage 10 Screw out the manual solenoid valve stem 11 Carefully open the liquid supply service valve 12 Leak test 13 Open suction and discharge valves and readjust suction check valve bypass if required Close the disconnect switches for the compressor and if applicable oil pump motor starters 14 Start the unit COALESCER FILTER ELEMENT When changing the coalescer filter element it is recom mended that the oil and oil filter s be changed Applicable strainer elements should be removed and cleaned 1 Refer to CHANGING OIL Steps 1 thru 8 2 Remove the coalescer head and gasket Discard the gasket 3 Remove and retain
93. id injection will overfeed and oil temperature will drop In solving the wrong problem a new problem was created The following list of abnormal system conditions can cause abnormal operation of the RXB compressor unit 1 Insufficient or excessive refrigeration load 2 Excessively high suction pressure RXB PLUS ROTARY SCREW COMPRESSOR UNITS MAINTENANCE Page 41 570 101 IOM 3 Excessively high suction superheat 4 Excessively high discharge pressure 5 Inadequate refrigerant charge or low receiver level 6 Excessively high or low temperature coolant to the oil cooler T Liquid return from the system carryover 8 Refrigerant underfeed or overfeed to the evaporators 9 Blocked tubes in the water cooled oil cooler from high mineral content of the water 10 Insufficient evaporator or condenser sizing 11 Incorrect refrigerant line sizing 12 Improper system piping 13 Problems in electrical service to the compressor unit 14 Air and moisture present in the system Make a list of all deviations from normal plant operation and normal compressor unit operation Delete any items which do not relate to the symptom and separately list those items that might relate to the symptom Use the list as a guide to further investigate the problem The second step in problem solving is to decide which items on the list are possible causes and which items are addi tional symptoms High discharge temperature and high oil tem
94. id valve feeding the evaporator when the liquid falls below that amount necessary for 5 min utes of liquid injection oil cooling TO EVAPORATOR FROM CONDENSER KING VALVE RECEIVER LOW LEVEL FLOAT SWITCH LOCATE TO PROVIDE 5 MIN LIQUID SUPPLY N yp COMPRESSOR LIOC2 OIL COOLING SYSTEM S70 101 IOM Liquid line sizes and the additional receiver volume quan tity of refrigerant required for 5 minutes of liquid injection oil cooling are given in the following table RXB VOLUME MODEL PIPE TUBING CU FT SCH 80 OD 12 15 100 ft liquid line For longer runs increase line size cordingly WATER COOLED OIL COOLING OPTIONAL The shell and tube type water cooled oil cooler is mounted on the unit complete with all oil piping The customer must supply adequate water connections and install the two way water regulating valve It is recommended that local codes permitting the water regulator be installed on the water outlet connection Insert the water regulator valve bulb and well in the chamber provided on the oil outlet connection Deter mine the size of the water cooled oil cooler supplied with the unit then refer to table for the water connection size and water flow range GPM The water supply must be sufficient to meet the required flow It is imperative that the condition of cooling water and
95. igital voltmeter 4 The voltage reading should be 1 48 VDC to 1 72 VDC at standard atmospheric pressure 14 7 PSIA or 0 PSIG When checking transducers at higher elevations an allowance in the readings must be made by subtracting approximately 0 02 VDC per 1000 feet of elevation above sea level There fore if PE 4 is measured at 5000 feet elevation under rela tively normal weather conditions the output voltage should differ by 0 10 VDC to read between 1 38 VDC and 1 62 VDC 5 Subtract 1 from the voltage 6 Multiply by 25 T This result is the absolute suction pressure PSIA The Operating display will indicate PSIG 14 7 PSIA 0 0 PSIG 8 Measure the voltage of PE 1 on connector P4 terminals WHT and BLK on the SBC 9 The voltage reading should be between 1 1 VDC and 1 29 VDC at standard atmospheric pressure PE 1 and PE 3 have a span of 300 PSI as compared to PE 4 with a span of 100 PSI Therefore atmospheric pressure changes have a lesser effect which is 0 0067 VDC per 1000 feet of elevation and 0 00067 VDC per 0 1 inch Hg barometric deviation 10 Measure the voltage of PE 3 on connector P4 termi nals WHT and BLK on the SBC 11 Measure the voltage of PE 1 on connector P4 termi nals WHT and BLK on the SBC 12 These two voltages should be within 04 VDC of one another 13 Test complete RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 46 MAINTENANCE Eee Frick PRESSURE TRANSDUCERS REP
96. il cooler requires a refrigerant side drain valve to be provided and installed by the customer 3 A safety valve should be installed if refrigerant isolation valves are used for the oil cooler The component and piping arrangement shown below is in tended only to illustrate the operating principles of thermosy phon oil cooling Other component layouts may be better suited to a specific installation Refer to publication E70 900E for ad ditional information on Thermosyphon Oil Cooling SYSTEM CONDENSER lt VAPOR 2 2 SN Wan STATIC HEAD SAFETY Fi TO OVERCOME lt 3 5 CONS 7 THERMOSYPHON PRESSURE DROP A K BEGEIUER LIQUID LIQUID OVERFLOW OIL TEMP EE DRAIN TO RECEIVER CONTROL VALVE 8 Ft Mn Y E CooL oLour gt Y X TO SYSTEM Y THERMOSYPHON EVAPORATOR OIL COOLER gt X OIL IN Refrigerant side drain valve RECEIVER required for plate type Mounted below Thermosyphon TSOCA thermosyphon oil coolers receiver level 1 The thermosyphon oil cooler is supplied with the oil side piped to the compressor unit and stub ends supplied on the refriger ant side 2 A three way oil temperature control valve is required where condensing temperature is expected to go below 65 F 3 A refrigerant
97. il return separation system or compressor operation has developed Refer to Maintenance for information on how to correct the problem Frick COMPRESSOR HYDRAULIC SYSTEM The compressor hydraulic system moves the movable slide valve MSV to load and unload the compressor It also moves the movable slide stop MSS to increase or decrease the compressor s volume ratio Vi CAPACITY CONTROL COMPRESSOR LOADING If the capacity control valve is mounted on the base the compressor loads when MSV so lenoid coil SV1 is energized If the capacity control valve is mounted on the compressor the compressor loads when MSV solenoid coil SV2 is energized Oil flows from the sole noid valve through the needle valve NV2 to compressor port 2 where it enters the load side of the slide valve piston This equalizes the force on the slide valve piston and dis charge pressure on the slide valve area loads the compressor COMPRESSOR UNLOADING If the capacity control valve is mounted on the base the compressor unloads when MSV solenoid SV2 is energized If the capacity control valve is mounted on the compressor the compressor unloads when MSV solenoid coil SV2 is energized Oil is allowed to flow from compressor port 2 through the needle valve to the MSV solenoid This allows discharge pressure on the slide valve piston to unload the slide valve as the piston moves outward ADJUSTMENT Capacity Control A needle valve NV2 is provided to
98. ilter to the main oil injection feed and the compressor An oil pressure regulating valve downstream of the pump is used to regulate oil pressure at the compressor by returning excess oil to the separator Oil pressure on RXB PLUS compressors with full time oil pumps should be adjusted to provide 20 25 PSI high stage or 30 35 PSI booster pounds of oil pressure at the high est normal head pressure or intermediate pressure expected with the compressor fully loaded The compressor will re quire maximum oil flow under these conditions COMPRESSOR OIL SEPARATION SYSTEM The RXB PLUS is an oil flooded screw compressor Most of the oil discharged by the compressor separates from the gas flow in the oil charge reservoir Some oil however is discharged as a mist which does not separate readily from the gas flow and is carried past the oil charge reservoir One or more coalescer filter elements then coalesce the oil mist into droplets the droplets of oil fall to the bottom of the coalescer section of the oil separator The return of this oil to the compressor is controlled by a needle valve on both high stage and booster applications NOTE Open needle the valve only enough to keep the coalescer end of the separator free of oil The sight glass located near the bottom of the coalescer section of the oil separator should remain empty during nor mal operation If an oil level develops and remains in the sight glass a problem in the o
99. in increments of 5 units CT The Cycle Time CT setpoint is the amount of time between the beginning of each load unload response It is adjustable to 5 10 15 20 25 or 30 seconds Use the STEP key to step to the desired setpoint then press the CHANGE key to change the CC PB DB and CT values Enter the desired value for the remaining setpoints and press ENTER when complete SETPOINTS DISPLAY Page 2 Refer to SETPOINTS DISPLAY SETPOINTS PAGE 2 on page 17 and SETPOINTS DISPLAY Page 2 on page 18 Display for illustrative purposes only RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 22 OPERATION eae k Ee Frick SETPOINTS DISPLAY Page 3 SETPOINTS PAGE 3 ID 02 04 09 90 offset act Mon 01 00 18 Baud 19200 Recycle 30 Sup Heat Alarm 10F no Sep Cond Alarm 10F no The new setpoints provided on this display allow monitoring of compressor superheat and condensing in the separator The following setpoints apply to the monitoring of the super heat and condensing in the separator ALARM SHUTDOWN The Alarm shutdown setpoints select the conditions for an alarm or shutdown alarm is selected the alarm will occur after a 30 second delay If shutdown is selected the shutdown will occur 60 seconds after the alarm NOTE The Superheat Cutout and Alarm follow the auxiliary failures on the annunciator display of the TEMPERATURE PRESSURE CONTROL PRO GRAM option The Sep Cond Alarm and Cutou
100. ing the indi cator dial as coupling hubs are rotated 5 Loosen motor anchor bolts and move or shim motor to correct the angular misalignment After adjustments have been made for angular misalignment retighten anchor bolts to prevent inaccurate readings Re peat Steps 3 through 5 to check corrections Further adjust ments and checks shall be made for angular misalignment until the total indicator reading is within the specified toler ance RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 6 INSTALLATION eae k Ee Frick FIG 1 ANGULAR MISALIGNMENT ELEVATION AS VIEWED FROM SIDE Tan FIG 2 DIAL INDICATOR ATTACHED AT 12 O CLOCK ELEVATION AS VIEWED FROM SIDE FIG 3 DIAL INDICATOR AT 6 O CLOCK Frick PARALLEL ALIGNMENT 6 To check parallel alignment as shown in Fig 4 reposi tion dial indicator so the stem is in contact with the rim of the compressor hub as shown in Fig 5 Check the dial indicator to be sure that the indicator stem is slightly loaded so as to allow movement in both directions 7 Check parallel height misalignment by setting dial indica tor at zero when viewed at the 12 o clock position Rotate both coupling hubs together 180 6 o clock position At this position the dial indicator will show TWICE the amount of parallel height misalig
101. irm unload capability If valve is mounted on base push B side to confirm unload capa bility If valve works problem is electrical SLIDE VALVE WILL LOAD BUT Solenoid coil may be burned out A side if mounted on compressor B side if mounted on WILL NOT UNLOAD base Replace coil Dirt inside solenoid valve preventing valve from operating both ways Clean valve Solenoid may be mechanically actuated by inserting a piece of 3 16 rod against armature pin and pushing spool to opposite end If valve is mounted on compressor push A side to confirm unload capability If valve is mounted on base push side to confirm unload capa bility If valve works problem is electrical SLIDE VALVE WILL UNLOAD BUT Solenoid coil may be burned out B side if mounted on compressor A side if mounted on WILL NOT LOAD base Replace coil Dirt inside solenoid valve preventing valve from operating both ways Clean valve Solenoid may be mechanically actuated by inserting a piece of 3 16 rod against armature pin and pushing spool to opposite end If valve works problem is electrical SLIDE STOP WILL NOT FUNCTION Solenoid coil may be burned out Replace EITHER DIRECTION Check solenoid coils see Vi Control table page 31 SLIDE VALVE WILL NOT MOVE Slipper seals worn out or damaged Unloader spindle or slide valve jammed Internal check valve bad Clean repair or replace Check needle valve adjustment RXB PLUS ROTARY SCREW C
102. is usually missing A good ground circuit must be continuous from the plant source transformer to the elec tronic control panel for proper operation Figure 2 Driving a ground stake at the electronic control will cause additional problems since other equipment in the plant on the same circuits will ground themselves to the ground stake causing large ground flow at the electronic equipment 3 PHASE A BUS TRANSFORMER _ ALUMINUM OR COPPER COPPER ELECTRONIC CONTROL ART2 Figure 2 WIRING PRACTICES Do not mix wires of different voltages in conduit An example of this would be the installation of a screw com pressor package The motor voltage is 480 volts and the panel control power is 120 volts The 480 volt circuit must be run from the motor starter to the motor in its own conduit The 120 volt circuit must be run from the mo tor starter control transformer to the control panel in its own separate conduit If the two circuits are run in the same conduit transients on the 480 volt circuit will be in ducted into the 120 volt circuit causing functional problems with the electronic control Dividers must be used in wire way systems conduit trays to separate unlike voltages The same rule applies for 120 volt wires and 220 volt wires Also never run low voltage wires in the same conduit with 120 volt wires Figure 3 RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 62 PROPER INSTALLATION OF ELECTRONIC EQUIPMENT
103. it no 111Q0451862 TROUBLESHOOTING FRICK SBC MICROPROCESSOR SYSTEM REFER TO WIRING DIAGRAMS SYMPTOM PROBABLE CAUSES and CORRECTIONS DISPLAY IS INOPERATIVE Check the 10 amp fuse 2FU which controls all voltage going to the microprocessor Shut off power to the microprocessor and confirm that all cable and wire connections are made COMPRESSOR AUXILIARY SHUTDOWN Output 1 controls the Compressor Start Relay 2CR If the compressor does not start and the LED for Output 1 is on check the fuse FU1 1 5 amp If the problem persists check the interposing relay 2CH The Compressor Starter Auxiliary Contacts turn on Input 5 when they are closed These contacts are located on the Compressor Starter OIL HEATERS DO NOT OPERATE The oil heaters should operate only when the compressor is NOT running and the oil in the separator sump is cold If the oil heaters do not work check fuse 1FU 10 amp If the fuse is not blown check between Wires 25 and 2 If 120VAC is not found check between wires 26 and 2 If 120VAC is found between wires 26 and 2 the Oil Heater Relay is defective Next check the voltage between Wires 11 and 2 If 120 VAC is present the Oil Heater Relay is defective If you do not read 120VAC between Wires 9 and 2 when the LED for output 10 is on check the fuse FU10 PLUS ROTARY SCREW COMPRESSOR UNITS Frick MAINTENANCE 570 101 IOM Page 43 TROUBLESHOOTING FRICK SBC MICROPROCESS
104. kkkkkkkkk Disch Temp Cutout kkkkkkkkkkkkkkkkkkkkk The Shutdown Record display keeps a record of the last six shutdowns cutouts This information will help troubleshoot persistent operational problems The most recent cutout will appear on the top line of page 1 of the display with the old est appearing on the last or bottom line of page 2 When a cutout occurs all information is moved down one line and the new cutout appears at the top of page 1 When the dis play is full the oldest record is dropped off the display and Is not retained in memory The information presented is ech oed from the Annunciator display providing the type of cut out the day the date and the time NOTE This informa tion will not be lost due to power failure FREEZE DISPLAY FREEZE DISPLAY P1 Thu 03 01 89 15 33 36 Suction Disch Oil CUTOUT Compressor 14 3hg 120g 060g OFF Mode 040F 135F 135F FREEZE DISPLAY P2 Thu 03 01 89 15 33 36 V Ratio SVPos Pump FLA Sep 132 F 2 2 000 off 000 HTR off Auto Auto L The Freeze display has the same appearance and contains the same information as the Operating display For a de scription of the information presented by the Freeze display refer to the Operating display The Freeze display freezes the information of the Operating display AT THE MOMENT OF A COMPRESSOR CUTOUT The information on the Freeze display can help the operator to identify the cause of a fault which occurred when no one was present T
105. kkkkkkkkkkkkkkkkkkk Oil Press Alarm kkkkkkkkkkkkkkkkkkkkk ANNUNCIATOR PG 04 Thu 03 01 89 15 33 36 Use STEP key to advance PAGE Hi Oil Temp Cutout kkkkkkkkkkkkkkkkkkkkk Hi Oil Temp Alarm kkkkkkkkkkkkkkkkkkkkk ANNUNCIATOR PG 05 Thu 03 01 89 15 33 36 Use STEP key to advance PAGE Low Oil Temp Cutout kkkkkkkkkkkkkkkkkkkkk Low Oil Temp Alarm kkkkkkkkkkkkkkkkkkkkk ANNUNCIATOR PG 06 Thu 03 01 89 15 33 36 Use STEP key to advance PAGE Disch Temp Cutout kkkkkkkkkkkkkkkkkkkkk Disch Temp Alarm kkkkkkkkkkkkkkkkkkkkk ANNUNCIATOR PG 07 Thu 03 01 89 15 33 36 Use STEP key to advance PAGE Comp Auxiliary kkkkkkkkkkkkkkkkkkkkk Pump Aux Not Used kkkkkkkkkkkkkkkkkkkkk ANNUNCIATOR PG 08 Thu 03 01 89 15 33 36 Use STEP key to advance PAGE Oil Level kkkkkkkkkkkkkkkkkkkkk Comp Differential kkkkkkkkkkkkkkkkkkkkk ANNUNCIATOR PG 09 Thu 03 01 89 15 33 36 Use STEP key to advance PAGE Superheat Cutout kkkkkkkkkkkkkkkkkkkkk Superheat Alarm kkkkkkkkkkkkkkkkkkkkk ANNUNCIATOR PG 10Thu 03 01 89 15 33 36 Use STEP key to advance PAGE AUX 1 Alarm kkkkkkkkkkkkkkkkkkkkk Aux 2 Shutdown kkkkkkkkkkkkkkkkkkkkk ANNUNCIATOR PG 11 Thu 03 01 89 15 33 36 Use STEP key to advance PAGE kkkkkkkkkkkkkkkkkkkkk Low Motor Amps Sensor Fault kkkkkkkkkkkkkkkkkkkkk Displays for illustrative purposes only S70 101 IOM Compressor Differential Cutout The differential cutout has been lowered from 55
106. l Temperature Alarm reported in degrees Fahrenheit will trigger a prealarm if the oil temperature equals or falls below this setpoint LO OIL PRESS CUTOUT The Low Oil Cutout will shut down the compressor when the oil pressure equals or falls below this setpoint LO OIL PRESS ALARM The Low Oil Alarm will trigger a prealarm when the oil pressure equals or falls below this setpoint When a prealarm or cutout occurs a flashing ALARM or CUTOUT indicator will appear in the lower right hand corner of the Operating display To determine the fault rotate to the Annunciator display by pressing the CHANGE key The Annunciator display lists all key operative points on nine sequential displays These displays can be rotated from page 1 thru page 9 by pressing the STEP key When a prealarm or cutout is triggered the pertinent point will flash and the time of the occurrence will be recorded to the right of the alarm RXB PLUS ROTARY SCREW COMPRESSOR UNITS 570 1 OPERATION 01 IOM Page 19 Revised 8 97 ANNUNCIATOR DISPLAY ANNUNCIATOR PG 01 Thu 03 01 89 15 33 36 Use STEP key to advance PAGE High Press Cutout kkkkkkkkkkkkkkkkkkkkk High Press Alarm kkkkkkkkkkkkkkkkkkkkk ANNUNCIATOR PG 02 Thu 03 01 89 15 33 36 Use STEP key to advance PAGE Low Press Cutout kkkkkkkkkkkkkkkkkkkkk Low Press Alarm kkkkkkkkkkkkkkkkkkkkk ANNUNCIATOR PG 03 Thu 03 01 89 15 33 36 Use STEP key to advance PAGE Oil Press Cutout kk
107. lected for the TIME setpoint NOTE Be careful not to select both compressors as lead compressors or as lag compressors as improper op eration will result NOTE One compressor will operate as a normal auto cycle compressor when any one of the following oc curs a Power is removed from one of the two compressors b Either of the compressors is NOT selected to AUTO or c If communication is lost between the compressors for any reason COMMUNICATIONS TROUBLESHOOTING Troubleshooting the communications Go to the SETPOINTS DISPLAY FIXED Page 2 by using the CHANGE key and the key The display will appear as SETPOINTS DISPLAY FIXED PAGE 2 Comm Activity Hi Oil Temp Cutout 167F Alarm 1586 Lo Oil Temp Cutout 49F Alarm 58F Lo Oil Press Cutout 005 Alarm 010 If the microprocessor is receiving information in the com munications port from the other compressor a 1 will flash between the brackets During normal operation a 1 will flash every 5 seconds At the same time information is displayed on the lower right hand corner of the Auto Cycle display concerning the lead lag information AUTO CYCLE DISPLAY AUTO CYCLE Start 20 0g Timer 01 min Stop 25 0 g Timer 01 min F1to Exit Suct Press 35 5 g Min SV 50 Lead Yes Active Yes 0101 This information is either 0 or 1 and represents what is being sent from the other
108. lowed by a carriage return line feed for all other temperatures If using the A command then the returned data would be XXXXXXXXXXXXX 2 13 characters followed by a carriage return line feed The first 4 characters are Suction Temp the next 3 Discharge Temp the next 3 are Oil and the last 3 are Separator g or h must be lower case exception to All commands must be caps statement at beginning of section CHANGE SETPOINTS COMMAND 01C Start command sequence Compressor ID code Change setpoint command New setpoint xx New setpoint y g or h for gauge or inches The following is the complete list of the setpoints that may be changed while in the change setpoints command 01 Capacity Control Setpoint 02 Change Low Pressure Cutout Setpoint 03 Change Low Pressure Alarm Setpoint 04xxx Change High Pressure Cutout Setpoint 05xxx Change High Pressure Alarm Setpoint 06xxx Change MLC Stop Load Setpoint 07xxx Change MLC Force Unload Setpoint 08xx Change Recycle Delay Setpoint 09 Change CTF Setpoint 01 Compressor ID code RETURNED ANSWER Axxxx The new setpoint which was sent followed by a carriage return line feed If the command was sent 01C01300g01 the capacity control setpoint would be changed to 30 0g and the returned answer is A300g followed by a carriage return line feed If the command sent was 01C0711001 the MLC force unload setpoint would be
109. mputer displays the instruction on the Operating display with an L load or U unload symbol at the same time as the appropriate out put is energized If the microprocessor receives information that indicates an abnormal operating condition has been reached or is present it will generate one or more of the following instruc tions 1 If a subsystem on the compressor unit such as the oil heater s or liquid injection can correct the problem the microprocessor will energize or de energize this system 2 If a prealarm setpoint has been reached the micro processor will trigger the prealarm and display this informa tion on the Operating display and the Annunciator display 3 If a cutout setpoint has been reached the microproces sor will shut down the compressor The microprocessor will indicate CUTOUT on the Operating display and the infor mation present on the Operating display at the moment of cutout will be stored and can be retrieved by rotating dis plays to the Freeze display Additional information will be available through the Annunciator and Shutdown Record displays A typical example of how the microprocessor responds can be illustrated by the responses generated by the micropro cessor as oil temperature increases Assume that the ambi ent temperature and compressor unit temperature are 45 F and you have just pressed the RUN key to start the com pressor unit AT 45 F The microprocessor receives information
110. mum Capacity Control shown as a percentage will limit the slide valve position to the dis played setpoint AUTO CYCLE ACTIVE Indicates whether Auto Cycle is active YES or not active NO Press the CHANGE key while at this setpoint to change the status Upon deactiva tion the compressor will return to the previous mode of operation ANALOG OFFSET DISPLAY ANALOG OFFSET Suc Disch Oil Sep Filt Spare Econ Temp O 0 0 0 0 0 Pres 00 0 0 0 0 The Analog Offset Display is accessed by pressing key All analog values can be offset or 3 to 9 units de pending on which value is being adjusted Use the STEP key to step through the desired setpoint Press the CHANGE key to change the value of the offset by 1 The actual analog value will be displayed on the top line of the display The Econ and channels 10 12 and 13 are dis played but do not pertain to the program Display for illustrative purposes only S70 101 IOM TEMPERATURE PRESSURE CONTROL PROGRAM OPTION NOTE The following displays are provided only when the Temperature Pressure Control Program option has been ordered with the RXB Plus Rotary Screw Compres sor Unit SETPOINTS DISPLAY Page 1 SETPOINTS PAGE 1 Capacity Control Press CUTOUT ALARM PB DB Press 25 30 01 3g 05 3g 10 1 0 Temp 40 0F 32 0 33 0F 10 0 5 The Setpoints Display is accessed by pressing the CHANGE key CONTROL This setpoint is used
111. n the panel that will keep interference to a minimum If you need to add these devices contact the manufacturer for the proper device types and placement Never run refrigerant tubing inside an electronic con trol panel If the refrigerant is ammonia a leak will totally destroy the electronics If the electronic control panel has a starter built into the same panel be sure to run the higher voltage wires where indicated by the manufacturer EMI from the wires can interfere with the electronics if run too close to the cir cuitry Never daisy chain or parallel connect power or ground wires to electronic control panels Each electronic con trol panel must have its own supply wires back to the power source Multiple electronic control panels on the same power wires create current surges in the supply wires which can cause controller malfunctions Daisy chaining ground wires allows ground loop currents to flow between electronic con trol panels which also causes malfunctions Figure 4 It is very important to read the installation instructions thor oughly before beginning the project Make sure you have drawings and instructions with your equipment If not call the manufacturer and have them send you the proper in structions Every manufacturer of electronic equipment should have a knowledgeable staff willing to answer your questions or fax additional information Following correct wir ing procedures will ensure proper installation of
112. nd if applicable the oil pump motor starters Start the unit OIL FILTER s DUAL RXB compressor units are furnished with one main oil filter A second filter is installed as optional A CAUTION equipment to minimize down time and reduce refrigerant loss 1 If dual oil fillers are furnished open the inlet and then the outlet service valves of the standby filter Open outlet and inlet service valves SLOWLY to prevent a sudden pressure drop which could cause an oil filter differential cutout 2 Close the outlet and then the inlet service valves of the filter being serviced Open the bleed valve on the filter can ister and SLOWLY purge to atmospheric pressure 3 Follow instructions 3 4 and 5 under OIL FILTER SINGLE 4 Place the unit back into service RXB PLUS ROTARY SCREW COMPRESSOR UNITS MAINTENANCE Page 37 570 101 IOM OIL RETURN STRAINER The unit must be shut down and equalized to atmospheric pressure NOTE Recover or transfer all refrigerant va por in accordance with local ordinances before open ing to atmosphere 1 Remove the large plug from the bottom of the strainer remove the element from the strainer 2 Wash the element in solvent and blow it clean with air 3 Replace the element and the large plug 4 Open the valves closed in Step 1 and check for leakage OIL PUMP STRAINER Optional To clean the full lube oil pump strainer the unit must be shut down The procedure is as follows
113. nd strap to prevent static electrcial discharge from your body Most problems encountered with the microprocessor and control circuits will be the result of a wiring fault blown fuse or failure of a peripheral control such as a solenoid coil or a pressure transducer Faults in the computer while possible are unlikely If a fault develops in the computer the prob ability is that all functions will cease and the display screen will go blank RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 42 MAINTENANCE Eee Frick The control system of the RXB PLUS compressor consists of a 120 volt AC high voltage side and a DC low voltage side The 120 volt side actuates solenoids relays alarms and other electromechanical functions The DC side oper ates the computer and its various sensors The microproces sor console contains the SBC single board computer and one display screen When working within the micropro A WARNING cessor console 120 VOLTS CAN CAUSE INJURY OR DEATH To troubleshoot the low voltage side of the RXB PLUS con trol circuits it is necessary to have the following tools Accurate digital multimeter Small wire stripper Small screwdriver omall snip nose pliers 15 watt soldering iron no larger 032 60 40 rosin core solder IC chip extraction and insertion tools Grounding strap Static free grounded work surface cO O O GQ N Available from Frick Order k
114. ndensed not com pressed Refrigerant flow to the cooler is automatic driven by the thermosyphon principle and cooling flow increases as the oil inlet temperature rises EQUIPMENT The basic equipment required for a ther mosyphon system consists of 1 A source of liquid refrigerant at condensing pressure and temperature located in close proximity to the unit to mini mize piping pressure drop The liquid level in the refrigerant source must be 6 to 8 feet above the center of the oil cooler 2 A shell and tube or plate type oil cooler with a 300 psi minimum design working pressure on both the oil and re frigerant sides Due to the many variations in refrigeration system design and physical layout several systems for ensuring the above criteria are possible SYSTEM OPERATION Liquid refrigerant fills the cooler tube side up to the Thermosyphon receiver liquid level Water or hot oil above the liquid temperature flowing through the cooler will cause some of the refrigerant to boil and vaporize in the tubes The vapor rises in the return line The density of the refrigerant liquid vapor mixture in the re turn line is considerably less than the density of the liquid in the supply line This imbalance provides a differential pres sure that sustains a flow condition to the oil cooler This re lationship involves 1 Liquid height above the cooler 2 Oil heat of rejection 3 Cooler size and piping pressure drops TO SYSTE
115. needle valve located at the bottom of the coalescer section of the oil separator Open all hydraulic control valves for the slide valve compressor loading and unloading and the slide stop volumizer Open all required oil cooling valves LIQUID INJECTION service valves should be fully open with the exception of the bleed valve which should be opened 1 4 turn WATER COOLED OIL COOLER confirm adequate water supply is present and adjust water regulating valve to midrange Close economizer service valves if applicable The economizer can be put into service once normal operation is established Confirm that the entire refrigeration system is ready for compressor operation and that sufficient load is available for compressor start up Close compressor motor main disconnect RXB PLUS ROTARY SCREW COMPRESSOR UNITS S70 101 IOM Frick 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 important that an adequate refrigerant load be available to load test the unit at normal operating conditions The following points should be kept in mind during initial start up 1 On start up the unit should be operated at as high a load as possible for 3 hours During this period adjust liquid injec tion oil cooling if applicable If the unit has water cooled oil cooling adjust the water control valve to the cooler No ad justment is re
116. ng the CLEAR key a second time will eliminate the flashing brackets 5 Having keyed the desired setpoint press the ENTER key The new setpoint will be entered and the flashing brack ets will move or step to the next setpoint NOTE A setpoint entry outside the parameters of the Adjustable Setpoint display will be refused and the origi nal Adjustable setpoint will be restored NOTE To clear any time values STEP to the desired setpoint press CHANGE and then press CLEAR HOW TO DETERMINE ADJUSTABLE SETPOINTS Adjustable Setpoints should reflect values compatible with normal system operation Too high a Low Suction Pressure Alarm setpoint may cause nuisance prealarms Similarly cutout setpoints should not fall within what are considered normal plant operation As a rule of thumb set the Low Suc tion Pressure Alarm 5 PSIG lower than the lowest normal suction pressure The Low Suction Pressure Cutout should be 5 to 10 PSIG lower than the Low Suction Pressure Alarm setpoint Frick The High Discharge Pressure Cutout should be set at 90 of the setting of the lowest high side relief valve The High Discharge Pressure Alarm should be set 10 PSIG lower than the Cutout The Capacity Control setpoint should be the equivalent of the normal suction condition FIXED SETPOINTS Fixed setpoints define the limits of acceptable compressor operation Fixed Setpoints are factory determined stored in programmed memory
117. nload reported as a percentage of the motor full load amps FLA will force the compressor to unload until the motor full load amps FLA fall within 196 of the setpoint or lower NOTE Consult motor manufacturer for recommended setpoint HI DISCH CUTOUT The High Discharge Pressure Cutout reported in pounds per square inch gauge g will shut down the compressor if the discharge pressure equals or exceeds this setpoint HI DISCH ALARM The High Discharge Pressure Alarm reported in pounds per square inch gauge g will trigger a prealarm if the discharge pressure equals or exceeds this setpoint CT FACTOR The Current Transformer Factor records the proper current transformer factor to match the compressor motor FLA rating to the current transformer primary rating The CTF factor is programmable and its correct value is determined by the following formula 1024 x FLA Full Load Amps CTF 10x CT Current Transformer Primary Amps See motor nameplate See CT located in starter panel EXAMPLE FLA 230 Amps CT 300 300 5 CTF 78 Round whole number 10 x 300 RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 18 OPERATION Eee Frick AUX 1 and AUX 2 May be configured for either an alarm or shutdown and with either a normally closed NC or nor mally open NO contact TO CHANGE THE ADJUSTABLE SETPOINTS Adjustable Setpoints are stor
118. nment 8 Loosen motor anchor bolts and add or remove shims under the four motor feet until parallel height misalignment is within specified tolerance when anchor bolts are retightened CARE MUST BE USED WHEN CAUTION CORRECTING FOR PARALLEL MISALIGNMENT TO ENSURE THAT THE AXIAL SPACING AND ANGULAR MISALIGN MENT IS NOT SIGNIFICANTLY DISTURBED 9 After the parallel height misalignment is within tolerance repeat Steps 1 through 5 until angular misalignment is within specified tolerance 10 Check parallel lateral misalignment by positioning dial indicator so the stem is in contact with the rim of the com pressor hub at 3 o clock as shown in Fig 6 Set indicator at zero and rotate both coupling hubs together 180 9 o clock position as shown in Fig 5 Adjust parallel lateral misalignment using the motor adjust ing screws until reading is within specified tolerance 11 Recheck angular misalignment and realign if necessary 12 Tighten motor anchor bolts and rotate both coupling hubs together checking the angular and parallel misalignment through the full 3609 travel at 90 increments If dial read ings are in excess of specified tolerance realign as required 13 When the coupling hubs have been aligned to within specified tolerance a recording of the cold alignment must be made for unit records and usage during hot alignment 14 Bump the motor to check for correct compressor rota tion COMPRESSOR ROTATION IS
119. nst shipping lists for any possible 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 of the 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 RXB PLUS ROTARY SCREW COMPRESSOR UNITS GENERAL INFORMATION Page 3 570 101 IOM COMPRESSOR and UNIT IDENTIFICATION Each compressor unit has 2 identification data plates The compressor data plate containing compressor model and serial number is mounted on the compressor body The unit data plate containing unit model serial number and Frick sales order number is mounted on the side of the motor base NOTE When inquiring about the compressor or unit or ordering repair parts provide the MODEL SERIAL and FRICK SALES ORDER NUMBERS from these data plates Frick ROTARY SCREW COMPRESSOR MODEL SERIAL NO REFRIGERANT VOL RATIO MAX SPEED RPM DESIGN PRESSURE YEAR OF MFR PSIG COMPRESSOR MFGD UNDER PATENTS LICENSED FROM SVENSKA ROTOR MASKINER AKTIEBOLAG SWEDEN WAYNESBORO PA 17268 COMPRESSOR DATA PLATE Frick ROTARY SCREW COMPRESSOR UNIT UNIT MODEL NO UNIT SER NO FRICK SALES ORD REFRIGERANT MAX DESIGN PRESSURE WAYNESBORO PA 17268 UNIT DAT
120. nter the gear and hub assembly so there is equal engagement on both shafts Adjust the space between hubs as specified in the CH Coupling Data Table below 3 Torque the clamping bolts in both hubs to the torque value given in the CH Data Table DO NOT USE ANY LUBRI CANT ON THESE BOLTS 4 Proceed to Coupling Alignment COMPRESSOR SHAFT RECTANGULAR KEY ROTOR IS BALANCED TO OFFSET SPACE MOTOR SHAFT DRIVE COUPLING FIG 3 COUPLING SHAFT KEYS INSTALLATION CH COUPLING DATA TABLE BETWEEN SHAFT SPACING ae TOTALS KEYWAY CLAMP SHAFT ENGAGEMENT INDICATOR BOLT SETSCREW MAX FACE SPACING READING TORQUE TORQUE 6 3 76 2 3 1 4 101 6 3 4 19 0 15 16 23 8 7 8 22 2 004 104 10 13 6 13 17 6 7 3 76 2 3 7 16 138 1 1 25 4 1 3 8 34 9 1 1 16 2 0 004 104 20 27 1 13 17 6 8 3 13 16 96 8 4 161 9 1 25 4 1 13 16 46 0 1 1 8 28 6 004 104 35 47 5 13 17 6 9C 3 9 16 90 5 5 7 16 149 2 1 1 4 31 8 2 3 8 60 3 1 7 16 36 5 004 104 35 47 5 13 17 6 S70 101 IOM COUPLING ALIGNMENT PROCEDURE The life of the compressor shaft seal and bearings as well as the life of the motor bearings is dependent upon proper coupling alignment Couplings may be aligned at the fac tory but realignment MUST ALWAYS be done on the job site after the unit is securely mounted on its foundation Ini tial alignment must be made prior to start up and rechecked after a few hours of operation Final HOT field alignment can only be made w
121. nts of 5 The Step key is used to select this setpoint then press the Change key to toggle through the selections Proportional Band This setpoint is used to determine the amount of time the load unload solenoid is energized ac cording to how far from the setpoint the actual control pres sure is The smaller the number the longer a load unload signal will be sent 1096 is the default value Selections are 2 5 10 15 20 or 25 The Step key is used to select this setpoint then press the Change key to toggle through the selections Cycle Time Cycle time is the amount of time between the beginning of each load unload response Ten seconds is the default value Cycle Time is adjustable between 5 and 30 seconds in 5 second intervals The Step key is used to select a setpoint then press the Change key to toggle through the selections Low FLA This setpoint is used to determine if the cou pling has broken 20 is the default value It is adjustable from 0 to 100 FLA Use the Step key to select a setpoint then enter the desired setpoint and press the Enter key SETPOINTS DISPLAY Page 2 MLC STOP LD The Motor Load Control Stop Load re ported as a percentage of the motor full load amps FLA will prevent the compressor capacity control pistons from loading when the setpoint is equaled or exceeded NOTE Consult motor manufacturer for recommended setpoint MLC FORCE ULD The motor Load Control Force U
122. ocal ordinances before opening to at mosphere The oil filter cartridge MUST be equalized to atmospheric pressure before opening Oil entrained refrigerant may va A CAUTION porize causing a pressure in crease Repeat venting and recov ery procedure if necessary 3 Remove the plug from the bottom of the filter canister and drain the oil Remove the canister cover and discard the gasket Remove the screws securing the filter assembly Pull the filter assembly from the canister and discard the gasket and the element 4 Flush the canister with clean Frick refrigeration oil wipe dry with a clean lint free cloth and replace the plug 5 Install a new element and tighten the nut on the end plate to 10 ft Ib torque Then while holding the nut with a wrench apply a second nut to act as a lock nut Replace the gasket and reinstall the filter assembly into canister securing with screws tightened to 7 ft lb torque Fill the canister with new Frick refrigeration oil Replace the gasket and reinstall the canister cover Torque cover bolts first to finger tight then 65 ft lb then 130 ft lb 6 Isolate the low pressure transducer PE 4 to prevent dam age during pressurization and leak test T Pressurize and leak test Evacuate the unit to 29 88 hg 1000 microns 8 Open suction and discharge the service valves and the low pressure transducer Readjust suction check valve by pass Close disconnect switches for the compressor a
123. on starter with circuit breaker disconnect Howev er the motor overcurrent protection disconnection device can be supplied by others usually as a part of an electrical power distribution board 3 A 2 0 KVA control power transformer CPT to supply 120 volt control power to the control system and separator oil heaters is included If environmental conditions require more than a 500 watt oil heater an appropriately oversized control transformer will be required 4 One 1 normally open compressor motor starter auxil iary contact and 1 normally open oil pump motor starter auxiliary contact opt should be supplied and wired as shown on the starter package wiring diagram In addition the compressor and oil pump motor starter opt coils and the CPT secondaries should be wired as shown on starter package wiring diagram 5 The compressor motor Current Transformer CT can be installed on any one phase of the compressor leads NOTE The CT must see all the current on any one phase there fore in wye delta applications BOTH leads of any one phase must pass through the CT 6 Oil Pump Option If the optional oil pump is specified an oil pump starter must be a component of the unit starter package The pump starter should be equipped with fuses or in the case where the compressor motor is a different voltage from the oil pump motor a circuit breaker discon nect suitable for separate power feed NOTE Do not install a compressor
124. or 3 Open vent valve V4 until 75 PSIG is registered at the Pressure Indicator 4 Monitor the oil temperature of the compressor If the oil temperature rises above 1309F R 717 or 1509F R 22 open vent valve V4 a very small amount This will reduce pressure on the equalizer and allow more refrigerant to flow to the compressor If the oil temperature drops below 110 F R 717 or 1309F R 22 close vent valve V4 a very small amount This will increase pressure on the equalizer The ideal condition is to maintain an oil temperature as stable as possible An incorrectly tuned liquid injection system will cause extreme swings in the discharge temperature and the oil temperature The vent valve V4 MUST be open CAUTION at least 1 4 turn during normal op eration A higher initial pressure step 2 may be required GAS AT HIGH STAGE DISCHARGE PRESSURE 4 T COMPRESSOR 72 C 2 SUCTION COMP R COMP R PORT 11 PORT 12 A 1 b lt FROM Sa COALESCER BLEED 0 LINE COMP R CONN 3 G lt COMP R CONN 4 2 LICO TE3 SVD LIQUID K Be DADA gt gt REFRIGERANT RECEIVER TCV1 z lt 17 RXB2PLI S70 101 IOM RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 34 OPERATION Frick PRESTART CHECKLIST
125. or Temp Menu F1 to Exit 85 5 0 The Auto Cycle Pressure Control Display is accessed by pressing the F4 key The Auto Cycle display provides for independently adjus table setpoints to turn the compressor on and off in response to the suction pressure or as an adjustable setpoint to limit the minimum slide valve position The compressor can be started and stopped by the following pressure setpoints even if the capacity control is selected to temperature START The suction pressure must be greater than or equal to the START setpoint in order to start the compressor This setpoint works in conjunction with the TIMER setpoint located to the right of it on the display Start TIMER This is a time delay used to start the com pressor The timer only accumulates time whenever the pres sure rises to or above the START setpoint and will reset if the pressure drops below the START setpoint STOP The suction pressure must be less than or equal to the displayed STOP setpoint limit in order to stop the com pressor This setpoint works in conjunction with the TIMER setpoint located to the right of it on the display NOTE This limit must be set higher than Low Suction Pressure Cut out and the Low Suction Pressure Alarm setpoints Stop TIMER The stop TIMER is a time delay used to stop the compressor The timer only accumulates time when ever the pressure drops to or below the STOP setpoint and will reset if
126. or out put data feedback The customer may supply his own mas ter sequencer panel usually a programmable controller or Frick can supply this sequencer if desired contact Frick Company for pricing Vp RUN COMPRESSOR LOAD COMPRESSOR UNLOAD COMPRESSOR INPUTS A SLNdLNO SPARE RXB COMPRESSOR WITH MICROPROCESSOR TYPICAL FOR EACH COMPRESSOR OUTPUTS BIT 0 BIT 1 BIT 2 BIT 3 uOSS3HdWOO HOVE HOS 1VOIdAL HATIOHLNOO 318VI AWVHOOHd ATIWNSN H3TIOHINOO SONSNOAS H31SVIN Y Y Y Y SLNdNI MASSEQ2 SUGGESTED PROGRAMMABLE CONTROLLER PROGRAM TO DECODE MICROPROCESSOR OUTPUT DATA CODES 0 Compressor 1 Running 10 Slide Valve Position 2 Running 20 Slide Valve Position 3 Running 30 Slide Valve Position 4 Running 40 Slide Valve Position 5 Running 50 Slide Valve Position 6 Running 60 Slide Valve Position 7 Running 70 Slide Valve Position 8 Running 80 Slide Valve Position 9 Running 90 Slide Valve Position A Running 100 Slide Valve Position B Running with MLC inhibit Lockout on Recycle Delay D Cutout E Undefined F Undefined MICODC MEANING OUTPUT DATA CODE e s s s Running Slide Valve Position Running with MLC Inhibit 1 Lockout on Recycle Delay Undefined
127. ors on a common economizing vessel regardless of economizer type each compressor must have a back pressure regulat ing valve in order to balance the economizer load or gas flow between compressors The problem of balancing load becomes most important when one or more compressors run at partial load exposing the economizer port to suction pressure In the case of a flash vessel there is no need for the redundancy of a back pressure regulating valve on the vessel and each of the multiple compressors Omit the BPR valve on the flash economizer vessel and use one on each compressor as shown in FIG 4 SUCTION INTERMEDIATE PRESSURE Le GAS TO COMPRESSOR X C ae ECONOMIZER STR VCK BPR HIGH PRESSURE LIQUID CONTROLLED PRESSURE lt SATURATED LIQUID TO EVAPORATOR FIG 3 FLASH ECONOMIZER SYSTEM SUCTION INTERMEDIATE PRESSURE GAS TO COMPRESSOR di ECONOMIZER EN VESSEL H tHe ird STR VCK BPR PX es C CONTROLLED PRESSURE lt SATURATED LIQUID TO EVAPORATOR ECONA FIG 4 MULTIPLE COMPRESSOR ECONOMIZER SYSTEM Frick ELECTRICAL NOTE Before proceeding with electrical installation read the instructions in the section Proper Installation of Electronic Equipment in an Industrial Environment RXB PLUS units are supplied with a SBC single
128. ound across Wires 15 and 2 the Slide Stop 3 5 Vi Solenoid should be energized If not the solenoid is defective If 120VAC is not found across Wires 15 and 2 when the LED for Output 4 is on check the fuse FUA Outputs 4 and 5 control the Slide Stop 2 2 Vi Solenoid If 120VAC is found across Wires 14 and 2 the Slide Stop 2 2 Vi Solenoid should be energized If not the solenoid is defective If 120VAC is not found across Wires 14 and 2 when the LED for Output 5 is on check the fuse FU5 Verify that the Liquid Injection TXV is modulating properly and not feeding excessive liquid to the compressor When oil temperature drops too low the microprocessor SHOULD de energize this solenoid Output 6 controls the Liquid Injection Solenoid If 120VAC is found across Wires 13 and 2 the Liquid Injection Solenoid should be energized If not the solenoid is defective If 120VAC is not found when the LED for Output 6 is on check the fuse FU6 Output 7 controls the Hi Vi Liquid Injection Port solenoid If 120VAC is found across Wires 12 and 2 the Hi Vi Liquid Injection Port Solenoid should be energized If not the solenoid is defective If 120VAC is not found when the LED for output 7 is on check the fuse FU7 NOTE This output should only be on when the Vi is at 5 0 Output 8 controls the Economizer Solenoid Valve If 120VAC is found across Wires 11 and 2 the Economizer Solenoid should be energized If not the solenoid is defective If 120VAC
129. ound loop currents which can cause equipment shut downs processor memory and program loss erratic behav ior and false readings Manufacturers of industrial elec tronic equipment take into consideration the effects of RFI EMI and ground loop currents and incorporate protection of the electronics in their designs These manufacturers re quire that certain installation precautions be taken to pro tect the electronics from these effects All electronic equip ment must be viewed as sensitive instrumentation and there fore requires careful attention to installation procedures These procedures are well known to instrument engineers but are usually not followed by general electricians There are a few basics that if followed will result in a trouble free installation The National Electric Code NEC is a guide line for safe wiring practices but it does not deal with proce dures used for electronic control installation Use the fol lowing procedures for electronic equipment installation These procedures do not override any rules by the NEC but are to be used in conjunction with the NEC code WIRE SIZING Size supply wires one size larger than required for am perage draw to reduce instantaneous voltage dips caused by large loads such as heaters and contactors and solenoids These sudden dips in voltage can cause the processor whether it be a microprocessor a computer or a PLC to malfunction momentarily or cause a complete reset
130. ount shown in the Indicator Rod Extension table 6 With the slide valve fully loaded depress the manual 3 5 Vi key Movement of the indicator rod should occur as the Vi is changed so that the rod extension corresponds to the table 7 Reassemble the parts if the functional check is satisfac tory If the indicator rod does not move to the proper position as the table indicates then the compressor is not changing Vi in either manual or optional automatic operation This would result in higher compressor motor horsepower consump tion and possibly high oil temperature The problem would be caused by a malfunction of either solenoid valve 3SOL or 4SOL or the solenoid coil Replace as required INDICATOR ROD EXTENSION in Vi RXB RXB POSITION 12 15 amp 19 24 30 39 amp 50 412 454 434 474 ae 297 339 319 359 5 0 235 277 258 298 CAPACITY CONTROL VALVE ON COMPRESSOR Mir de ENERGIZE b COIL TO LOAD ENERGIZE a COIL TO UNLOAD VLR1CONT s F S70 101 IOM COMPRESSOR OIL COOLING SYSTEMS The RXB PLUS unit can be equipped with one of several systems for controlling the compressor oiltemperature They are single or dual port liquid injection thermosyphon or water cooled oil coole
131. ous sensors into com puter binary language and RAM random access memory integrated circuit chips to store information which can be readily changed by the microprocessor or as in the case of adjustable setpoints by the operator The SBC collects in formation processes the information and delivers instruc tions to the displays and to the output modules The SBC gathers information from several sources on the compressor unit Pressure transducers sense changes in pressure and return a variable DC voltage of 1 to 5 VDC to the SBC The signals are converted into binary code which the microprocessor understands The microprocessor scans the incoming data many times per second and compares the information it receives with the instructions programmed in the PROM chips information stored in the RAM chips and instructions it has received from the console keyboard As operating conditions change the microprocessor also forwards the information it is receiving to the display screen When an operating condition or conditions develop which the microprocessor program identifies as requiring a spe cific action the microprocessor generates an instruction RXB PLUS ROTARY SCREW COMPRESSOR UNITS OPERATION Page 25 570 101 IOM which is forwarded to the output modules The instruction triggers a solid state output device capable of handling con trol voltage and the instruction is executed In some cases such as load and unload instructions the co
132. perature readings may both be symptoms of a problem and not casually related High suction superheat or a low receiver level however could cause both symptoms The third step is to identify the most likely cause and take action to correct the problem If the symptoms are not re lieved move to the next item on the list and repeat the pro cedure until you have identified the cause of the problem Once the cause has been identified and confirmed make the necessary corrections S70 101 IOM TROUBLESHOOTING THE RXB PLUS MICROPROCESSOR This section contains information on troubleshooting and making corrections to the microprocessor and control cir cuits of the RXB PLUS unit The section is composed of four parts a general information section a troubleshooting guide a repair procedure guide and a section with illustra tive schematics and data GENERAL INFORMATION THE COMPONENTS WITHIN THE CAUTION MICROPROCESSOR CONSOLE CAN BE INADVERTENTLY DAM AGED BY STATIC ELECTRICITY OR MISHANDLING ONLY QUALIFIED TECHNICIANS SHOULD DIRECTLY HANDLE THESE COMPONENTS 1 DO NOT REMOVE the microprocessor console cover or attempt to make corrections to the microprocessor power supply without shutting off the control power Accidental shorts can irreparably damage the SBC single board com puter or the display screen 2 DO NOT HANDLE the SBC or the display screen board when their cables are disconnected without first attaching a grou
133. pressure alarm and cutout logic pump running begins after a 30 second delay which al lows the oil pump to build pressure Prealarms are self clearing At this time the alarm will stop flashing but the time of the first occurrence will still be re corded to the right of the alarm Pressing the CLEAR key while at the Annunciator display will clear all alarms and or cutouts In order to restore the Annunciator display and resume nor mal operation it will be necessary to go through the follow ing steps 1 Correct the conditions causing the alarm 2 Press the ALARM SILENCE key This action may pre cede correcting the conditions causing the alarm 3 To clear or reset the Annunciator pages press the CLEAR key This will also clear the ALARM or CUTOUT indicator from the Operating display 4 Press F1 to call up the Operating display If the condi tions causing the alarm have not been corrected or a new fault has occurred a new ALARM or CUTOUT message will appear NOTE Use of the Emergency Stop Button may trip one or more alarm setpoints SHUTDOWN RECORD DISPLAY SHUTDOWN RECORD P1 Thu 03 01 89 15 33 36 HI Oil Temp Cutout kkkkkkkkkkkkkkkkkkkkk Hi Oil Temp Cutout kkkkkkkkkkkkkkkkkkkkk Low Temp Cutout RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 20 OPERATION Eee Frick SHUTDOWN RECORD P2 Thu 08 01 89 15 33 36 Low Temp Cutout kkkkkkkkkkkkkkkkkkkkk Disch Temp Cutout kkkkkkkkkkkk
134. quired for thermosyphon oil cooling 2 The compressor slide valve potentiometer should be cali brated 3 After three hours stop the unit and open the motor s main disconnect Check hot alignment and adjust as necessary 4 Pull and clean the suction strainer after 24 hours of opera tion Repeat every 24 hours until the system is clean NORMAL START UP PROCEDURE 1 Confirm that system conditions permit starting the com pressor 2 Press the RUN key 3 Allow the compressor to start up and stabilize At start up the slide stop volumizer and the slide valve capacity con trol are in the AUTO mode RESTARTING COMPRESSOR UNIT AFTER CONTROL POWER INTERRUPTION PLANT POWER FAILURE 1 Check ADJUSTABLE setpoints 2 Follow normal start up procedure S70 101 IOM MAINTENANCE This section provides instructions for normal maintenance a recommended maintenance program troubleshooting and correction guides typical wiring diagrams and typical P and diagrams THIS SECTION MUST BE READ AAWARNING AND UNDERSTOOD BEFORE AT TEMPTING TO PERFORM ANY MAINTENANCE OR SERVICE TO THE UNIT CLOSE ALL COMPRESSOR PACK AWWARNING AGE ISOLATION VALVES PRIOR TO SERVICINGTHE UNIT FAILURE TO DO SO MAY RESULT IN SERIOUS INJURY NORMAL MAINTENANCE OPERATIONS When performing maintenance A CAUTION you must take several precautions to ensure your safety L If the unit is running push STOP key to shut down th
135. r Output 10 Oil Pump Start Output 11 Spare Output 12 Programmable Control Data Bit 0 Output 13 Programmable Control Data Bit 1 Output 14 Programmable Control Data Bit 2 Output 15 Programmable Control Data Bit 3 Output 16 26 27 Compressor ID Code Example If the answer returned was A1000001 1000000000100000001 the inputs outputs on compressor 1 which are energized are Oil level input 1 Aux 1 Input 7 Aux 2 Input 8 Oil Heater Output 10 RXB PLUS ROTARY SCREW COMPRESSOR UNITS 570 101 IOM OPERATION Page 29 READ FAILURES COMMAND 01F Start command sequence 01 Compressor ID Code F Read Failures command Returned Answer A00000000000000000000000002 Character Description Position Acknowledge of command sent High Press Cutout High Press Alarm Low Press Cutout Low Press Alarm Oil Press Cutout Oil Press Alarm Hi Oil Temp Cutout Hi Oil Temp Alarm Lo Oil Temp Cutout Lo Oil Temp Alarm Disch Temp Cutout Disch Temp Alarm Comp Auxiliary Pump Auxiliary Oil Level Comp Differential Dirty Filter Spare Aux 1 Alarm or Cutout Aux 2 Alarm or Cutout Spare Spare Spare 25 26 Compressor ID Code Example If the answer returned was A00000100000000000000000002 compressor 2 has an Oil Press Alarm S70 101 IOM RXB COMPRESSOR The Frick RXB rotary screw compressor utilizes mating asymmetrical profile helical rotors to provide a continuous pulse free flow of refrigerant vapor and is designed for bot
136. rator heater s indicating ON or OFF FORCED UNLD A Forced Unload message indicates that the percentage of motor full load amps has exceeded the maximum limit and the microprocessor is unloading the com pressor until the percentage FLA falls back to normal limits SETPOINTS DISPLAY SETPOINTS PAGE 1 ID 33 03 01 89 Cap Control 14 3 hg Thu 15 33 36 Lo Suct Cutout 20 0 hg Baud 2400 Lo Suct Alarm 18 0 hg Recy Delay 30 Display for illustrative purposes only RXB PLUS ROTARY SCREW COMPRESSOR UNITS OPERATION Page 17 570 101 IOM SETPOINTS PAGE 1B Dead Band Prop Band 96 Cycle Time sec LOW 96 FLA SETPOINTS PAGE2 MLC Stop LD 095 CT Factor 078 MLC Force ULD 100 Aux1 Alarm NO Hi Disch Cutout 050 g Aux2 Shutd NO Hi Disch Alarm 045 g SETPOINTS PAGE 3 HIGH STAGE RXB NP 22 PB 10 1 0 Oil Heater 113F Lig Inj Con Disch Cut 212F Hi Disch Alarm 194F SETPOINTS PAGE 4 Hi Oil Temp Cutout 1678 Alarm 158F Lo Oil Temp Cutout 496 Alarm 58 Lo Oil Press Cutout 005 Alarm 010 The information furnished by these displays is as follows SETPOINTS DISPLAY Page 1A CAP CONTROL The Capacity Control setpoint reported in pounds per square inch gauge g or inches of mercury hg controls the loading and unloading of the compressor when Capacity is in the automatic AUTO mode LO
137. re DECREASE TO 2 2 Vi FUA m of ro e DECREASE TO 3 5 Vi FU3 lt a gt COIL SLIDE VALVE UNLOAD o SHOWN W SOL ON COMPR zb COIL W SOL ON BASE FU2 lt b gt COIL SLIDE VALVE LOAD 17 o SHOWN W SOL ON COMPR lt a gt W SOL ON BASE Be 2 START RUN NOTE C Gs Gs AUX 2 SEE NOTE B 64 7 sk AUX 1 SEE NOTE B FROM LN 15 OIL PUMP AUX a I os m m OIL PUMP AUX 549 28 324 COMPR AUX T i s COMPRESSOR AUX COMPR RUNTIME METER LIQUID INJECTION Lact o ro PRESSURE REGULATOR ONLY ON BOOSTERS WITH LIQ INJ REMOTE UNLOAD 4 od REMOTE UNLOAD REMOTE LOAD ss J s 5X REMOTE LOAD REMOTE START RUN STOP 4 gt REMOTE START RUN STOP 1 LSL OIL LEVEL GJ 1 9T NOT REQUIRED WITH N O HELD CLOSED FULL LUBE OIL PUMP 5 2 RXBELD1 PLUS ROTARY SCREW COMPRESSOR UNITS Frick MAINTENANCE 570 101 IOM Page 55 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 MICRO PANEL ASSEMBLY WIRING DIAGRAM or WIRING IF ISOLATED 2CR CONTACT IS USED JUMP TO 6 SEE NOTEA 0 Y 2CR v OL
138. rge Pressure and Temperature are measur ed at the compressor outlet and are respectively displayed in pounds per square inch gauge g and degrees Fahren heit OIL Oil Pressure and Temperature are measured prior to entering the compressor and are respectively displayed in pounds per square inch gauge g and degrees Fahrenheit ALARM CUTOUT An Alarm or Cutout message indicates an Alarm or Cutout setpoint has been reached or exceeded Rotate the display mode to the Annunciator display for de tails In the event of a cutout rotate to the Freeze display for further details COMPRESSOR The compressor displays the status of the compressor unit The mode of operation will be indicated as either manual Man Mode when the RUN key has been Frick pressed automatic AUTO MODE when Auto Cycle has been activated remote RMT MODE when the REMOTE key has been pressed or off OFF MODE RECYCLE DELAY A Recycle Delay message indicates that the compressor has started and has shut down within the time delay setpoint period The Recycle Delay will pre vent the compressor from starting until the delay time ex pires and is intended to prevent damage to the compressor motor from successive restarts During Recycle Delay the microprocessor will alternatively flash RECYCLE DELAY and the remaining delay time in minutes NOTE Consult Motor Manufacturer for the recom mended duration of the Recycle Delay If the RUN
139. rs Each system is automatically con trolled independent of compressor loading or unloading Oil cooling systems maintain oil temperature within the follow ing ranges LIQUID INJECTION EXTERNAL OIL COOLING OIL COOLING R 717 110 130 F 110 130 F 110 130 F R 22 130 150 F Thermosyphon oil cooling TSOC or Water cooled oil cool ing WCOC LICO r r gt lt gt lt gt 5 X X J X LIQUID gt REFRIGERANT SQ FROM TCV1 RECEIVER X Y Y H X x T 3 PDCV C X X pm poc RXB1PLI PLUS ROTARY SCREW COMPRESSOR UNITS 32 OPERATION Eee Frick SINGLE PORT LIQUID INJECTION The single port liquid injection system is designed to permit liquid refrigerant injection into one port on the compressor at any given moment and operate as outlined Solenoid valve SV7 is energized by the microprocessor when the temperature element TE3 installed in the piping after the oil filter exceeds the LICO setpoint High pressure liq uid refrigerant is then supplied to the temperature control valve TCV1 The temperature control valve is equalized to a constant back pressure by the differential pressure con trol valve PD
140. side safety valve is required in this location only when refrigerant isolation valves are installed between the cooler and thermosyphon receiver If no valves are used between the cooler and TSOC receiver the safety valve on the TSOC receiver must be sized to handle the volume of both vessels Then the safety valve on the cooler vent liquid refrigerant side can be eliminated 4 The system receiver must be below the thermosyphon receiver in this arrangement S70 101 IOM ECONOMIZER HIGH STAGE OPTIONAL The economizer option provides an increase in system ca pacity and efficiency by subcooling liquid from the condenser through a heat exchanger or flash tank before it goes to the evaporator The subcooling is provided by flashing liquid in the economizer cooler to an intermediate pressure level The intermediate pressure is provided by a port located part way down the compression process on the screw compressor As the screw compressor unloads the economizer port will drop in pressure level eventually being fully open to suc tion Because of this an output from the microprocessor is generally used to turn off the supply of flashing liquid on a shell and coil or DX economizer when the capacity falls be low approximately 45 60 capacity 85 90 slide valve position This is done because the compressor will be more efficient operating at a higher slide valve position with the economizer turned off than it will at a low slide valve posi
141. signed mixing valve if ordered are factory mounted and piped The for 500 psi DWP and is set to relieve at 75 psi delta P The customer must supply and install all piping and equipment safety valve piping contains flanged connections should the located outside of the shaded area on the piping diagram valve require maintenance or replacement with consideration given to the following Extra caution should be used when servicing an oil sepa 1 The refrigerant source thermosyphon or system receiv rator with this arrangement If the oil cooler is valved off er should be in close proximity to the unit to minimize piping from an oil separator which has been evacuated for ser pressure drop vicing then the oil cooler could relieve into the separa 2 The liquid level in the refrigerant source must be 6 to 8 tor vessel if the 75 psi delta p setpoint is exceeded feet above the center of the oil cooler Other units which do not use this special safety valve ar rangement will have factory mounted safety valves on the shell side of the oil cooler which the installing contractor should pipe into house safety systems designated suitable 4 Frick recommends the installation of an angle valve in the for oil relief piping before the thermosyphon oil cooler to balance the thermosyphon system Frick also recommends the installa tion of sight glasses at the TSOC inlet and outlet to aid in troubleshooting The factory mounted plate type ther mosyphon o
142. ss the STEP key so that the brackets beside Enter Access Code flash key the proper five digit access code and press ENTER The Setpoints Access will toggle from disabled to enabled and adjustable setpoint entry is now possible TO DISABLE THE KEYBOARD press the F2 function key to call up the Security display press the STEP key until the brackets beside Enter Access Code flash key the proper five digit access code and press ENTER Now press the STEP key until the brackets beside Setpoints Access flash and press the CHANGE key to toggle from enabled to dis abled TO CHANGE THE ACCESS CODE press the F2 function key to call up the Security display press the STEP key until the brackets beside Enter Access Code flash key the proper five digit access code and press ENTER Now select the Enter Access Code a second time by pressing the STEP key until the brackets beside Setpoints Access flash key in the new five digit access code and press ENTER NOTE Power loss will not effect the Security display NOTE IF NO ACCESS CODE WAS ENTERED AND THE DISABLED COMMAND WAS SELECTED THE ACCESS CODE IS 00000 LOST OR FORGOTTEN ACCESS CODE Consult Frick Company for assistance SETBACK DISPLAY SETBACK DISPLAY Thu 03 01 89 15 33 36 Setback Setpoint 05 0 g Active No Mon Start Time F1 To Exit Stop Time The F3 function key will call up the Setback display The Setback feature enables
143. ssor Fuse 2 AMP For F 1 amp F 2 Temperature Probe TE 1 4 Pressure Transducer 0 100 PSIA PE 4 Pressure Transducer 0 300 PSIA 1 3 Float Switch Emergency Stop Button Contact Block for 111Q0280832 Above Fuse 15 AMP Battery Backup Kit Coalescing Filter Element Separator Head Gasket Microprocessor Service Tool Kit Includes CMOS Extractor Tool CMOS Insertion Tool Digital Multimeter Wrist Grounding Strap Antistatic Pad AO phot 11100280687 11100043229 11100043231 913 0047 01 913 0047 03 531A0028H01 959A0082H01 959A0053H01 951A0056H02 951 0056 03 951 0056 41 951A0056H42 534B0293H01 534C0625H01 951A0056H39 951A0056H40 640D0012H01 649D0979H01 333Q0000068 111Q0281061 333Q00001 16 33300000548 33300000194 33300000195 33300000206 33300000207 33300000117 11100280930 640B0019H01 111Q0280958 333Q0000573 111Q0280818 333Q0000426 333Q0000427 913A0086H01 111Q0280832 11100280833 11100281053 64040020601 531B0065H04 531B0065H06 531B0065H05 531B0065H03 959A0090H03 959A0090H02 959A0090H01 111Q0451862 a UI SHUN eJnsseJg pue 9JON Page 65 570 101 IOM 5 inss id UOO3 A OM 1ueJeDujes pinbr1 Dui ee 4 dv
144. t Frick Company The HAND OFF AUTO Oil Pump Selector Switch 155 controls oil pump operation and must be in the AUTO position before the compressor can be started Verify that the Slide Valve has unloaded to 5 or less If the Slide Valve has not unloaded troubleshoot the hydraulic system The compressor will not start until the Slide Valve is unloaded Output 1 controls the motor starter Check between terminals 38 and 2 for 120VAC If 120VAC is not found when the LED for Output 1 is on check the fuse FU1 k kawasay Frick EPROM MEMORY I C CHIP REPLACEMENT Microprocessor EPROM memory chips are located in side the microprocessor console on the SBC board A spe cial tool is required to remove these chips to lessen the chance of damaging them See Troubleshooting The Microprocessor The procedure to replace EPROM memory chips is outlined below 1 Shut off control power 2 Remove the microprocessor console cover 3 Using a chip extraction tool remove the old EPROM chips from the SBC board Pay particular attention to the orienta tion of the notch on the end of the chip then install new chip with the notch in the same position NOTE The chip la beled 4 must be inserted into socket U4 and the chip labeled 5 must be inserted into socket U5 SBC BOARD REPLACEMENT The procedure to replace SBC boards is outlined below 1 Shut off control power 2 Remove the old board from the machine and the
145. t are new failure features and are currently the last two listed in the Annunciator Display for the TEMPERATURE PRES SURE CONTROL program option OFFSET This setpoint is the degrees F above the satura tion point temperature where the alarm or shutdown will oc cur ACT The function selects whether the alarm shutdown is activated or not SETPOINTS DISPLAY Page 4 SETPOINTS PAGE 4 Active When Running in Temperature Cap Cont Low Suction Press Stop Load Low Suction Press Force Unload Low suction pressure and motor load control features were added to the TEMPERATURE PRESSURE CONTROL pro gram and placed on this display They are active only while the compressor is operating in Temperature Capacity Control Mode The two new setpoints are Low Suction Press Stop Load and Low Suction Press Force Unload Both are entered as a pressure in gauge or inches of mercury HG When suc tion pressure reaches the stop load setpoint loading of the compressor Is inhibited When the suction reaches the force unload setpoint the compressor will unload until the suction pressure is greater than the force unload setpoint Control will then be released to allow normal operation SETPOINTS DISPLAY Pages 5 and 6 Refer to SETPOINTS DISPLAY FIXED PAGES 1 amp 2 on page 17 and SETPOINTS DISPLAY Fixed Pages 1 and 2 on page 19 Use the STEP key to step to the desired setpoint then press the CHANGE key to change it Press EN
146. t requires the connection of the liquid line sized as shown in the table and careful insertion of the expansion valve bulb into the thermowell provided in the separator High pressure gas is connected through the regulator to the ex ternal port on the liquid injection valve to control oil tem perature Refer to the liquid injection piping diagram NOTE For booster applications the high pressure gas connection must be taken from a high side source high stage compressor discharge This should be a minimum 3 8 line connected into the solenoid valve provided This gas is required by the expansion valve external port to control oil temperature High stage compressor units may be supplied with single port low Vi or dual port low Vi and high Vi liquid injection oil cooling Single port will be furnished for low compression ratio operation and dual port for high compression ratio op eration Booster compressor units use single port liquid in jection oil cooling due to the typically lower compression ratios The control system on high stage units with dual port liq uid injection oil cooling switches the liquid refrigerant supply to the high port when the compressor is operating at higher compression ratios 3 5 Vi and above for best efficiency The following table gives the condensing temperature s with the corresponding maximum evaporator temperature limit for liquid injection usage and the minimum evaporator tem perature for a
147. tains all the components of the single port system with the addition of a double acting sole noid valve SV9 and operates as outlined Solenoid valve SV7 is energized by the microprocessor when the temperature element installed in the oil piping after the oil filter exceeds the LICO setpoint Liquid refriger ant is then passed through the temperature control valve TCV1 to the double acting solenoid valve SV9 Depending on the compressor s operating volume ratio Vi the micropro cessor will select the flow of the liquid refrigerant to either compressor port 3 or port 4 When the compressor operates at 3 5 or 2 2 Vi compressor port 3 low Vi supplies the liquid cooling At 5 0 Vi port 4 high Vi supplies the liquid cooling The temperature control valve TCV1 is equalized to a con stant back pressure by the differential pressure control valve PDCV Both the differential pressure control valve PDCV and the double acting solenoid valve SV9 use discharge gas to maintain downstream pressure The gas downstream of both valves is bled off to the compressor suction to ensure steady and constant operation of the valves a T RXB PLUS ROTARY SCREW COMPRESSOR UNITS OPERATION 570 101 IOM Page 33 LIQUID INJECTION ADJUSTMENT PROCEDURE 1 Close vent valve V4 2 Open service valve V5 until approximately 80 PSIG is registered at the Pressure Indicat
148. ter If applicable check Full Time Oil Pump for correct rotation OPEN oil pump motor disconnect Confirm that motor overload and CT is properly sized With ALL motor disconnects OPEN turn control power ON and check ALL voltages Check that oil heater circuit is on CAUTION The oil heater should be on 24 hours before initial start up is attempted Confirm that the Emergency Stop Button is not depressed Disengage by gently twisting to the left Confirm Microprocessor function Rotate through displays Rotate to the ADJUSTABLE setpoints display 2 pages and enter setpoints including DAY DATE and TIME Return to the Operating display then rotate back to the ADJUSTABLE setpoints display to confirm that the proper setpoints have registered Press F1 to return to the Operating display Rotate to the ANNUNCIATOR display Confirm that all setpoints are normal and that no alarm or cutout indications are present Press F1 to return to the Operating display Open all oil circuit service valves to allow normal oil flow If applicable start the oil pump by turning the oil pump switch to HAND Confirm oil pressure buildup pump rotation Separator oil level may drop as oil filter s and oil cooler fills up Add oil as required Allow oil pump to operate 10 minutes to flush the lubricating circuit Shut down oil pump Place the oil pump switch in the AUTO mode Open discharge and suction service valves Open the oil return
149. that the oil temperature is below 499F the Low Oil Temperature Cutout setpoint and and shuts down the unit The microprocessor will prevent the compressor package from running The microprocessor also instructs the oil heater s output to ener gize the oil heater s AT 50 F When the oil temperature reached 50 F the microprocessor would allow the Low Oil Temperature Cutout to be cleared and the compressor unit could now be started Assume that the RUN key has been pressed and that the com pressor has now started The Low Oil Temperature Alarm would still be engaged and cannot be cleared until oil tem perature exceeds 58 F The oil heater s shut off on com pressor start AT 1139 The microprocessor instructs the liquid injection solenoid output to deenergize the liquid injection solenoid AT 122 F The microprocessor instructs the liquid injection solenoid output to energize AT 110 F TO 150 F Normal operating range The microprocessor continues monitoring oil temperature and reporting this information on the Operating display S70 101 IOM AT 158 F The microprocessor triggers the High Oil Temperature Alarm and displays the alarm on the Operating display and the Annunciator display 1672 F microprocessor instructs the compressor motor to shut down and displays a CUTOUT indication on the Operating display It stores the operating conditions at the moment of RXB PLUS ROTARY SCREW COMPRESSOR UN
150. the pressure rises above the STOP setpoint RXB PLUS ROTARY SCREW COMPRESSOR UNITS OPERATION Page 23 570 101 IOM MIN SV Minimum Slide Valve Position shown as a per centage will limit the slide valve position to the displayed setpoint ACTIVE Indicates whether Auto Cycle is active or not Press the CHANGE key while at this setpoint to change the sta tus Upon deactivation the compressor will return to the previous mode of operation AUTO CYCLE TEMP CONTROL DISPLAY AUTO CYCLE Start 50 0 F Timer 01 min C C Temp Stop 220 0 F 01 min Min SV 5096 Active Yes for Press Menu F1 to Exit 44 3 F The Auto Cycle Temperature Control Display is accessed by pressing F4 and then the keys The Auto Cycle display provides for independently adjust able setpoints to turn the compressor on and off in response to the suction temperature or as an adjustable setpoint to limit the minimum slide valve position The compressor can be started and stopped by the following temperature setpoints even if the capacity control is selected to pressure START The CC capacity control Temperature must be greater than or equal to the START setpoint in order to start the compressor This setpoint works in conjunction with the setpoint located to the right of it on the display Start TIMER This is a time delay used to start the com pressor The timer only accumulates time when
151. the status ACTIVE This setpoint indicates whether the Auto Cycle Mode is active or not Press the CHANGE key while at this setpoint to change the status OPERATION For operation of the LEAD LAG sequence both units must be in Auto Cycle compressor mode one compressor micro selected as the LEAD compressor the other compressor selected as the LAG compressor and the slide valves must be in Auto mode With NO Compressor Running The lead will start when its START setpoint is reached for the amount of time selected for the TIME setpoint With ONE Compressor Running If the load rises The lag compressor will start when its START setpoint is reached for the amount of time selected for the TIME set point and the lead compressor is running at 100 slide valve or running with the motor load inhibit RXB PLUS ROTARY SCREW COMPRESSOR UNITS Page 24 OPERATION k Frick If the load falls The lead compressor will stop when its STOP setpoint is reached for the amount of time selected for the TIME set point With TWO Compressors Running If the load rises The lead and lag compressor will load independently If the load falls The lag compressor will unload to its MIN SV setpoint Then the lead compressor will unload to its MIN SV set point The lag compressor will stop when the suction pres sure drops below the STOP setpoint for the amount of time se
152. tive plastic It would be a good idea to call the manufacturer before drilling the panel to be sure you are entering the panel at the right place When routing conduit to the top of an electronic control panel condensation must be taken into consideration Water can condense in the conduit and run into the panel causing cata strophic failure Route the conduit to the sides or bottom of the panel and use a conduit drain If the conduit must be routed to the top of the panel use a sealable conduit fitting which is poured with a sealer after the wires have been pulled terminated and the control functions have been checked A conduit entering the top of the enclosure must have an O ring type fitting between the conduit and the enclosure so that if water gets on top of the enclosure it cannot run in between the conduit and the enclosure This is extremely important in outdoor applications 480 VOLT S BHASE S BUS did GROUND BUS 120 V CALP C ID _ gt lt SEPARATE 7 CONDUIT ELECTRONIC df CONTROL Figure 3 Frick Never add relays starters timers transformers etc in side an electronic control panel without first contacting the manufacturer Contact arcing and EMI emitted from these devices can interfere with the electronics Relays and timers are routinely added to electronic control panels by the manufacturer but the manufacturer knows the accept able device types and proper placement i
153. to select either Pressure Capacity Control or Temperature Capacity Control NOTE There are only two setpoints press for pressure capac ity control and temp for temperature capacity control CC The capacity control setpoint is for normal operation not setback CUTOUT This setpoint will stop the compressor if the suc tion pressure drops below the pressure setpoint for 90 sec onds or if the CC Temperature drops below the temperature setpoint There is no time delay on the temperature cutout ALARM An alarm will be activated if the suction pressure drops below the pressure setpoint or if the CC Temperature drops below the temperature setpoint There is no time de lay for either NOTE Lo Temp Cutout and Alarm are active when op erating in temperature capacity control mode only These are failures based on the controlling temperature input They precede the auxiliary failures on the annun ciator display PB The Proportional Band PB is used to determine the amount of time the load unload solenoid is energized ac cording to how far away from the setpoint the actual control pressure or temperature is The smaller the number the more load unload will be sent A PB of 10 is default It is adjust able to 2 5 10 15 20 or 25 percent DB The Dead Band DB is a plus or minus value above or below the setpoint which the compressor will nei ther load nor unload It is adjustable between 5 and 5 0 psig or degrees
154. tor starter and the oil pump motor starter if applicable 11 The unit is ready to put into operation SUCTION CHECK VALVE BYPASS A 1 4 angle valve HV 1 on P amp I diagram is installed be tween the compressor and suction flange that can be used as a suction valve bypass This feature has several uses including reducing starting torque improving oil quality and relieving the refrigerant to low side for servicing In most cases the valve should be left open approximately 1 4 to 1 2 turn at all times If the compressor back spins or too much oil foaming is experienced while venting partially close valve to slow speed of equalization If system is on AUTO CYCLE and short cycling occurs the valve must be closed To relieve refrigerant to low side close separator discharge service valve Slowly open bypass valve if closed and wait for pressure to equalize Close bypass and suction service valves before evacuating the unit OIL FILTER SINGLE To change the filter cartridge proceed as follows Frick 1 If a single oil filter is installed push STOP key to shut down the unit Open disconnect switches for the compres sor and if applicable oil pump motor starters 2 Close discharge service valve SLOWLY vent the separa tor to low side system pressure using the suction check valve bypass Close suction valve and suction check valve by pass NOTE Recover or transfer all refrigerant vapor in accordance with l
155. tor on the compressor end of the separator Using a pressure type pump and the recommended Frick oil open the charging valve and pump oil into the separator Oil distillers and similar equipment which act to trap oil must be filled prior to unit operation to normal design outlet lev els The same pump used to charge the unit may be used for filling these auxiliary oil reservoirs NOTE The sight glass located near the bottom of the separator shell at the discharge end should remain empty when the unit is in operation The presence of oil in this end of the vessel during operation indicates liq uid carryover or malfunction of the oil return OIL HEATER Standard units are equipped with a 500 waitt oil heater pro viding sufficient heat to maintain the oil temperature for most indoor applications during shutdown cycles to permit safe Frick start up Should additional heating capacity be required because of unusual environmental condition contact Frick Company The heater is energized only when the unit is not in operation DO NOT ENERGIZE THE HEATER CAUTION WHEN THERE IS NO OIL IN THE UNIT OTHERWISE THE HEATER WILL BURN OUT THE OIL HEATER WILL BE ENERGIZED WHENEVER 120 VOLT CONTROL POWER IS APPLIED TOTHE UNIT AND THE COMPRESSOR IS NOT RUNNING UNLESS THE 10 AMP FUSE 1FU IN THE CONTROL PANEL IS REMOVED LIQUID INJECTION OIL COOLING The liquid injection system provided on the unit is self con tained bu
156. ts data loss during power inter ruption It will maintain the adjustable setpoints stored in RAM Random Access Memory for up to 1 year after power loss Expected battery life is 10 years A trickle charge main tains the battery backup at peak charge when control volt age is present To prevent power loss the battery backup is shipped dis abled To enable the battery backup a jumper pin located near the top of the microprocessor circuit board see illus tration page 52 must be moved from OFF pins 1 2 to ON pins 2 3 NOTE It is not necessary to disconnect the battery backup during extended downtime Frick RXB PLUS ROTARY SCREW COMPRESSOR UNITS OPERATION Page 15 570 101 IOM OPERATION and START UP INSTRUCTIONS GENERAL INFORMATION The Frick RXB PLUS Rotary Screw Compressor Unit is an integrated system consisting of six major subsystems 1 Microprocessor Control Panel 2 Compressor 3 Compressor Lubrication System 4 Compressor Oil Separation System 5 Compressor Hydraulic System 6 Compressor Oil Cooling System The information in this section of the manual provides the logical step by step instructions to properly start up and op erate the RXB PLUS Rotary Screw Compressor Unit THE FOLLOWING SUBSECTIONS MUST BE READ AND UNDERSTOOD BEFORE ATTEMPTING TO START OR OPERATE THE UNIT MICROPROCESSOR CONTROL PANEL e

Maintenance ROTARY SCREW COMPRESSOR UNITS

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