Frick Rwb ii 60 Owner's manual

Installation - Operation - Maintenance

ROTARY SCREW COMPRESSOR UNITS

ALL REFRIGERANTS

MODELS

60 through 480

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 OFTHE UNIT.

S70-200 IOM/AUG 2001

File: SERVICE MANUAL - Section 70

Replaces: S70-200 IOM/JAN 2001

Dist: 3, 3a, 3b, 3c

RWB II ROTARY SCREW COMPRESSOR UNITS

INSTALLATION - OPERATION - MAINTENANCE

S70-200 IOM

Page 2

Contents

Maintenance

GENERAL INFORMATION .............................................22

NORMAL MAINTENANCE OPERATIONS......................22

GENERAL MAINTENANCE............................................22

COMPRESSOR SHUTDOWN and START-UP ...............22

GENERAL INSTRUCTIONS FOR REPLACING

COMPRESSOR UNIT COMPONENTS. ..................23

OIL FILTER (OF-1) MAIN SINGLE/DUAL .......................23

STRAINER - DEMAND OIL PUMP .................................23

STRAINER - LIQUID INJECTION ...................................24

COALESCER FILTER ELEMENT(S) ..............................24

CHANGING OIL ..............................................................24

DEMAND PUMP DISASSEMBLY ...................................25

RECOMMENDED MAINTENANCE PROGRAM.............29

VIBRATION ANALYSIS ...................................................29

MOTOR BEARINGS........................................................29

OIL QUALITY and ANALYSIS .........................................29

OPERATING LOG ...........................................................30

MAINTENANCE SCHEDULE .........................................30

TROUBLESHOOTING GUIDE ........................................31

ABNORMAL OPERATION ..............................................31

ANALYSIS and CORRECTION................................31

SERVICING THE COLD-START VALVE .........................31

PRESSURETRANSDUCERS -TESTING......................31

PRESSURETRANSDUCERS - REPLACEMENT ..........32

SV POSITION POTENTIOMETER

REPLACEMENT AND ADJUSTMENT ....................33

VOLUMIZER® POTENTIOMETER

REPLACEMENT AND ADJUSTMENT ....................33

TEMPERATURE and/or PRESSURE ADJUSTMENT ....34

OIL LEVEL TRANSMITTER ............................................34

REPLACEMENT .............................................................34

TROUBLESHOOTING

RWB II COMPRESSOR ...........................................35

OIL SEPARATION SYSTEM ....................................35

HYDRAULIC SYSTEM.............................................36

LIQUID INJECTION OIL COOLING SYSTEM .........37

DEMAND PUMP SYSTEM ......................................38

THERMAL EXPANSION VALVES ...................................39

JORDAN TEMPERATURE REGULATOR VALVE ...........40

BARE COMPRESSOR MOUNTING ...............................41

GREASE COMPATIBILITY..............................................41

NLGI Grease Compatibility Chart....................................41

P & I DIAGRAM ..............................................................42

PROPER INSTALLATION OF ELECTRONIC EQUIPMENT

IN AN INDUSTRIAL ENVIRONMENT ......................46

FORMS

OPERATING LOG SHEET.......................................49

COMPRESSOR PRESTART CHECKLIST ..............50

START-UP REPORT ................................................51

VIBRATION DATA SHEET........................................53

RECOMMENDED SPARE PARTS .................................54

Indicates an imminently hazardous situation which,if not avoided,will result in death or serious

injury.

Indicates a potentially hazardous situation or practice which,if not avoided, will result in death

or serious injury.

SAFETY PRECAUTION DEFINITIONS

Indicates a potentially hazardous situation or practice which,if not avoided, will result in damage

to equipment and/or minor injury.

NOTE: Indicates an operating procedure, practice, etc.,or portion thereof which is essential to highlight.

PREFACE .........................................................................3

DESIGNLIMITATIONS......................................................3

JOB INSPECTION ............................................................3

TRANSIT DAMAGE CLAIMS ............................................3

COMPRESSOR and UNIT IDENTIFICATION ...................3

Installation

FOUNDATION ...................................................................4

RIGGING and HANDLING ................................................4

SKID REMOVAL................................................................4

MOTOR MOUNTING.........................................................5

CHECKING MOTOR/COMPRESSOR ROTATION ............5

COMPRESSOR/MOTOR COUPLINGS

INSTALLATION ..........................................................5

COUPLING ALIGNMENT PROCEDURE..........................7

HOT ALIGNMENT OF COMPRESSOR/MOTOR ..............9

OIL PUMP COUPLING .....................................................9

HOLDING CHARGE AND STORAGE...............................9

COMPRESSOR UNIT OIL ................................................9

OIL CHARGE ....................................................................9

OIL HEATER(S) ................................................................9

THERMOSYPHON OIL COOLING .................................10

LIQUID INJECTION OIL COOLING (Optional)................11

WATER-COOLED OIL COOLING (Optional)...................12

LIQUID LINE SIZES/RECEIVERVOLUME.....................12

ECONOMIZER - HIGH STAGE (OPTIONAL)..................12

ELECTRICAL ..................................................................14

MOTOR STARTER PACKAGE ........................................14

CURRENTTRANSFORMER (CT) RATIOS ....................15

MINIMUM BURDEN RATINGS .......................................15

BATTERY BACKUP ........................................................15

Operation

OPERATION and START-UP INSTRUCTIONS ..............16

TDSH COMPRESSOR ...................................................16

COMPRESSOR LUBRICATION SYSTEM......................16

NO PUMP OIL SYSTEM .................................................16

COLD-START SYSTEM ..................................................16

DEMAND PUMP OIL SYSTEM.......................................17

COMPRESSOR OIL SEPARATION SYSTEM ................17

COMPRESSOR HYDRAULIC SYSTEM.........................18

VOLUMIZER® VOLUME RATIO CONTROL ...................18

COMPRESSOR OIL COOLING SYSTEMS ....................19

SINGLE-PORT LIQUID INJECTION ...............................19

RWB II BOOSTER OR SWING DUTY APPLICATION ....19

DUAL-PORT LIQUID INJECTION ...................................19

LIQUID INJECTION ADJUSTMENT PROCEDURE .......19

SUCTION CHECK VALVE...............................................20

SUCTION CHECKVALVE BYPASS................................20

LOW AMBIENT OPERATION .........................................20

POWER ASSIST KIT ......................................................20

INITIAL START-UP..........................................................21

INITIAL START-UP PROCEDURE..................................21

NORMAL START-UP PROCEDURE ..............................21

RWB II ROTARY SCREW COMPRESSOR UNITS

GENERAL INFORMATION S70-200 IOM

Page 3

PREFACE

This manual has been prepared to acquaint the owner and

serviceman with the INSTALLATION, OPERATION, and

MAINTENANCE procedures as recommended by Frick for

RWB II Rotary Screw Compressor Units.

For information about the functions of the electrical control

panel,communications,specifications,andwiring diagrams,

see S90-010 OM (

Quantum

panel) or S70-200 OM (Plus

panel).

Itis most importantthat these units beproperlyapplied to an

adequately controlled refrigeration system.Your authorized

Frickrepresentativeshouldbe consulted forexpert guidance

in this determination.

Proper performance and continued satisfaction with these

units is dependent upon:

CORRECT INSTALLATION

PROPER OPERATION

REGULAR, SYSTEMATIC MAINTENANCE

To ensure correctinstallationand 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

practicesandlocalcodes,suchasthoseoutlinedinASHRAE

literature.

A refrigeration compressor is aVAPOR 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 assures 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.

E70-200 SED.

JOB INSPECTION

Immediately upon arrival examine all crates, boxes and ex-

posed compressor and component surfaces for damage.

Unpack all items and check against shipping lists for any

possible shortage.Examine all items for damage in transit.

TRANSIT DAMAGE CLAIMS

Allclaimsmustbemadebyconsignee.This is anICCrequire-

ment.Request immediate inspection by the agent of the car-

rier and be sure the proper claim forms are executed.

Report damage or shortage claims immediately to Frick,

Sales Administration Department, in Waynesboro, PA.

COMPRESSOR and UNIT IDENTIFICATION

Each compressor unit has 2 identification data plates.The

compressor data plate containing compressor model and

serial number is mounted on the compressor body.The unit

data plate containing unit model, serial number and Frick

salesordernumberismountedonthesideofthemotorbase.

NOTE: When inquiring about the compressor or unit,or

ordering repair parts, provide the MODEL, SERIAL, and

FRICKSALES ORDER NUMBERS from thesedataplates.

UNIT DATA PLATE

COMPRESSOR DATA PLATE

RWB II ROTARY SCREW COMPRESSOR UNITS

INSTALLATION

S70-200 IOM

Page 4

ALLOWABLE FLANGE LOADS

NOZ. MOMENTS (ft-lbf) LOAD (lbf)

SIZE AXIAL VERT. LAT. AXIAL VERT. LAT.

NPS MRMCMLPV

CVL

1 252525505050

1.25 25 25 25 50 50 50

1.5 50 40 40 100 75 75

2 100 70 70 150 125 125

3 250 175 175 225 250 250

4 400 200 200 300 400 400

5 425 400 400 400 450 450

6 1000 750 750 650 650 650

8 1500 1000 1000 1500 900 900

10 1500 1200 1200 1500 1200 1200

12 1500 1500 1500 1500 1500 1500

14 2000 1800 1800 1700 2000 2000

FOUNDATION

Each RWB II Rotary Screw Compressor Unit is shipped

mounted on a wood skid which must be removed prior to

unit installation.

Allow space for servicing both ends

of the unit. A minimum of 36 inches

is recommended.

The first requirement of the compressor foundation is that it

must be able to support the weight of the compressor pack-

ageincluding coolers,oil,andrefrigerantcharge. Screwcom-

pressors are capable of converting large quantities of shaft

power into gas compression in a relatively small space and

amassisrequired to effectivelydampenthese relativelyhigh

frequency vibrations.

Firmlyanchoring thecompressor packageto a suitablefoun-

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

arrangementdrawingsfromFrickCo.to determinethe mount-

ing foot locations and to allow for recommended clearances

aroundthe unit forease of operation and servicing. Founda-

tions 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 con-

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 RIGGING and HANDLING),

the feet must then be shimmed in order to level the unit. The

shims should be placed to position the feet roughly one inch

above the housekeeping 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.

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 I-beams 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

vibrationdirectly to the structure. However,this mayincrease

package vibration levels because the compressor is not in

contact with any damping mass. The 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.

Inanyscrewcompressor installation, suctionanddischargelines

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.

When applying screw compressors at high pressures, the

customer must be prepared for package vibration and noise

higherthanthevaluespredictedfornormal refrigerationduty.

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 S70-210 IB.

RIGGING and HANDLING

THISSCREWCOMPRESSOR PACK-

AGEMAYBETOP-HEAVY.USE CAU-

TION IN RIGGING AND HANDLING.

The unit can be moved with rigging, using a crane or forklift,

by hooking into the four lifting eyes on the compressor and

motor bases. If no motor is mounted, the lifting ring should

be moved to the compressor side of the center of the unit

because 60 percent of the weight is toward the compressor

end.If a motor is mounted appropriate adjustment in the lift-

ing point should be made to compensate for motor weight.

Adjustment of the lifting point must also be made for any

additions to the standard package such as an external oil

cooler, etc., as the center of balance will be effected.

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.

SKID REMOVAL

If the unit is rigged into place the skid can be removed by

takingoffthenutsand bolts that arefasteningtheunitmount-

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.

RWB II ROTARY SCREW COMPRESSOR UNITS

INSTALLATION S70-200 IOM

Page 5

13/16 96.8 4 101.6 11/16 27.0 113/16 46.0 11/828.6 .004 .104 55 74.6 3/8- 24 UNF 13 17.6

5/16 109.5 57/16 138.1 17/16 36.5 23/16 61.9 17/16 36.5 .004 .104 55 74.6 3/8- 24 UNF 13 17.6

10 45/16 109.5 63/8161.9 111/16 42.9 29/16 65.1 111/16 42.9 .004 .104 130 176.4 1/2- 20 UNF 13 17.6

11 47/8123.8 57/8149.2 2 50.8 27/873.0 17/847.6 .004 .104 130 176.4 1/2- 20 UNF 13 17.6

DBZ-B HUB FACE MAXIMUMTOTAL CLAMP BOLT

COUPLING SPACING +/- INDICATOR READING TORQUE (LUBE) SIZE

SIZE in. mm in. mm in. mm ft-lb Nm

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 to see that the

shafts are properly spaced for the coupling being used.

Refer to the coupling data tables for the applicable dimen-

sion (pages 5 and 6).

CHECKING MOTOR/COMPRESSOR ROTATION

Make sure coupling hubs are tight-

enedto the shaft beforerotatingthe

motor to prevent them from flying

off and possibly causing serious injury or death.

COMPRESSOR ROTATION IS

CLOCKWISEWHENFACINGTHE

END OF THE COMPRESSOR

SHAFT. Under NO conditions

shouldthemotorrotationbe check-

edwiththecouplingcenterinstalled

asdamage to the compressor may

result.Bumpthemotortocheckfor

correct compressor rotation. After

verification, install gear or disk drive spacer, as applicable.

COMPRESSOR/MOTOR COUPLINGS

INSTALLATION

RWB II 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:

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 DATATABLE

CH COUPLING – TheT.B.Woods Elastomeric CH Coupling

is used in most applications up to 600 HP. 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.Torqueistransmittedfromthe motor through the elas-

tomeric gear which floats freely between the hubs.Install as

follows:

1. Slideone hub onto eachshaft as far as possible.Itmaybe

necessary to use a screwdriver as a wedge in the slot to

open the bore before the hubs will slide on the shafts.

2. Hold the elastomeric gear between the hubs and slide

both hubs onto the gear to fully engage the mating teeth.

Centerthegear and hub assemblyso there is equal engage-

ment 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

giveninthe CH DataTable.DO NOT USE ANY LUBRICANT

ONTHESE BOLTS.

4. Proceed to Coupling Alignment.

DBZ-B COUPLING – TheThomas DBZ-B coupling is used

on applications above 600 HP and with sleeve bearing mo-

tors that do not have axial end float constraint.The DBZ-B

coupling consists of two drive hubs and a flexible metal disc

drive spacer that is bolted to both hubs.A flexible steel disc

pack serves as the drive element.This disc pack is bolted to

the coupling hubs and prevents axial end float between the

compressor and motor shafts which may occur with sleeve

bearing motors. On sleeve bearing motors, the magnetic

center must be determined and maintained by securing the

coupling to the motor shaft with the shaft properly located.

Injury may occur if loose clothing, etc. becomes entan-

gled on the spinning motor shaft.

Ifthemotoriscoupledtothe compres-

sor using a fixed-end-play coupling,

such as a DBZ-B coupling, and the

motor is not properly centered, addi-

tionalthrust loads will betransmitted to the compressor bear-

ings that could result in premature bearing failure.Install as

follows:

1. Remove the eight locknuts and long bolts attaching the

center member to the disc pack.

2. Slide the disc pack and coupling hub assemblies on their

respective shafts.

3. Adjust the distance between hub faces as specified in the

DBZ-B DataTable by sliding the hubs.Key and secure hubs

CH COUPLING HUB MAXTOTAL KEYWAY

COUP- BETWEEN SHAFT SPACING SHAFT ENGAGEMENT FACE INDICATOR CLAMP BOLT SETSCREW

LING MIN* MAX MIN MAX SPACING READING TORQUE (DRY) TORQUE

SIZE in. mm in. mm in. mm in. mm in. mm in. mm ft-lb Nm SIZE ft-lb Nm

226 313/16 96.8 1/64 .40 .003 .076 14 19.5 5/16 - 24 UNRF

263 45/16 109.5 1/32 .79 .004 .102 22 30.6 3/8- 24 UNRF

301 47/8123.8 1/32 .79 .004 .102 37 51.5 7/16 - 20 UNRF

351 57/8149.2 1/32 .79 .004 .102 55 76.5 1/2- 20 UNRF

401 611/16 169.9 1/32 .79 .004 .102 49 68.2 1/2- 20 UNRF

DBZ-B COUPLING DATATABLE

* Required for shaft seal removal.

RWB II ROTARY SCREW COMPRESSOR UNITS

INSTALLATION

S70-200 IOM

Page 6

BP HUB FACE * DISC PACK CLAMPBOLT

SERIES SPACING BOLTTORQ. TORQ. DRY SIZE

SIZE in. mm ft-lb Nm ft-lb Nm UNF

BP48 4.88 124 40 54 41 56 3/8-24

BP53 5.88 150 60 81 65 88 7/16-20

BP58 6.00 152 120 163 100 136 1/2-20

BP58 6.69 170 120 163 100 136 1/2-20

BP63 7.00 179 120 163 100 136 1/2-20

* Max total indicator reading .003 in.or .076 mm for all sizes.

All rotating power transmission equipment is potentially dangerous. Ensure that the couplings are

properly guarded prior to turning on the power. Coupling guards are provided with the equipment

and must be in place and secured properly while the equipment is in operation.

SERIES 52 COUPLING DATATABLE

to the shafts by tightening setscrews.

4. Reinstall the eight previously removed bolts and locknuts.

Alternately tighten each locknut as you would the lug nuts

onanautomobile.NOTE:ALWAYSTURNTHE NUT.NEVER

TURNTHE BOLT.

5.Torque the locknuts to the value shown in the DBZ-B Data

Table for the size coupling being installed.

Lubricated and/or plated bolts and locknuts develop

higher bolt tension with less tightening than those that

are dry and not plated. Torques for

lubricated and/or plated bolts and lock-

nuts will generally fall in the lower

range; while those that are dry or as received from the fac-

tory fall into the upper range.Torque readings should be ob-

served while locknut is being turned.

6. Proceed to coupling alignment.

SERIES 52 COUPLING – TheThomas Series 52 coupling is

alsoused on applications above600HP.It has twodrivehubs,

a center spool, and disc packs which are bolted between the

center spool and each drive hub.A center spool and two flex-

ible steel disc packs serve as the drive element.These three

parts,situated betweenthe motor and compressorhubs,pre-

ventaxialend float betweenthe motor andcompressorshafts.

Endfloat tends to occur with sleevebearing motors.The mag-

neticcenter of the sleeve bearing motorsmustbe determined

and maintained by securing the coupling hub to the motor

shaft with the shaft properly located.

Injury may occur if loose clothing, etc. becomes en-

tangled on the spinning motor shaft.

Ifthemotoriscoupledtothe compres-

sor using a fixed-end-play coupling

such as the Series 52 coupling and

themotorisnot properlycentered,the additional thrust loads

will be transmitted to the compressor bearings. This addi-

tional thrust could result in premature bearing failure.Install

as follows:

1. Before proceeding with the alignment process found on

pages 7 and 8 of this manual, disassemble the Series 52

coupling noting the arrangement of bolts, washers, and

nuts as THEY MUST BE REPLACED IN THE SAME OR-

DER.Mark the adjoiningboltholesofeachpart,the twohubs,

the two disc packs, and the center spool, so they are put

back together in the same position.

2. Mount the coupling hubs on their respective shafts. The

hub is bored for an interference fit on the shaft. Heating of

the coupling hub may be necessary for assembly. DO NOT

SPOT HEAT THE HUB as it may cause distortion. Heat in

water, oil, or use a SOFT open flame and quickly position on

the shaft.

3. Adjust the distance between hub faces, as specified in the

Series 52 Coupling Data Table, by sliding the hubs. Key and

secure the hubs to the shafts by tightening the set screws.

4. Reassemblethe coupling with the discpacksandthe cen-

ter spool. Ensure that they are reassembled exactly as they

were disassembled.

WOODS BP SERIES COUPLING – isalso used on applica-

tions above 600 HP.It utilizes a center spool and two flexible

steeldiscpacksas the driveelement.Thesethreeparts,situ-

atedbetweenthe motor andcompressor hubs, prevent axial

end float between the motor and compressor shafts. End

float tends to occur with sleeve bearing motors.

Injury may occur if loose clothing, etc. becomes en-

tangled on the spinning motor shaft.

Ifthemotoriscoupledtothe compres-

sor using a fixed-end-play coupling

andthe motor is notproperlycentered,

theadditionalthrust loadswillbetransmittedtothe compres-

sor bearings.This additional thrust could result in premature

bearing failure. Install the BP Series coupling using the fol-

lowing instructions:

1. Before proceeding with the alignment process in the fol-

lowing section, disassemble the BP Series coupling noting

the arrangement of bolts, washers, and nuts as THEY

MUST BE REPLACED IN THE SAME ORDER. Mark the

adjoining bolt holes of each part, the two hubs, the two disc

packs, and the center spool, so they are put back together in

the same position.

2. Install the motor and compressor coupling hubs on their

respective shafts with the keys. Ensure that the hubs slide,

so that when the shim packs are installed, no axial stresses

are transferred to the shim packs because the coupling hub

is stuck.

3. Reassemblethe coupling with the discpacksandthe cen-

ter spool. Center the coupling between the shafts and en-

BP SERIES COUPLING DATATABLE

225 5 127.0 1/32 .914 .004 .102 .004 .102 7.5 10.5 1/4-20UNRF

262 5 127.0 1/32 .914 .004 .102 .004 .102 22 30.6 3/8-24UNRF

312 5-1/2 139.7 3/64 1.295 .004 .102 .004 .102 37 51.5 7/16-20 UNRF

350 6 152.4 3/64 1.295 .004 .102 .004 .102 55 76.5 1/2-20 UNRF

375 7 177.8 1/16 1.574 .004 .102 .004 .102 55 76.5 1/2-20 UNRF

425 7 177.8 1/16 1.574 .004 .102 .004 .102 96 133.6 5/8-18UNRF

450 8 203.2 1/16 1.574 .004 .102 .004 .102 96 133.6 5/8-18UNRF

500 9 228.6 5/64 2.083 .004 .102 .004 .102 250 348.0 7/8-14UNRF

COUP- HUB FACE MAXTOTAL INDICATOR READING CLAMP BOLT

LING SPACING +/- ANGULAR PARALLEL TORQUE (LUBE) SIZE

SIZE in. mm in. mm in. mm in. mm ft-lb Nm

RWB II ROTARY SCREW COMPRESSOR UNITS

INSTALLATION S70-200 IOM

Page 7

Figure 1 - Angular Misalignment

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 factory

but realignment MUST ALWAYS be done on the job site af-

tertheunitis securely mounted on its foundation.Initial align-

ment must be made prior to start-up and rechecked after a

few hours of operation.Final (HOT) field alignment can only

be made when the unit is at operating temperature. After fi-

nal(HOT)alignment has been made and foundtobesatisfac-

tory forapproximatelyone week, the motormaybe 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.

The following procedure is applicable to both the CH and

DBZ-B couplings.Dial indicators are to be used to measure

the angular and parallel shaft misalignment.Coupling align-

mentis attained byalternately measuring angularandparal-

lel misalignment and repositioning the motor until the mis-

alignment is within specified tolerances.

ALWAYS LOCK OUT MAIN MOTOR

DISCONNECT BEFORETOUCHING

MOTOR SHAFT. MISALIGNMENT

MUST NOT EXCEED .004" FOR ALL CH, DBZ-B AND

SERIES 52 COUPLINGS EXCEPT DBZ-B 226 WHICH

SHALL NOT EXCEED .003".

ANGULAR ALIGNMENT

1.To check angular alignment, as shown in Figure 1., attach

dialindicator rigidlyto the motor hub.Moveindicator stemso

it is in contact with the outside face of compressor hub, as

shown in Figure 2.

NOTE:When DBZ-B couplings are used on motors with

sleeve bearings, it is necessary to secure the two cou-

pling hubs with a bolt to prevent them from drifting apart

when rotating.

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.

Figure 2 - Dial Indicator Attached (at 12 o'clock)

Figure 3 - Dial Indicator at 6 o'clock

surethat the keysare fullyengaged in their keyways.Ensure

that they are reassembled exactly as they were disas-

sembled.Torque disc pack hardware to specification in BP

Series Coupling Data Table.

4. Key and secure the hubs to the shafts by tightening the

clamping bolts.Make sure that the keyways are offset 180°

to maintain balance.

5.Torque theclamping bolts of bothhubs to the torquevalue

given in the Data Table. DO NOT USE ANY LUBRICANT

ONTHESE BOLTS.

6.IMPORTANT:Only after theshaftclamping bolts are tight-

ened to their final torque can the keyway setscrew be tight-

ened! If the keyway setscrew is tightened before the shaft

clampingbolts are tightened,then the hub canbe cockedon

the shaft.

7. Proceed to Coupling Alignment.

3. Setthedial indicator at zerowhen viewedat the 12 o’clock

position, as shown in Figure 2.

4. Rotate both coupling hubs together 180° (6 o’clock posi-

tion), as shown in Figure 3.At this position the dial indicator

will showTOTAL angular misalignment.

NOTE:The use of a mirror is helpful in reading the indi-

cator dial as coupling hubs are rotated.

5. Loosen motor anchor bolts and move or shim motor to

correct the angular misalignment.

Afteradjustmentshavebeenmade forangular 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.

RWB II ROTARY SCREW COMPRESSOR UNITS

INSTALLATION

S70-200 IOM

Page 8

PARALLEL ALIGNMENT

6. To check parallel alignment, as shown in Figure 4, reposi-

tion dial indicator so the stem is in contact with the rim of the

compressor hub, as shown in Figure 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

parallelheight misalignment.

8. Loosen motor anchor bolts and add or remove shims un-

der the four motor feet until parallel height misalignment is

withinspecifiedtolerancewhenanchor bolts are retightened.

CARE MUST BE USEDWHEN COR-

RECTING FOR PARALLEL MIS-

ALIGNMENTTOENSURETHATTHE

AXIALSPACINGANDANGULAR MISALIGNMENT IS NOT

SIGNIFICANTLY DISTURBED.

9. After the parallel height misalignment is within tolerance,

repeatSteps 1through 5 until angularmisalignmentis within

specifiedtolerance.

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 Figure 6.

Set indicator at zero and rotate both coupling hubs together

180° (9 o'clock position), as shown in Figure 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 couplinghubs

together, checking the angular and parallel misalignment

throughthe full 360°travelat 90° increments.Ifdial readings

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.

Installthecoupling guardbeforeop-

erating the compressor.

When installing drive spacer, make

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.

Figure 4 - Parallel Misalignment

Figure 5 - Dial Indicator Attached (at 9 o'clock)

Figure 6 - Dial Indicator at 3 o'clock

RWB II ROTARY SCREW COMPRESSOR UNITS

INSTALLATION S70-200 IOM

Page 9

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 coupling

motor hub, then take readings of both the face and rim of the

compressorhub.Ifthesereadingsare within tolerance,record

reading, attach coupling guard and restart unit. However, if

the reading is not within limits, compare the hot reading with

thecold alignment and adjustforthis difference;i.e.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 re-

moved from under the motor.

Aftertheinitial hot alignment adjustment ismade,restart unit

and bring to operating temperature.Shut down and recheck

hotalignment. Repeat procedure unithot alignment is within

specified tolerance. INSTALL COUPLING GUARD BE-

FORE OPERATING COMPRESSOR.

OIL PUMP COUPLING

Compressor units with direct motor/pump coupled pumps

need no pump/motor coupling alignment since this is main-

tained by the close-coupled arrangement.

HOLDING CHARGE AND STORAGE

Each RWB II compressor unit is pressure and leak tested at

theFrickfactoryand then thoroughly evacuatedand 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 en-

sure that the nitrogen charge is safely released.

Holding charge shipping gauges

onseparator and external oil cooler

are rated for 30 PSIG and are for

checking the shipping charge only. They must be re-

moved before pressure testing the system and before

charging the system with refrigerant. Failure to remove

these gauges may result in catastrophic failure of the

gauge and uncontrolled release of refrigerant resulting

in serious injury or death.

All units must be kept in a clean, dry location to prevent cor-

rosion damage.Reasonable consideration must be given to

proper care for the solid-state components of the micropro-

cessor.

Unitwhichwillbestored formore than two months musthave

the nitrogen charge checked periodically.

COMPRESSOR UNIT OIL

DO NOT MIX OILS of different

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

Frick compressors must be ap-

proved in writing by Frick engineer-

ing or warranty claim may be denied.

Use of filter elements other than

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

thereisanydoubtduetotherefrigerant,operatingpressures,

or temperatures, refer to Frick Pub.E160-802 SPC for guid-

ance.

OIL CHARGE

Thenormalcharginglevelismidway

in the top sight glass located mid-

way along the oil separator shell.

Normal operating level is midway

betweenthe top sight glass and bot-

tom sight glass. The table gives the

approximate oil charge quantity.

* Includes total in oil separator and

piping.Additional oil supplied for oil

cooler.

Add oil by attaching the end of a

suitable-pressure-type hose to the

oilchargingvalve,locatedonthetop

of the oil separator at the compres-

sorend.Using a pressure-type pump andtherecommended

Frickoil,open the charging valve and pump oilintothe sepa-

rator.NOTE:Fill slowly because oil will fill up in the sepa-

rator faster than it shows in the sight glass.

Oil distillers and similar equipment which act to trap oil must

be filled prior to unit operation to normal design outlet levels.

The same pump used to charge the unit may be used for

filling these auxiliary oil reservoirs.

NOTE:The sight glass located in the coalescing end of

the separator near the discharge connection should re-

main empty.

OIL HEATER(S)

Standard units are equipped with two or three 500 watt oil

heaters,providingsufficient heat to maintain theoiltempera-

ture for most indoor applications during shutdown cycles to

permit safe start-up. Should additional heating capacity be

requiredbecause of low ambient temperature,contact Frick.

The heaters are energized only when the unit is not in op-

eration.

DO NOT ENERGIZETHE HEATERS when there is no oil

intheunit,the heaterswill burnout.

The oil heaters will be energized

whenever 120 volt control power is

applied to the unit and the compressor is not running,

unless the 16 amp circuit breaker in the micro enclosure

is turned off.

60 35

76 35

100 65

134 65

177 110

222 110

270 140

316 140

399 140

480 170

BASIC*

CHARGE

(gal.)

RWB II

MODEL

NO.

RWB II ROTARY SCREW COMPRESSOR UNITS

INSTALLATION

S70-200 IOM

Page 10

OIL FILTER(S)

Use of filter elements other than

Frick must be approved in writing

by Frick engineering or warranty

claim may be denied.

The oil filter(s) and coalescer filter element(s) shipped with

the unit are best suited to ensure proper filtration and opera-

tion of the system.

THERMOSYPHON OIL COOLING

Thermosyphonoilcoolingisaneconomical,effectivemethod

for cooling oil on screw compressor units. Thermosyphon

cooling utilizes liquid refrigerant at condenser pressure and

temperaturethat is partially vaporizedat the condenser tem-

perature in a plate and shell vessel, cooling the oil to within

15°F of that temperature. The vapor, at condensing pres-

sure, is vented to the condenser inlet and reliquified. This

methodisthe most cost effectiveofall currently applied cool-

ing systems since no compressor capacity is lost or com-

pressor power penalties incurred.The vapor from the cooler

need only be condensed, not compressed. Refrigerant flow

to the cooler is automatic, driven by the thermosyphon prin-

ciple 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 minimum above the center of the

oil cooler.

2. A plate and shell oil cooler with:

Plate Side: Oil 400 psi design

Shell Side: Refrigerant 400 psi design

Due to the many variations in refrigeration system design

and physical layout, several systems for assuring the above

criteria are possible.

SYSTEMOPERATION-Liquidrefrigerantfillsthe cooler shell

side up to the Thermosyphon receiver liquid level. See Fig-

ure 7.

Hotoil(abovetheliquidtemperature)flowingthroughthecooler

will cause some of the refrigerant to boil and vaporize. The

vapor rises in the return line. The density of the refrigerant

liquid/vapormixtureinthereturnline is considerablylessthan

the density of the liquid in the supply line.This imbalance pro-

vides a differential pressure that sustains a flow condition to

the oil cooler.This relationship involves:

1. Liquid height above the cooler.

2. Oil heat of rejection.

3. Cooler size and piping pressure drops.

Current thermosyphon systems are using two-pass oil cool-

ers and flow rates based on 3:1 overfeed.

The liquid/vapor returned from the cooler is separated in the

receiver.The vapor is vented to the condenser inlet and need

only be reliquified since it is still at condenser pressure.

OILTEMPERATURE CONTROL - Oil temperature will gen-

erallyrun about 15- 35°F abovecondensing temperature.In

manycases, an oil temperaturecontrol isnotrequired if con-

densing temperature is above 65°F as oil temperature can

be allowed to float with condenser temperature.

Condensing Temperature: 65°F - 105°F

OilTemperature: 80°F - 140°F

INSTALLATION -The plate and shell type thermosyphon oil

cooler with oil-side piping and a thermostatically controlled

mixingvalve(if ordered) are factory mountedand piped.The

customer must supply and install all piping and equipment

located outside of the shaded area on the piping diagram

with consideration given to the following:

1.The refrigerant source, thermosyphon or system receiver,

should be in close proximity to the unit to minimize piping

pressure drop.

2. The liquid level in the refrigerant source must be 6to 8

feet minimum above the center of the oil cooler.

3. A safety valve should be installed if refrigerant isolation

valves are used for the oil cooler.

The component and piping arrangement shown in Figure 8,

is intended only to illustrate the operating principles of ther-

mosyphon oil cooling. Other component layouts may be bet-

ter suited to a specific installation. Refer to publication E70-

900EforadditionalinformationonThermosyphon OilCooling.

HOT OIL IN

FROM

SEPARATOR

120-140 F

OIL OUT

TO SYSTEM CONDENSER

95 F

2.5#/FT

395 F

36#/FT

TS RECEIVER

Figure 7

RWB II ROTARY SCREW COMPRESSOR UNITS

INSTALLATION S70-200 IOM

Page 11

OPT. OIL TEMP

CONTROL VALVE

HOT

REFRIGERANT

OUT

REFRIGERANT IN

COOL

OIL OUT

HOT OIL IN

LIQUID

LEVEL

STATIC HEAD

TO OVERCOME

CONDENSER

PRESSURE DROP

6 Ft.

Min.

SYSTEM

CONDENSER

SAFETY

VALVE

VAPOR

THERMOSYPHON

RECEIVER

LIQUID OVERFLOW

DRAIN TO RECEIVER

TO SYSTEM

EVAPORATOR

SYSTEM

RECEIVER

(Mounted below Thermosyphon

receiver level)

PLATE COOLER

TSOC

LIQUID INJECTION OIL COOLING

(OPTIONAL)

The liquid injection system provided on the unit is self-con-

tained but requires the connection of the liquid line sized as

shown in the table and careful insertion of the expansion

valvebulbintothe thermowellprovidedintheseparator.High

pressure gas is connected through the regulator to the ex-

ternal porton the liquidinjection valveto control oil tempera-

ture.

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 3/8" line

connected into the solenoid valve provided.This gas is

required by the expansion valve external port to control

oil temperature.

It is IMPERATIVE that an uninterrupted supply of high pres-

sure liquid refrigerant be provided to the injection system at

all times. Two items of EXTREME IMPORTANCE 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.

The dual dip tube method uses two dip tubes in the receiver.

The liquid injection tube is below the evaporator tube to en-

sure continued oil cooling when the receiver level is low. See

Figure 9.

Figure 8

1. The thermosyphon oil cooler is supplied with the oil side piped to the compressor unit and stub ends supplied on the refrigerant

side.

2. A three-way oil temperature control valve is required where condensing temperature is expected to go below 65°F.

3. A refrigerant-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 andTSOC receiver, the safety valve on theTSOC 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.

Figure 9

RWB II ROTARY SCREW COMPRESSOR UNITS

INSTALLATION

S70-200 IOM

Page 12

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

dropin pressure level,eventuallybeing fullyopen to suction.

Because of this, an output from the microprocessor is gen-

erally used to turn off the supply of flashing liquid on a shell

and coil or DX economizer when the capacity falls below

approximately 45%-60% capacity (85%-90% slide valve po-

sition). This is done because the compressor will be more

efficient operating at a higher slide valve position with the

economizerturned off,thanit will at a low slide valveposition

with the economizer turned on. Please note however that

shell and coil and DX economizers can be used at low com-

pressor capacities in cases where efficiency is not as impor-

tant as assuring that the liquid supply is subcooled. In such

cases,the economizerliquidsolenoidcan be left open when-

ever the compressor is running.

WATER-COOLED OIL COOLING (Optional)

The plate and shell 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 if ordered in lieu of a three-way oil

temperature valve. It is recommended (local codes permit-

ting) that 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. The

watersupply mustbe sufficient tomeetthe required flow.

Frickrecommendsa closed-loop system forthe waterside of

*Based on 100 foot liquid line.For longer runs, increase line

size accordingly.

** For models 60 and 76, contact Frick engineering.

LIQUID LINE SIZES/RECEIVER VOLUME

Liquid line sizes and the additional receiver volume (quanti-

ty of refrigerant required for 5 minutes of liquid injection oil

cooling) are given in the following table:

LIQUID LINE SIZE and RECEIVER VOLUME

LINE SIZE* POUND LIQUID

RWB II SCH 80 OD PER VOLUME

MODEL ** PIPE TUBING 5 MIN. CU FT

R-717 HIGH STAGE*

100-134 3/4 – 80 2.0

177-270 1 – 140 4.0

316-480 1-1/4 – 250 7.0

R-717 BOOSTER*

100-134 1/2 – 20 0.5

177-270 3/4 – 30 1.0

316-480 1 – 40 1.5

R-22 HIGH STAGE*

100-134 1-1/4 1-1/8 290 4.0

177-270 1-1/2 1-3/8 570 8.0

316-480 2 2-1/2 1,050 14.0

R-22 BOOSTER*

100-134 3/4 7/8 44 0.6

177-270 3/4 7/8 59 0.8

316-480 3/4 7/8 92 1.2

The level-control method utilizes a float level control on the

receiver to close a solenoid valve feeding the evaporator

when the liquid falls below that amount necessary for 5 min-

utes of liquid injection oil cooling. See Figure 10.

Figure 10

the oil cooler.Careful attention to water treatment is essen-

tial to ensure adequate life of the cooler if cooling tower wa-

ter is used. It is imperative that the condition of cooling

water and closed-loop fluids be analyzed regularly and

as necessary and maintained at a pH of 7.4,but not less

than 6.0 for proper heat exchanger life. After initial start-

up of the compressor package, the strainer at the inlet of the

oilcoolershouldbecleanedseveraltimesinthefirst24 hours

of operation.

In some applications, the plate and shell oil cooler may be

subjectedtoseverewaterconditions,includinghightempera-

ture and/or hard water conditions.This causes accelerated

scalingrateswhich will penalize the performanceof the heat

exchanger. A chemical cleaning process will extend the life

of the Plate and Shell heat exchanger. It is important to es-

tablish regular cleaning schedules.

Cleaning:A 3% solution of Phosphoric or OxalicAcidis rec-

ommended. Other cleaning solutions can be obtained from

your local distributor, but they must be suitable for stainless

steel.The oil cooler may be cleaned in place by back flush-

ing with recommended solution for approximately 30 min-

utes.After back flushing, rinse the heat exchanger with fresh

water to remove any remaining cleaning solution.

NOTE:The water-regulating valve shipped with the unit

will be sized to the specific flow for the unit.

OIL COOLER DATATABLE

RWB II TYPICAL CONNECTION

MODEL COOLER INLET OUTLET

60 - 134 High Stage 116 Plates 3

100 - 270 Booster 66 Plates 2

177/222 High Stage 190 Plates 3

270 High Stage 288 Plates 3

316/399 Booster 56 Plates 3

316/399 High Stage 136 Plates 4

480 Booster 72 Plates 3

480 High Stage 188 Plates 4

RWB II ROTARY SCREW COMPRESSOR UNITS

INSTALLATION S70-200 IOM

Page 13

Due to the tendency of the port pressure to fall with de-

creasing compressor capacity, a back-pressure regulator

valve(BPR) isgenerallyrequiredon a flash economizer sys-

tem (Figure 13) 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 pressure will ap-

proach suction pressure at a decreased slide valve position.

In cases where wide swings in pressure are anticipated in

the flash economizer vessel, it may be necessary to add an

outlet pressure regulator to the flash vessel outlet to avoid

overpressurizing the economizer port, which could result in

motoroverload.Example:Asystemfeedingliquidto 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

preventsdirtfrompassing 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

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

forinstallationin the economizer line,asopposed to disc-

type check valves.The latter are more prone to gas- pul-

sation-induced failure. The isolation and check valves

and strainer should be located as closely as possible to

the compressor, preferably within a few feet.

Figure 12 - Direct Expansion Economizer System

Figure 11 - Shell and Coil Economizer System

Figure 14- Multiple Compressor Economizer System

Figure 13 - Flash Economizer System

HIGH

PRESSURE

LIQUID

INTERMEDIATE PRESSURE

GAS TO COMPRESSOR

SUCTION

STR VCK

SUBCOOLED

HIGH PRESSURE

LIQUID TO

EVAPORATOR

ECONOMIZER

COOLER

ECON1

HV-2

HIGH

PRESSURE

LIQUID

INTERMEDIATE PRESSURE

GAS TO COMPRESSOR

SUCTION

STR VCK

SUBCOOLED

HIGH PRESSURE

LIQUID TO

EVAPORATOR

ECONOMIZER

COOLER

WIRING

ECON2

HV-2

HIGH

PRESSURE

LIQUID

INTERMEDIATE PRESSURE

GAS TO COMPRESSOR

SUCTION

STR VCK

CONTROLLED

PRESSURE

SATURATED LIQUID

TO EVAPORATOR

ECONOMIZER

VESSEL

BPR

ECON3

HV-2

INTERMEDIATE PRESSURE

GAS TO COMPRESSOR

SUCTION

STR VCK BPR

CONTROLLED PRESSURE

SATURATED LIQUID TO EVAPORATOR

ECONOMIZER

VESSEL

ECON4

HV-2

For refrigeration plants employing multiple compressors 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 Figure 14.It is also recommended

thatthe back-pressureregulating valves,usedon economizer

lines, should be specified with electric shutoff option. The

electric shutoff feature is necessary to prevent flow from the

common economizer vessel to the suction side of a stopped

compressor, through the suction check valve bypass line, if

the other compressors and the common economizer vessel

are still operating and the HV2 valve on the suction bypass

is open.

For refrigeration plants using a Packaged Refrigerant Recir-

culation (PRR) unit and a direct expansion (DX) economizer

system it is necessary to operate the liquid feed solenoid on

the PRR unit and the liquid feed solenoid on the DX vessel

off of a common signal to avoid liquid overfeed on the DX

economizer system.

Ifmultiplecompressors are operatedwith a common econo-

mizer vessel, it is necessary to install a back-pressure regu-

lator valve with an electric shutoff option in the vapor line

pipedto the compressor's economizerport.If anelectricshut-

off is not installed in the economizer vapor line, valve HV-2

must remain closed to avoid a gas bypass from the econo-

mizer line through the suction check valve bypass, back to

the suction line on a compressor that is shut down.

RWB II ROTARY SCREW COMPRESSOR UNITS

INSTALLATION

S70-200 IOM

Page 14

ECONOMIZER LOAD BALANCING

The most energy efficient manner to operate an economizer

system, when using multiple compressors on a common

economizer vessel, is to take as much of the flash gas as

possible to the compressors that are fully loaded.This can

be done in at least two ways.

1. Use the economizer output from the microprocessor to

turnoff a solenoid, or toactuate the electric shutoff option on

a back-pressure regulator, based on percent of slide valve

travel.This will direct all the flash vapor to the other loaded

compressors.

2. Adual-setpointback-pressureregulator valvecan be used

in each of the individual economizer vapor lines. When a

compressor is running near full load, the BPR valve will op-

erateonthe desired setpoint, or basicallywideopen,to mini-

mize pressure drop in the line. When one compressor un-

loads below the slide valve position where the economizer

outputonthe microprocessor turns on, thedual-setpointfea-

ture of the regulator can be actuated by this output to control

the pressure, on the vessel side of the regulator, to be a few

psi higher. Consequently, the flash gas will be sent to the

loaded compressors first, until they can’t handle all the va-

por and the pressure in the vessel starts to rise.Then, some

ofthevaporwill go tothe unloadedcompressortohelp main-

tainthevesselat the desired pressure.Anexampleof a back-

pressureregulator with electric shutoff and thedual-setpoint

feature is an R/S A4ADS.

ELECTRICAL

NOTE:Beforeproceeding withelectrical installation,read

theinstructions in thesection“ProperInstallationof Elec-

tronic Equipment in an Industrial Environment”.

RWB II units are supplied with a

QUANTUM

control system.

Caremust be takenthat thecontrolsarenotexposedto physi-

cal damage during handling, storage, and installation. The

single-box control door must be kept tightly closed to pre-

vent moisture and foreign matter from entry.

NOTE:All customer connections are made in the single-

box control mounted on the oil separator. This is the

ONLY electrical enclosure and it should be kept tightly

closed whenever work is not being done in it.

MOTOR STARTER PACKAGE

SBC Board damage may occur

without timer relay installed in

control panel as shown in Starter

Wiring Diagram, Figure 15. All Frick motor starter pack-

ages have the timer relay as standard.

Motorstarter andinterlockwiring requirementsare shownin

the Starter Wiring Diagram. All of the equipment shown is

supplied by the installer unless a starter package is pur-

chasedseparatelyfromFrick .Starterpackagesshould con-

sist of:

1. The compressor motor starter of the specified HP and

voltageforthe startingmethodspecified(across-the-line,au-

totransformer, 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

if assistance is required.

2. Ifspecified,the starter packagecanbe supplied as a com-

binationstarter with circuitbreakerdisconnect.However, the

motorovercurrentprotection/disconnection devicecanbeap-

pliedbyothers, usually as apart of anelectrical power distri-

bution board.

3. The oil pump starter with fuses, or in the case where the

compressor motor is a different voltage from the oil pump

motor,with a circuit breaker disconnect suitableforseparate

power feed.

4. A 2.0 KVA control power transformer (CPT) to supply 120

volt control power to the microprocessor control system and

separator oil heaters is included. If environmental conditions

require more than the usual two 500 watt oil heaters, an ap-

propriately oversized control transformer will be required. If

frequentpowerfluctuations are anticipated orextremelynoisy

power lines are encountered,a regulating control transformer

should be considered. Contact FRICK for assistance.

5. For customer-supplied across-the-line starters, a shunt-

ing device must be installed across the CurrentTransformer

(terminals 3 & 4).

If the shunting device is not in-

stalled,the Analog I/O board on the

Quantum

panel may be severly

damaged at start-up (see Starter Wiring Diagram,

Figure 15).

6. One each normally open compressor motor and oil pump

motor starter auxiliary contact should be supplied. In addi-

tion to the compressor and oil pump motor starter coils, the

CT and CPT secondaries should be wired as shown on the

starter packagewiring diagram.The load on the control panel

for the compressor motor starter coil should not exceed a

Nema size 3 starter.For larger starters, an interposing relay

must be used to switch the compressor motor starter coil(s).

NOTE: Do not install a compressor HAND/OFF/AUTO

STARTERWIRING DIAGRAM

Figure 15

RWB II ROTARY SCREW COMPRESSOR UNITS

INSTALLATION S70-200 IOM

Page 15

BATTERY BACKUP

The battery backup is used only for date and time retention

during power interruption. All setpoints and other critical in-

formation are saved on EEPROM chips.

NOTE: It is not necessary to disconnect the battery

backup during extended downtime.

NOTE:The microprocessor will not operate without U24

and U35 EPROM chips installed. When U24 and U35

EPROM chips are not installed,the screen will display:

System Board Initialized

No boot device available,

Press enter to continue.

switch in the starter package as this would bypass the

compressor safety devices.

7.Thecompressor motorCurrentTransformer(CT) is installed

on any one phase of the compressor leads.

NOTE:The CT must see all the current of any one phase,

therefore in wye-delta applications BOTH leads of any

one phase must pass through the CT.

CURRENTTRANSFORMER (CT) RATIOS

The CT ratio for various motor sizes (with a 5 amp second-

ary) is given in the following table:

VOLTAGE

HP 200 230 380 460 575 2300 4160

20 100:5 100:5 50:5 50:5 50:5 - -

25 100:5 100:5 50:5 50:5 50:5 - -

30 200:5 100:5 100:5 50:5 50:5 - -

40 200:5 200:5 100:5 100:5 50:5 - -

50 200:5 200:5 100:5 100:5 100:5 - -

60 300:5 200:5 200:5 100:5 100:5 - -

75 300:5 300:5 200:5 200:5 100:5 - -

100 400:5 300:5 200:5 200:5 200:5 - -

125 500:5 400:5 300:5 200:5 200:5 - -

150 600:5 500:5 300:5 300:5 200:5 - -

200 800:5 600:5 400:5 300:5 300:5 100:5 50:5

250 800:5 800:5 500:5 400:5 300:5 100:5 50:5

300 1000:5 1000:5 600:5 500:5 400:5 100:5 50:5

350 - 1000:5 800:5 500:5 500:5 100:5 100:5

400 - - 800:5 600:5 500:5 200:5 100:5

450 - - 1000:5 800:5 600:5 200:5 100:5

500 - - 1000:5 800:5 600:5 200:5 100:5

600 - - 1200:5 1000:5 800:5 200:5 100:5

700 - - - 1200:5 1000:5 200:5 200:5

800 - - - - 1000:5 300:5 200:5

900 - - - - 1200:5 300:5 200:5

1000 - ----300:5200:5

1250 - ----400:5200:5

1500 - ----500:5300:5

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.

BURDEN MAXIMUM DISTANCE FROM

RATING FRICK PANEL

USING # USING # USING #

ANSI VA 14 AWG 12 AWG 10 AWG

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 148ft 236 ft

CONTROL POWER REGULATOR

Compressorunitsthatwillbeusedinareasthatsufferbrown-

outsand other significant powerfluctuations canbesupplied

with a control power regulator.See the following illustration,

Recommended Regulator Installation.

RECOMMENDED REGULATOR INSTALLATION

REMOVE JUMPERS 6 TO 6B & 2 TO 2B

DC POWER

EMI FILTER

SUPPLY

SEE SOLA CONNECTION CHARTS FOR

INPUT & OUTPUT CONNECTIONS

REMOVE FERRITE TUBE

WHEN SOLA IS ADDED,

NOTE: AT SOLA ASSEMBLY, MAKEWIRES 6, 2, GND, 6B, & 2B,

10 FT LONG. CUTWIRESTO LENGTH AT INSTALLATION

REGULATOR

H3H4

OUTPUT

INPUT

120/240 V. IN, 120 V. OUT

SOLA #63-23-112-4, 120 VA, 60 HZ

SHOWN HERE- CONSULT FRICK

FOR OTHER VOLTAGES/HZ

SOLA ENCLOSURE

GND TERM

2A6A

PS 1

LINE

LOAD

GREEN

FERRITE

TUBE

2B 2

GND LUG IN

H2 H1

LUG

GREEN

GND TERM

IN MICRO 2

Figure 16

RWB II ROTARY SCREW COMPRESSOR UNITS

OPERATION

S70-200 IOM

Page 16

OPERATION and START-UP INSTRUCTIONS

The Frick RWB II Rotary Screw Compressor Unit is an inte-

grated system consisting of six major subsystems:

1.Control Panel (See publication S90-010 O, M, & CS for

Quantum Panel and S70-200 OM for the Plus panel).

2.Compressor

3.Compressor Lubrication System

4.Compressor Oil Separation System

5.Compressor Hydraulic System

6.Compressor Oil Cooling System

7.Compressor Easy-Start System

The information in this section of the manual provides the

logical step-by-step instructions to properly start up and op-

erate the RWB II Rotary Screw Compressor Unit.

The following subsections must be read and understood

before attempting to start or operate the unit.

TDSH COMPRESSOR

The Frick RWB II rotary screw compressor utilizes mating

asymmetrical profile helical rotors to provide a continuous

flow of refrigerant vapor and is designed for both high pres-

sureand lowpressureapplications.Thecompressorincorpor-

ates 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-pointangularcontactballbearingstocarry

axial loads are mounted at the discharge end of compres-

sor.

3. Balancepistons located in theinletend of the compressor

toreduceaxial loads on theaxialloadbearings andincrease

bearing life.

4. Moveable slide valve to provide infinite step capacity con-

trol from 100 to 10%.

5. VOLUMIZER® volume ratio control to allow infinitely vari-

able volume ratio from 2.2 to 5.0 during compressor opera-

tion for all models except 480 which is 2.2 to 4.2.

6. Ahydraulic unloader cylinder to operatethe slidestopand

slide valve.

7. Bearing and casing design for 350 PSI discharge pres-

sure.This PSI rating applies only to the compressor and

does not reflect the design pressure of the various sys-

tem components.

8. All bearing and control oil vented to closed thread in the

compressor instead of suction port to avoid performance

penalties from superheating suction gas.

9. Shaft seal design to maintain operating pressure on seal

well below discharge pressure, for increased seal life.

10. Oil injected into the rotors to maintain good volumetric

and adiabatic efficiency even at very high compression ra-

tios.

11. Shaft rotation clockwise facing compressor, suitable for

all types of drives.SEE CAUTION.

12. Dual compressor casing design for very low airborne

noise transmission.

COMPRESSOR ROTATION IS

CLOCKWISE WHEN FACING THE

COMPRESSOR DRIVE SHAFT. THE

COMPRESSOR SHOULD NEVER BE OPERATED IN RE-

VERSEROTATION AS BEARING DAMAGEWILL RESULT.

Figure 16

COMPRESSOR LUBRICATION SYSTEM

The lubrication system on an RWB II screw compressor unit

performs several functions:

1. Provides lubrication to bearings and seal.

2. Provides a cushion between the rotors to minimize noise

and vibrations.

3.Helps keepthecompressorcooland preventsoverheating.

4. Provides an oil supply to hydraulically actuate the slide

valve and slide stop.

5. Provides oil pressure to the balance pistons to help in-

crease bearing life.

6. Provides an oil seal between the rotors to prevent rotor

contact or gas bypassing.

Thecompressorunit maybe equipped with eitherano pump

or a demand pump lubrication system. Additionally, either

systemmaycontain dual oilfilters and liquid injection, water-

cooled, or thermosyphon oil cooler for compressor oil cool-

ing.

NO PUMP OIL SYSTEM

The RWB II screw compressor unit is designed to be

self-lubricating. Oil being supplied to the compressor from

theoil separatoris at system headpressure.Withinthecom-

pressor, oil porting to all parts of the compressor is vented

backto a point inthe compressor’sbody that isata pressure

lowerthancompressordischargepressure.The compressor’s

normaloperationmakesthecompressorunit operate essen-

tially as its own oil pump. All oil entering the compressor is

moved by the compressor rotors out the compressor outlet

and back to the oil separator.

For normal high-stage operation an oil pump is not required.

COLD-START SYSTEM

The RWB II package is equipped with a special "cold start"

discharge check valve on the gas outlet connection of the oil

separator (see Figure 17).This valve causes the oil separa-

tor to develop oil pressure rapidly on initial start in order to

lubricate the compressorwithoutrequiring anoilpump,even

in cold ambient temperatures with all pressures equalized.

For high-stage packages, the cold-start valve is equipped

RWB II ROTARY SCREW COMPRESSOR UNITS

OPERATION S70-200 IOM

Page 17

with a large spring that creates 30 psi of pressure in the oil

separator(abovesuctionpressure),forlubrication ofthecom-

pressor.

DONOTATTEMPTTOSERVICETHECOLD STARTVALVE.

PLEASE CONTACTTHE FRICK SERVICE DEPARTMENT.

Once the compressor is running it will begin to force gas to

the condenser at connection P2. As the condenser heats up

it will begin to rise in pressure as the compressor suction

pulls down in pressure. As soon as differential pressure is

developed between the condenser and suction, these pres-

sures act across a piston inside the cold-start valve to par-

tially overcome the spring force.When the differential pres-

surereaches and exceeds30 psi,thepiston fully overcomes

the spring force and powers the valve fully open for very low

operating pressure drop.

For booster applications, the valve is equipped with a lighter

spring which produces 15 psioilpressureabovesuctionpres-

sure before it fully powers open.

The RWB II package is also equipped with a suction check

valvebypass.Theoil separatorwill slowlybleeddown to sys-

tem suction pressure when the unit is stopped.This allows

the compressor drive motor to have an easier start, and the

discharge check valve will seat more tightly. See the "SUC-

TION CHECK VALVE BYPASS" section for operation.

NOTE: For alarm descriptions and shutdown or cutout

parameters, see publication S90-010 O.

COLD STARTVALVE

DEMAND PUMP OIL SYSTEM

This system is designed to provide adequate compressor

lubrication forsomehighstage applications that operate with

low differential pressure across the compressor suction and

discharge and all booster applications.

During the period from start-up to normal operation the oil

pressure alarm and oil pressure cutout setpoints will vary

according to formulas built into the microprocessor control

program.

NOTE: For alarm descriptions and shutdown or cutout

parameters, see publication S90-010 O.

COMPRESSOR OIL SEPARATION SYSTEM

The RWB II 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 dis-

charged 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

intodroplets which fallto thebottom of the coalescersection

ofthe oil separator.The returnof this oil to the compressor is

controlledbya throttling valveon both high stage and booster

applications (see Figure 18).

NOTE: Open throttling valve only enough to keep coa-

lescer end of separator free of oil.

The sight glass located near the bottom of the coalescer

section of the oil separator should remain empty during nor-

maloperation.Ifanoilleveldevelopsand remains in the sight

glass, a problem in the oil return separation system or com-

pressor operation has developed.Refer to MAINTENANCE

for information on how to correct the problem.

OIL SEPARATION SYSTEM

Figure 17

Figure 18

RWB II ROTARY SCREW COMPRESSOR UNITS

OPERATION

S70-200 IOM

Page 18

COMPRESSOR HYDRAULIC SYSTEM

The compressor hydraulic system moves the movable slide

valve(MSV) toloadandunloadthecompressor.It also moves

the movable slide stop (MSS) to increase or decrease the

compressor’s volume ratio (Vi).

The hydraulic cylinder located at the inlet end of the TDS

compressor serves a dual purpose.It is separated by a fixed

bulkhead into two sections.The movable slide valve (MSV)

section is to the left of the bulkhead and the movable slide

stop(MSS) to the right.Bothsectionsare considered double

acting hydraulic cylinders as oil pressure moves the pistons

in either direction.

Both sections are controlled by double-acting, four-way so-

lenoid valves which are actuated when a signal from the

appropriate microprocessor output energizes the solenoid

valve.

Compressor Loading: The compressor loads when MSV

solenoidYY2 is energized and oil flows from the oil manifold

throughvalveports P and B to cylinderport SC-2and enters

the load side of the cylinder.Simultaneously, oil contained in

the unload side of the cylinder flows out cylinder port SC-1

through valve ports A and T to compressor closed thread

port.

Compressor Unloading: The compressor unloads when

MSV solenoid YY1 is energized and oil flows from the oil

manifold through valve ports P and A to cylinder port SC-1

and enters the unload side of the cylinder. Simultaneously,

oil contained in the load side of the cylinder flows out com-

pressorportSC-2through valveportsBandT tocompressor

closed thread port.

Figure 19

NOTE: High Stage Operation: An alternative piping ar-

rangement has been provided to increase slide valve

response time during high stage operation.

Higheroperatingpressureswillslowthecompressorunload-

ingresponse time.Unloadingresponsetimecan be increased

by closing valve 1 (oil manifold pressure) and opening valve

2 to compressor suction pressure. See Figures 19 and 20.

NEVER OPENVALVE 1

AND

VALVE 2 ATTHE SAMETIME

DURING COMPRESSOR OPERATION.

VOLUMIZER® VOLUME RATIO CONTROL

Vi Increase

Models 60 through 480: The volume ratio Vi is increased

when MSS solenoidYY3 is energized and oil flows from the

oilmanifoldthrough valveports P and A to cylinder port SC-3

and enters the increase side of the cylinder.Simultaneously,

oil contained in the decrease side of the cylinder flows out

cylinder port SC-4 through valve ports B and T to compres-

sor closed thread port.

Vi Decrease

Models 60 through 480: The volume ratio Vi is decreased

when MSS solenoidYY4 is energized and oil flows from the

oilmanifoldthrough valveports P and B to cylinder port SC-4

and enters the decrease side of the cylinder.Simultaneous-

ly, oil contained in the increase side of the cylinder flows out

cylinder port SC-3 through valve ports A and T to compres-

sor closed thread port.

MSV and MSS HYDRAULIC CYLINDER and SOLENOIDVALVES

MODELS 60 – 480

RWB II ROTARY SCREW COMPRESSOR UNITS

OPERATION S70-200 IOM

Page 19

COMPRESSOR OIL COOLING SYSTEMS

The RWB II unit can be equipped with one of several sys-

temsforcontrolling the compressor oil temperature.Theyare

single or dual-port liquid injection, or thermosyphon and

water-cooled oil coolers. Each system is automatically con-

trolled, independent of compressor loading or unloading.

Oil cooling systems should maintain oil temperature within

the following ranges for R-717 and R-22:

Liquid Injection External*

Oil Cooling Oil Cooling

130 - 150°F 120 - 140°F

*Thermosyphon oil cooling (TSOC) orWater-cooledoilcool-

ing (WCOC).

SINGLE-PORT LIQUID INJECTION

The single-port liquid injection system is designed to permit

liquidrefrigerant injection into oneport on thecompressor at

any given moment and operates as outlined.

SolenoidvalveSV5isenergizedbythe microprocessor when

thetemperaturesensor,installed in theoilmanifold,exceeds

the LICO set point. High pressure liquid refrigerant is then

supplied to the temperature control valve (TCV). The tem-

perature control valve is equalized to a constant back pres-

sure by the differential pressure control valve (PDCV).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 compres-

sor suction to ensure steady and constant operation of the

valve.

RWB II BOOSTER OR SWING DUTY

APPLICATION

Discharge gas from the high stage compressor is required

toassistthedifferentialpressure control valve(PDCV) inpro-

viding the temperature control 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 shutdown. A Frick-installed timer limits the

high pressure gas to only thirty seconds duration, since in-

termediate gas pressure and spring tension are sufficient to

maintain closure on unit shutdown.A metering valve is also

provided for use as a service valve and to allow discharge

gas flow regulation to prevent excessive force and resulting

closure“hammering”.

A field-installed 1/4 inch OD tubing connection is required

between the high stage compressor discharge piping line

(or receiver) and the check valve.

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-

antintooneoftwoports optimally located on the compressor.

This minimizes the performance penalty incurred with liquid

injection oil cooling.

The dual-port system contains all the components of the

single-port system with the addition of a double acting sole-

noid valve SV7 and operates as outlined.

SolenoidvalveSV5isenergizedbythe microprocessor when

thetemperaturesensor,installed in theoilmanifold,exceeds

the LICO set point.Liquid refrigerant is then passed through

the temperature control valve (TCV) to the double-acting

solenoid valve SV7.Depending on the compressor’s operat-

ing volume ratio (Vi), the microprocessor will select the flow

ofthe liquid refrigeranttoeithercompressor portSL-1 orSL-2,

whichever is more efficient.

When the compressor operates BELOW 3.5Vi, compressor

port SL-1 supplies the liquid cooling. When the (Vi) rises

ABOVE 3.5Vi, port SL-2 supplies the liquid cooling.

Thetemperaturecontrol valveis equalizedtoaconstantback

pressure by the differential pressure control valve (PDCV).

Both the differential pressure control valve (PDCV) and the

double-actingsolenoid valveSV7 use discharge gas to main-

tain downstream pressure. The gas downstream of both

valvesis bled off tothecompressor suction to ensuresteady

and constant operation of the valves.

LIQUID INJECTION ADJUSTMENT

PROCEDURE

1. Close back-pressure bleed valve (V4).

2. Set pressure regulator valve (PDCV) for approximately

100 to 110 psig.

3. Open back-pressure bleed valve (V4) approximately one

quarter turn.

4. Monitor the oil temperature of the compressor. If the oil

temperature rises above 150°F, open back-pressure bleed

valve (V4) a very small amount.This will reduce pressure on

the equalizer and allow more refrigerant to flow to the com-

pressor.Iftheoiltemperaturedropsbelow130°F, close back-

pressure bleed valve (V4) a very small amount.This will in-

crease pressure on the equalizer and allow less refrigerant

to flow to the compressor, thus raising the oil temperature.

Theidealconditionistomaintainanoiltemperatureasstable

as possible.By keeping the liquid injection system correctly

tuned,extremeswingsin the discharge temperatureand the

oil temperature can be avoided.

Back-pressure bleed valve (V4) must always be cracked

open a small amount to prevent re-

frigerant from condensing in the

tubing.

RWB II ROTARY SCREW COMPRESSOR UNITS

OPERATION

S70-200 IOM

Page 20

SUCTION CHECK VALVE

Low temperature booster compressor operations require a

more positive suction check valve closure. This is accom-

plished by allowing the high stage discharge pressure gas

to assist the spring tension and intermediate pressure clos-

ingforce.

Frick provides a power assist kit consisting of a mounted

and wired solenoid valve and timer on all RWB II booster

compressors. High stage compressors are supplied with a

power assist kit when the design suction temperature is less

thanorequalto0°F.The wiringdiagramin S90-010 M (Quan-

tum) or S70-200 OM (Plus) shows the wiring included when

required.Introductionof high discharge pressure gas is made

to the check valve. A timer limits the high pressure gas to

onlythirty seconds duration since intermediate gas pressure

and spring tension are sufficient to maintain closure on unit

shutdown. A metering valve is also provided for use as a

service valve and to allow discharge gas flow regulation to

prevent excessive force and resulting closure “hammering”.

SUCTION CHECK VALVE BYPASS

Duringnormaloperation,valveHV1 is closed.Thisisapump-

out connection to allow refrigerant removal to the system

suction prior to evacuation for servicing.Valve HV-2 must be

open in most systems at all times. It should normally be

cracked open to allow the oil separator to slowly bleed down

to system suction pressure when the unit is stopped (having

this valve cracked open allows the compressor drive motor

to have an easier start, and the discharge check valve will

seat more tightly).If the drive coupling backspins, the valve

shouldbeadjusteddownuntil the backspinstops.If the sepa-

rator oil level foams excessively on shutdown, HV-2 should

be closed slightly. If the separator takes more than 20 – 30

minutes to equalize to suction pressure after shutdown, HV-

2 can be opened slightly. See Figure 20.

NOTE: HV-2 should be closed on systems with suction

pressures below atmospheric pressure, to avoid the

pos

sibility of air leakage into the system during shut-

down. However, on high-stage or booster systems with

check valve, HV-2 can remain open.

HV-2 also should beclosedon systems that utilizeautocycle

torestart thecompressor,based on increase insystem suc-

tionpressure duringshutdown,ifslowlybleedingtheoilsepa-

ratorgas tosuction will raise the suction pressureenough to

cause short cycling of the compressor.

Also it is important to close HV-2, if the oil pump is to be run

forlongperiods of time with thecompressorstopped,toavoid

oil being pumped up the suction line.

Ifmultiple compressors are operatedwith a common econo-

mizer vessel, it is necessary to install a back-pressure regu-

lator valve with an electric shut-off option in the vapor line

pipedto the compressor's economizerport.Ifanelectric shut-

off is not installed in the economizer vapor line, valve HV-2

must remain closed to avoid a gas bypass from the econo-

mizer line through the suction check valve bypass, back to

the suction line on a compressor that is shut down.

LOW AMBIENT OPERATION

Itis recommended that oil separatorsbe insulated asamini-

mum requirement to preserve the heat generated by the oil

heaters.It is important that the coalescer end of the separa-

tor be insulated to prevent refrigerant condensation.

Onsystemslocatedoutdoorsorinunheatedbuildingswhere

the ambient temperature could drop below +40°F, insulating

and/or heat tracing of the compressor lube oil systems is

highly recommended.

When low ambient temperatures (below +20°F) are a possi-

bility,it is recommendedthatlubeoillines,oilfilters,oilpumps

and oil coolers be heat traced and insulated.

Freeze-up protection must also be provided for all water-

cooled equipment

SUCTION CHECK VALVE

POWER ASSIST KIT

Low temperature booster compressor operations require a

more positive suction check valve closure. This is accom-

plished by allowing the high pressure discharge gas to as-

sist the spring tension and intermediate pressure closing

force.The powerassist kit(Figure21)isfactoryinstalled with

the discharge gas pressure being supplied from a connec-

tion on the dry end of the oil separator.It may be necessary

POWER ASSIST KIT

TO COMPRESSOR

DISCHARGE

PWRASST

Figure 21Figure 20

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