Frick SBTP 4013 Owner's manual

Form 070.655-IOM (MAY 2019)
INSTALLATION - OPERATION - MAINTENANCE
File: SERVICE MANUAL - Section 070
Replaces: NOTHING
Dist: 3, 3a, 3b, 3c
ROTARY SCREW COMPRESSOR
SBTP 4013, 4018, and 4021
THIS MANUAL CONTAINS RIGGING, ASSEMBLY, START-UP,
AND MAINTENANCE INSTRUCTIONS. READ THOROUGHLY
BEFORE BEGINNING INSTALLATION. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR DEATH,
DAMAGE TO THE UNIT, OR IMPROPER OPERATION.
Check www.jci.com/FRICK for the latest version of this publication.

070.655-IOM (MAY 19)
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SBTP 408 ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
Contents
GENERAL INFORMATION
Preface ............................................................................. 3
Design limitations ............................................................. 3
Job inspection .................................................................. 3
Standard bare compressor ............................................... 3
Transit damage claims ...................................................... 3
Compressor identication ................................................ 3
Long term storage............................................................. 4
Preparing compressor for storage..................................... 4
Maintaining compressor.................................................... 5
Description........................................................................ 5
FRICK 408 mm compressor .......................................... 5
Compressor lubrication system .................................... 5
Oil pump ....................................................................... 5
Construction details...................................................... 6
INSTALLATION
Design limits ..................................................................... 7
Outline dimensions ........................................................... 7
Holding charge and storage .............................................12
Rigging and handling........................................................12
Foundation ......................................................................12
Customer connections .....................................................12
Compressor oil.................................................................13
Oil pump ..........................................................................13
Compressor rotation is clockwise when facing the end
of the compressor shaft...............................................13
Motor mounting (foot mounted only)...........................13
Compressor/motor coupling requirements...................13
Coupling alignment requirements ................................13
Oil heater(s) .....................................................................13
Oil lter(s) .......................................................................13
Oil cooling requirements................................................. 14
Dehydration / evacuation test ......................................... 14
Electrical installation ....................................................... 14
Slide stop transmitter ................................................. 14
Capacity slide valve transmitter .................................. 14
Directional control valves ...........................................15
OPERATION
Operation and start-up instructions ................................16
Compressor hydraulic system .........................................16
Volumizer volume ratio control .......................................16
Low ambient operation ...................................................17
Initial start-up .................................................................17
Initial start-up procedure ............................................17
Normal start-up procedure .........................................17
MAINTENANCE
General information ........................................................18
Normal maintenance operations .....................................18
General maintenance ..................................................18
Changing oil ................................................................18
Recommended maintenance program ........................18
Vibration analysis.............................................................18
Oil quality and analysis ....................................................19
Operating log ..............................................................19
Troubleshooting guide .....................................................19
Abnormal operation analysis and
correction ...................................................................19
Capacity linear transmitter replacement -
slide valve .................................................................. 20
Volumizer transmitter replacement - slide stop.......... 20
Bare compressor replacement ....................................... 20
Shutdown due to
improper oil pressure ..................................................... 20
Troubleshooting the 408 mm compressor .......................21
Troubleshooting the hydraulic system ..............................21
Troubleshooting the oil pump and system .......................22
Vibration data sheet........................................................ 24
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.
Indicates an operating procedure, practice, etc., or portion thereof which is essential to highlight.
WARNING
CAUTION
DANGER
NOTICE

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SBTP 408 ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
THE INFORMATION CONTAINED IN THIS
DOCUMENT IS SUBJECT TO CHANGE
WITHOUT NOTICE
GENERAL INFORMATION
PREFACE
This manual has been prepared to acquaint the owner and
serviceman with the Installation, Operation, and
Maintenance procedures as recommended by Johnson
Controls-FRICK®for 408 mm Hydro-dynamic Rotary Screw
Compressors.
It is most important that these compressors be properly
applied to an adequately controlled refrigerant or gas sys-
tem. Your authorized Johnson Controls-FRICK representa-
tive should be consulted for expert guidance in this deter-
mination.
Proper performance and continued satisfaction with these
units is dependent upon:
CORRECT INSTALLATION
PROPER OPERATION
REGULAR, SYSTEMATIC MAINTENANCE
To ensure correct installation and application, the equipment
must be properly selected and connected to a properly
designed and installed system. The engineering plans, and
piping layouts, for example, must be detailed in accordance
with the best practices and local codes, such as those
outlined in ASHRAE and API literature.
A screw compressor is a vapor pump. To be certain that it
is not being subjected to pumping liquid, it is necessary that
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 are made for control; operating cycles and stand
still periods are reasonable; and that high side components
are sized within system and compressor design limits.
It is required that the discharge temperature be kept high
enough to prevent condensation of any moisture in the
compressor and oil separator.
DESIGN LIMITATIONS
FRICK 408 mm compressors are designed for operation
within the pressure and temperature limits which are
specied by Johnson Controls-FRICK and our CoolWare™
selection software. They are primarily used for compressing
refrigerant gas and most hydrocarbon gasses.
If your application is for sour gas, there are special
requirements to protect the compressor. Contact Johnson
Controls-FRICK Compressor Engineering for application
details.
JOB INSPECTION
Immediately upon delivery, examine all crates, boxes, and
exposed compressor and component surfaces for damage.
Unpack all items and check against shipping lists for any
discrepancy. Examine all items for damage in transit.
STANDARD BARE COMPRESSOR
Items not included with bare compressor that are available
as sales order options include a solenoid valve block, and
solenoid valves.
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
Johnson Controls-FRICK Sales Administration Department,
Waynesboro, PA.
COMPRESSOR IDENTIFICATION
Each compressor has an identication data plate, containing
compressor model and serial number mounted on the
compressor body.
NOTICE
When inquiring about the compressor or unit, or
ordering repair parts, provide the model and serial
numbers from the data plate (See Figure 1), as well as
the Johnson Controls-FRICK sales order number.
100 CUMBERLAND VALLEY AVENUE
WAYNESBORO, PA 17268
ROTARY SCREW COMPRESSOR
MODEL NO.
MAX DRIVER SPEED MAX ALLOWABLE PRESSURE
PART NO.
RPMPSIG BARG
ASSEMBLED IN
FROM FOREIGN AND DOMESTIC MATERIALS
SERIAL NO.
Figure 1: Identication data plate
Rotary screw compressor serial numbers are dened by the
following information:
Example: 10240A90000015Z
Global Additional
Plant Decade Month Year seq. no. remarks
1024 0 A 9 0000015 Z
Month:
A = JAN, B = FEB, C = MAR, D = APR, E = MAY, F = JUN,
G = JUL, H = AUG, K = SEP, L = OCT, M = NOV, N = DEC.
Additional Remarks:
R = Remanufactured;
Z = Deviation from Standard Conguration.

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SBTP 408 ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
The name plates in Figure 2 show which refrigerants are
compatible with the compressor as manufactured.
R290, R1270, NATURAL GAS
COMPRESSOR OPERATES ON AND IS
COMPATIBLE WITH THE FOLLOWING
REFRIGERANTS
Figure 2: Refrigerant name plates
LONG TERM STORAGE
Long term storage (6 months to 5 years) provisions are
required, regardless of storage environment, if start-up
and/or useful operation does not occur within six (6) months
of equipment shipment. Special provisions may be required
for storage of less than six (6) months if the storage area is
subject to unusual environment such as high humidity, large
changes in temperature, dusty atmosphere, etc.
It is recommended that arrangements be made with the
local Johnson Controls-FRICK service organization
(arranged through factory service) regarding surveillance
and maintenance during the storage period. It will be the
customer’s responsibility to submit a monthly report
showing the condition of the unit and noting any
discrepancies to the guidelines listed herein. Failure to
comply with this long term storage recommendation may
void the warranty.
Long term storage of equipment may lead to the
deterioration of components over the period of time.
Synthetic components in the compressor may deteriorate
over time even if they are not kept ooded with oil. A warm
and dry environment is essential to minimize environmental
and corrosion damage. Long term storage of the affected
equipment at a customer’s site may involve additional
requirements and interested parties should refer to the
Johnson Controls web site, www.johnsoncontrols.com/
FRICK, for specic instructions (Location: Bare Compressors\
General\Warranties\Screw Compressor Purchased for Long
Term Storage).
The following guidelines must be followed to maintain the
screw compressor warranty.
PREPARING COMPRESSOR FOR STORAGE
Evacuate compressor to remove moisture. Evacuation lines
are to be connected to port SM1. Evacuation lines are to be
connected to the Schrader valves provided with the
compressor. One valve is connected to compressor suction.
The other valves are located on the cylinder. Break vacuum
with dry nitrogen and bring pressure to zero psig.
Pump oil into the same ports mentioned in step 1. Johnson
Controls-FRICK recommends break-in oil P/N 111Q0831809
for storage purposes. The amount of oil needed is:
4021 120 gallons
4018 115 gallons
4013 100 gallons
After the compressor is oil charged, pressurize compressor
to 5 psig to 15 psig with nitrogen.
Compressor and packaged equipment storage log
Model Serial No.
Compressor, motor
oil pump and
refrigerant pump
shaft rotation
1½ Turn
Rotor
Housing
Charge
Charge
added
Visual
Inspection
Per qai-3 Charge Checked by Date
Compressor
model
Rotor
diameter
mm
Rotor
L/D
Max
speed
rpm
Theoretical
displacement
ft³/ rev (m³/rev)
Displacement at
3550 rpm
driver speed
ft³/rev (m³/rev)
Displacement at
2950 rpm
driver speed
ft³/rev (m³/h)
4013 408 1.3 3,600 1.41180 (0.03998) 5,012 (8,515) 4,165 (7,076)
4018 408 1.8 3,600 1.95481 (0.05535) 6,940 (11,790) 5,767 (9,798)
4021 408 2.13 3,600 2.31319 (0.06550) 8,212 (13,952) 6,824 (11,594)
Table 1: Compressor specications
Table 2: Compressor and packaged equipment storage log

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SBTP 408 ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
MAINTAINING COMPRESSOR
Ensure that the 5-15 psig nitrogen charge is maintained
with 15 psig preferred.
Rotate the male rotor shaft every two weeks. Mark the
shaft to ensure the rotor does not return to the original
position.
The compressor must be stored inside a dry building
environment.
Grease the male rotor shaft to prevent rust.
Record all information in a “Compressor Long Term Storage
Log.” See bottom of page 4.
Contact Johnson Controls-FRICK Service with any questions
regarding long term storage.
DESCRIPTION
FRICK 408 MM COMPRESSOR
The FRICK 408 mm rotary screw compressor utilizes mating
asymmetrical prole helical rotors to provide a continuous
ow of vapor and is designed for both high-pressure and
low-pressure applications. The compressor incorporates
the following features:
1. High-capacity sleeve bearings to carry radial loads at
both the inlet and outlet ends of the compressor.
2. Heavy-duty, tilt-pad thrust bearings are mounted at the
discharge end of the compressor to carry axial loads.
3. Moveable slide valve to provide fully modulating capacity
control from 100% to approximately 15% (condition
dependent) of full load capacity.
4. Volumizer volume ratio control to allow innitely
variable volume ratio from 2.2 to 5.0 for all 408 mm
models (except the 4021: Vi = 2.2 – 4.3) during
compressor operation.
5. A hydraulic cylinder to operate the slide stop and slide
valve.
6. Housings are designed for 600 psig pressure.
7. Shaft seal housing is designed to maintain operating
pressure on seal well below discharge pressure for
increased seal life.
8. Oil injected into the rotors to maintain good volumetric
and adiabatic efciency even at very high compression
ratios.
9. Shaft rotation clockwise facing compressor from the
drive end, suitable for all types of drives. See the
following warning.
WARNING
Compressor rotation is clockwise when facing the
compressor drive shaft. The compressor should never
be operated in reverse rotation, as bearing damage
will result.
10. Suction and discharge anges are ANSI B16.1 Class 300
for all models.
11. The 408 mm compressors must be tted with a suitable
strainer, #60 mesh X .0065” diameter stainless steel
wire or better, to prevent damage to the compressor
from particles entering the suction area.
COMPRESSOR LUBRICATION SYSTEM
The lubrication system on a 408 mm screw compressor
performs several functions:
1. Provides lubrication to bearings and seal.
2. Provides a cushion between the rotors to minimize
noise and vibrations.
3. Helps keep the compressor cool and prevents
overheating.
4. Provides an oil supply to hydraulically actuate the slide
valve and slide stop.
5. Provides an oil seal between the rotors to prevent rotor
contact or gas bypassing.
OIL PUMP
A full-time lube oil pump is required for all sleeve bearing
compressor applications. Refer to CES 6608 for basic oil
pump requirements and basic piping diagrams. Actual
system operating conditions may necessitate the need for
piping systems other than those addressed by CES 6608.
Contact Johnson Controls-FRICK Service for assistance.
The pump must be run prior to starting the compressor to
ensure adequate oil pressure and temperature is being
supplied to the machine. This is accomplished by using an
automated diverting valve which bypasses oil ow back to
the oil separator until the proper oil conditions are veried.
At that point, the diverter valve should be switched to direct
oil to the compressor, and the compressor can be started.
At shutdown, the oil pump must continue to run until the
compressor has stopped rotating. Failure to provide
adequate oil pressure and temperature to the compressor
while it is running may lead to equipment damage.

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SBTP 408 ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
CONSTRUCTION DETAILS
Housing: All 408 mm screw compressor castings are steel
to ensure structural integrity and mechanical and thermal
stability under all operating conditions.
Rotors: The rotors are machined from AISI-1141 or Y40Mn
steel to the exacting tolerances of the latest FRICK prole.
The ve-lobed male rotor is directly connected to the
driver. The seven-lobed female rotor is driven by the male
on a thin oil lm.
Bearings:
The SBTP compressor models utilizes API
compliant journal bearings and tilting pad thrust bearings to
absorb radial and axial loads respectively. The cylindrical
sleeve bearings are oil grooved for optimal lubrication and
higher radial load capability. The tilting pad thrust bearing
uses offset pads and directed lubrication to minimize power
loss and maintain lower bearing temperatures at lower oil
ows for maximum bearing life
.
Shaft seal: The compressor is supplied with a single-face
type mechanical shaft seal with metallic stationary and
rotating faces. Materials vary to suit the application. Tandem
style seals can also be supplied at additional cost if required
The seal is capable of withstanding static pressure up to
700 psig.
Volumizer variable volume ratio control: The FRICK
compressor includes a method of varying the internal volume
ratio to match the system pressure ratio. Control of the
internal volume ratio eliminates the power penalty associated
with over- or under-compression. Volume ratio control is
achieved by the use of a slide stop which is a movable portion
of the rotor housing that moves axially with the rotors to
control discharge port location. The slide stop is moved by
hydraulic actuation of a control piston.
Stepless capacity control: Capacity control is achieved by
use of a movable slide valve. The slide valve moves axially
under the rotors to provide fully modulated capacity control
from 100% to approximately 12% minimum load capacity.
Approximate minimum load capacity varies slightly with
compressor model, pressure ratio, discharge pressure level,
and rotor speed.
The slide valve is positioned by hydraulic movement of its
control piston. When in the unloaded position, gas is
bypassed back to suction through a recirculation slot before
compression begins and any work is expended, providing
the most efcient unloading method available for part-load
operation of a screw compressor.

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SBTP 408 ROTARY SCREW COMPRESSOR
INSTALLATION
INSTALLATION
DESIGN LIMITS
General information for all of the models is provided below.
Please see CoolWare™ to determine the limits for a specic
application.
The rotor and bearing design set limitations of the 408 mm
compressors must not be exceeded (See CoolWare™).
OUTLINE DIMENSIONS
Drawings for reference only can be found on pages 8 to 10.
Complete dimensions and access connections can be found
on the outline drawing 534E1279. If you do not have this
drawing, please request it by contacting Johnson Controls-
FRICK sales.

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SBTP 408 ROTARY SCREW COMPRESSOR
INSTALLATION
COMPRESSOR PORT LOCATIONS - SBTP 408 MM
A
SC-15
SC-5
ST-1
SM-1
SC-9
SV-1
SC-6
ST-2
AC
C
SC-10
SC-11
AXIAL BEARING RTD
AXIAL BEARING RTD
AXIAL BEARING RTD
VIEW C-C
B B
Figure 3: Compressor port locations
Figure 4: Compressor port locations, view C-C
SD-1
AXIAL BEARING RTD

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SBTP 408 ROTARY SCREW COMPRESSOR
INSTALLATION
COMPRESSOR PORT LOCATIONS - SBTP 408 MM
SC-4
SC-4
VIEW B-B
SC-12
SC-8
SE-1
SC-1
SB-2 SC-5
SP-1
SP-2
SB-3
SC-7
SE-2
VIEW A-A
PROXIMITY SENSOR
AXIAL PROBE
4X PROXIMITY SENSOR
HORIZ. PROBE
4X RADIAL BEARING RTD
4X PROXIMITY SENSOR
VERT. PROBE
2X PROXIMITY SENSOR
PHASE PROBE
SUCTION COMPRESSORS
4018 AND 4021
16” - 400# ANSI FLANGE
1 1/4-7 UNC-2B X 2.56 DP
20X ON 22.500 B.C.
COMPRESSOR 4013
12” - 400# ANSI FLANGE
1 1/4-7 UNC-2B X 2.18 DP
16X ON 17.750 B.C.
PROXIMITY SENSOR
AXIAL PROBE
Figure 5: Compressor port locations, view A-A
Figure 6: Compressor port locations, view B-B

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SBTP 408 ROTARY SCREW COMPRESSOR
INSTALLATION
COMPRESSOR PORT LOCATIONS - SBTP 408 MM
VIEW D-D
T
SL-1
SC-3
SC-2
SL-2
P
DISCHARGE
Figure 7: Compressor port locations, view D-D
D
D