Johnson Controls Frick 408S Owner's manual
Form 070.250-IOM (APR 2011)
INSTALLATION - OPERATION - MAINTENANCE
File: SERVICE MANUAL - Section 070
Replaces: NOTHING
Dist: 3, 3a, 3b, 3c
408 mm
ROTARY SCREW COMPRESSOR
MODELS 408S, 408L, 408XL
THIS MANUAL CONTAINS RIGGING, ASSEMBLY, START-UP,
AND MAINTENANCE INSTRUCTIONS. READ THOROUGHLY
BEFORE BEGINNING INSTALLATION. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR DEATH,
DAMAGE TO THE UNIT, OR IMPROPER OPERATION.
Please check www.jci.com/frick for the latest version of this publication.
070.250-IOM (APR 11)
Page 2
408 MM ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
Contents
GENERAL INFORMATION
INSTALLATION
OPERATION
VOLUMIZER VOLUME RATIO CONTROL
MAINTENANCE
NORMAL MAINTENANCE OPERATIONS
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
CAUTION
DANGER
WARNING
IAQ
NOTICE
NOTICE
WARNING
CAUTION 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.
NOTICE
070.250-IOM (APR 11)
Page 3
408 MM ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
THE INFORMATION CONTAINED IN THIS
DOCUMENT IS SUBJECT TO CHANGE
WITHOUT NOTICE
GENERAL INFORMATION
PREFACE
CORRECT INSTALLATION
PROPER OPERATION
REGULAR, SYSTEMATIC MAINTENANCE
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
JOB INSPECTION
STANDARD BARE COMPRESSOR
TRANSIT DAMAGE CLAIMS
COMPRESSOR IDENTIFICATION
NOTICE
When inquiring about the compressor or unit, or
ordering repair parts, provide the MODEL, SERIAL, and
JOHNSON CONTROLS-FRICK SALES ORDER NUMBERS
from the data plate. See Figure 1.
Figure 1 - Identication Data Plate
EXAMPLE: 10240A90000015Z
GLOBAL ADDITIONAL
PLANT DECADE MONTH YEAR SEQ NO. REMARKS
070.250-IOM (APR 11)
Page 4
408 MM ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
Figure 2 - Refrigerant Name Plates
LONG TERM STORAGE
PREPARING COMPRESSOR FOR STORAGE
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
Geometrical
Rotor Max Swept Volume
Compressor diameter Rotor speed Drive shaft end CFM m³/h
Model mm L/D rpm ft³/ rev m³/rev 3550 rpm 2950 rpm
408S 408 1.3 3,600 1.144804 0.03998 5,012 7,076
408L 408 1.8 3,600 1.954806 0.05535 9,640 9,798
408XL 408 2.13 3,600 2.313187 0.0655 8,212 11,594
070.250-IOM (APR 11)
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408 MM ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
MAINTAINING COMPRESSOR
Contact Johnson Controls-Frick Service with any
questions regarding long term storage.
DESCRIPTION
FRICK 408 MM COMPRESSOR
SEE 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.
COMPRESSOR LUBRICATION SYSTEM
BALANCE PISTON PRESSURE REGULATION
BALANCE PISTON OIL PUMP BOOST
CONTROL
OIL PUMP
070.250-IOM (APR 11)
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408 MM ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
DEMAND OIL PUMP
CONSTRUCTION DETAILS
HOUSING:
ROTORS:
BEARINGS:
SHAFT SEAL:
VOLUMIZER VARIABLE VOLUME RATIO CONTROL:
STEPLESS CAPACITY CONTROL:
070.250-IOM (APR 11)
Page 7
408 MM ROTARY SCREW COMPRESSOR
INSTALLATION
INSTALLATION
DESIGN LIMITS
Please see CoolWare to determine the limits for a specic
application.
OUTLINE DIMENSIONS
for reference only
534E1237.
070.250-IOM (APR 11)
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408 MM ROTARY SCREW COMPRESSOR
INSTALLATION
COMPRESSOR PORT LOCATIONS - 408 MM
A
B
A
C
C
B
SC-1 SC-3
SC-5
SC-7
SM-1
SC-9
SV-1
SC-9
ST-2
SC-6
ST-1
SC-10
SC-11
VIEW C-C
070.250-IOM (APR 11)
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408 MM ROTARY SCREW COMPRESSOR
INSTALLATION
COMPRESSOR PORT LOCATIONS - 408 MM
VIEW A-A
VIEW B-B
SB-2 SC-7 SD-1
SC-1
SC-7
SP-1
SP-2
SB-3
SC-4
SC-4 SC-12
SC-8
SUCTION
COMPRESSOR 4013
12"-300# ANSI FLANGE
1 -7 UNC-2B x 2.18 DP
16X ON 17.750 B.C.
¹⁄₈
SUCTION
COMPRESSORS 4018 & 4021
16"-300# ANSI FLANGE
1¼-7 UNC-2B x 2.56DP
20X IB 22.500 B.C.
MODEL
PSI MAX P,A,&B PSI MAX T
V/Hz Amps
Hydraulic Valve Division
Elyria, Ohio 44036-2026 USA
MODEL
PSI MAX P,A,&B
PSI MAX-T
V/Hz
Hydraulic Valve Division, Elyria, Ohio 44036-2026 USA
CAUTION
REFER TO INSTALLATION OPERATION AND
MAINTENANCE MANUAL FOR ADDITIONAL
INFORMATION.
THIS EQUIPMENT HAS BEEN PRESSURIZED
WITH NITROGEN GAS. TEMPORARY VALVES
AND GAUGES HAVE BEEN INSTALLED.
ESCAPING GAS MAY CAUSE INJURY!
RELIEVE PRESSURE PRIOR TO OPENING
LINES OR MAKING FIELD CONNECTIONS.
REMOVE CHARGING VALVES OR GAUGES
PRIOR TO PRESSURIZING SYSTEM.
1.
2.
3.
070.250-IOM (APR 11)
Page 10
408 MM ROTARY SCREW COMPRESSOR
INSTALLATION
COMPRESSOR PORT LOCATIONS - 408 MM
SL-2
SL-1
SC-3
SC-2
SC-14 SC-13
VIEW D-D
DISCHARGE
12 -300# ANSI FLANGE
1 -7 UNC-2B x 3.00 DP
16X ON 17.750 B.C.
¹⁄₈
"
D
D
SC-4
SC-2
BP
070.250-IOM (APR 11)
Page 11
408 MM ROTARY SCREW COMPRESSOR
INSTALLATION
COMPRESSOR PORT LOCATIONS - 408 MM
PORT SIZE O-RING DESCRIPTION
SB-2 1"-300# ANSI, 5/8-11 UNC, 1.37 DP. — INLET BEARING & BALANCE PISTON
SB-3 1½-300# ANSI, 3/4-10 UNC, 1.75 DP. — OUTLET BEARINGS & SEAL
SC-1 9/16-18 UNF-2B STRAIGHT THREAD 980A0012K60 SLIDE VALVE
SC-2 9/16-18 UNF-2B STRAIGHT THREAD 980A0012K60 SLIDE VALVE
SC-3 9/16-18 UNF-2B STRAIGHT THREAD 980A0012K60 SLIDE STOP
SC-4 9/16-18 UNF-2B STRAIGHT THREAD 980A0012K60 CYLINDER DRAIN
SC-5 3/4-16 UNF-2B STRAIGHT THREAD 980A0012K62 SUCTION PRESSURE
SC-6 3/4-16 UNF-2B STRAIGHT THREAD 980A0012K62 DISCHARGE PRESSURE
SC-7 3/4-16 UNF-2B STRAIGHT THREAD 980A0012K62 OIL PRESSURE
SC-8 1/8-27 NPTF — SEAL WEEPAGE
SC-9 1M\,-12 UN-2B STRAIGHT THREAD 980A0012K72 CLOSED THREAD PRESSURE
SC-10 1B\,-12 UN-2B STRAIGHT THREAD 980A0012K71 SLIDE VALVE TOOL/DISCH. PRESSURE
SC-11 1B\,-12 UN-2B STRAIGHT THREAD 980A0012K71 DRAIN/DISCHARGE PRESSURE
SC-12 3/4-16 UNF-2B STRAIGHT THREAD 980A0012K62 DRAIN/SUCTION PRESSURE
SC-13 3/4-16 UNF-2B STRAIGHT THREAD 980A0012K62 CYLINDER OIL PRESSURE
SC-14 3/4-16 UNF-2B STRAIGHT THREAD 980A0012K62 CYLINDER VENT
SD-1 3/4-16 UNF-2B STRAIGHT THREAD 980A0012K62 COALESCER BLEED/
SUCTION PRESSURE
SL-1 1½-300# ANSI, 3/4-10 UNC, 1.75 DP. — LOW Vi LIQUID INJECTION
SL-2 1½-300# ANSI, 3/4-10 UNC, 1.75 DP. — HIGH Vi LIQUID INJECTION
SM-1 3-300# ANSI, 3/4-10 UNC, 1.63 DP. — MAIN OIL INJECTION
ST-1 1Z\zn-12 UNF-2B STRAIGHT THREAD 980A0012K66 SUCTION TEMPERATURE
ST-2 1Z\zn-12 UNF-2B STRAIGHT THREAD 980A0012K66 DISCHARGE TEMPERATURE
SV-1 4-300# ANSI, 3/4-10 UNC, 1.63 DP. — VAPOR INJECTION (4018 & 4021)
SV-1 3-300# ANSI, 3/4-10 UNC, 1.88 DP. — VAPOR INJECTION (4013)
070.250-IOM (APR 11)
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408 MM ROTARY SCREW COMPRESSOR
INSTALLATION
HOLDING CHARGE AND STORAGE
WARNING
Holding-charge shipping gauges (if mounted) are rated
for 30 psig and are for checking the shipping charge
only. They must be removed before pressure testing
and operating the system. Failure to remove these
gauges may result in catastrophic failure of the gauge
resulting in serious injury or death.
Access valves are bronze and they must be replaced with
steel plugs when package is assembled.
CAUTION
THIS EQUIPMENT HAS BEEN PRESSURIZED WITH
NITROGEN GAS. TEMPORARY VALVES & GAUGES
HAVE BEEN INSTALLED.
1. RELIEVE PRESSURE PRIOR TO OPENING LINES OR
MAKING FIELD CONNECTIONS.
2. REMOVE CHARGING VALVES OR GAUGES PRIOR
TO PRESSURIZING SYSTEM.
3.
REFER TO INSTALLATION OPERATION AND MAINTE-
NANCE MANUAL FOR ADDITIONAL INFORMATION.
ESCAPING GAS MAY CAUSE INJURY
RIGGING AND HANDLING
LIFTING RINGS
Figure 3 - Lifting Rings
FOUNDATION
CAUTION
Allow proper spacing for servicing (see Dimensional
Outline Drawing).
NOTICE
Weights are for standard compressor in Ductile Iron.
Contact factory for weights of optional models.
ALLOWABLE FLANGE LOADS
NOZ. MOMENTS (ft-lbf) LOAD (lbf)
SIZE AXIAL VERT. LAT. AXIAL VERT. LAT.
NPS MRMCMLP VCVL
1 25 25 25 50 50 50
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 1,000 750 750 650 650 650
8 1,500 1,000 1,000 1,500 900 900
10 1,500 1,200 1,200 1,500 1,200 1,200
12 1,800 1,500 1,600 1,500 1,400 1,200
14 2,000 1,800 1,800 1,700 2,000 2,000
16 2,250 2,000 2,000 1,700 2,200 2,000
CUSTOMER CONNECTIONS
070.250-IOM (APR 11)
Page 13
408 MM ROTARY SCREW COMPRESSOR
INSTALLATION
COMPRESSOR OIL
WARNING
DO NOT MIX OILS of different brands, manufacturers,
or types. Mixing of oils can cause excessive oil foam-
ing, nuisance oil level cutouts, oil pressure loss, gas or
oil leakage and catastrophic compressor failure. Cool-
Ware will select a specic Frick oil for the refrigerant
being used. Depending on the application, a different
oil can be selected provided it is of the proper viscos-
ity and is compatible with the refrigerant and com-
pressor elastomers.
OIL PUMP
CAUTION
Excess or improper oil pressure could cause catastroph-
ic compressor failure due to male axial bearing failure.
See CoolWare™ for your application’s requirements.
COMPRESSOR
COMPRESSOR ROTATION IS CLOCKWISE WHEN FACING
THE END OF THE COMPRESSOR SHAFT
MOTOR MOUNTING (FOOT MOUNTED ONLY)
COMPRESSOR/MOTOR COUPLING REQUIREMENTS.
COUPLING ALIGNMENT REQUIREMENTS
Maximum radial runout is .004” total indicator reading.
Maximum axial runout is .004” total indicator reading.
OIL HEATER(S)
OIL FILTER(S)
β
070.250-IOM (APR 11)
Page 14
408 MM ROTARY SCREW COMPRESSOR
INSTALLATION
OIL COOLING REQUIREMENTS
DEHYDRATION / EVACUATION TEST
PASS
FAIL
ELECTRICAL INSTALLATION
SLIDE STOP TRANSMITTER
Figure 5 - Slide Stop Transmitter
Figure 6 - Wiring Diagram for Slide Stop Transmitter
CAPACITY SLIDE VALVE TRANSMITTER
END VIEW
DIN CONNECTOR
STAINLESS STEEL WELL
HEAT ISOLATOR
CAST ALUMINUM HOUSING
COMPRESSOR UNLOAD CYLINDER
SHADED AREA SHOWS
CAPACITY LINEAR TRANSMITTER
Figure 7 - Capacity Slide Valve Transmitter
070.250-IOM (APR 11)
Page 15
408 MM ROTARY SCREW COMPRESSOR
INSTALLATION
Figure 8 - Wiring Diagram for Slide Valve Transmitter
DIRECTIONAL CONTROL VALVES
OPERATION
Figure 9 - Directional Control Valve Wiring Diagram
070.250-IOM (APR 11)
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408 MM ROTARY SCREW COMPRESSOR
OPERATION
OPERATION
OPERATION AND START-UP INSTRUCTIONS
THE FOLLOWING SUBSECTIONS MUST BE READ AND
UNDERSTOOD BEFORE ATTEMPTING TO START OR
OPERATE THE UNIT.
COMPRESSOR HYDRAULIC SYSTEM
(The solenoid valves and manifold block are
available as a sales order option)
High stage compressor loading:
High stage compressor unloading:
NOTICE
To control the rate of loading and unloading, throttle
the needle valve at SC1 port.
Booster Compressor Loading:
Booster Compressor Unloading:
NOTICE
To control the rate of loading and unloading, throttle
valves SC1 and SC2.
NOTICE
To slow all valve movements - loading, unloading, and
Vi change - throttle valve 2.
Figure 10 - Solenoid Valve Block
CAUTION
NEVER open valve BP and valve SC2 at the same time
during compressor operation.
VOLUMIZER VOLUME RATIO CONTROL
Compressor Vi increase:
Compressor Vi decrease:
070.250-IOM (APR 11)
Page 17
408 MM ROTARY SCREW COMPRESSOR
OPERATION
LOW AMBIENT OPERATION
INITIAL START-UP
INITIAL START-UP PROCEDURE
Figure 11 - Hydraulic Schematic
SC4
BP
SC2
SC3
SC1
SC3
2
SC4
SC3
SC13
1
2
SC2
SC1
2
SC2
1
1
2
A
B
1
P
T
BP
B
A
T
P
SC1
SV-3
T
HYDRAULIC SCHEMATIC
408 MM
P
SV-2
SCREW IN FLOW
REGULATING
NEEDLE VALVE
DIRECTION
CONTROL
VALVE
CUSTOMER
SUPPLIED
PUMP
DIRECTION
CONTROL
VALVE
SP-1
YY2 (LOAD)
YY4 (DECREASE VI)
COMPRESSOR
TOP VIEW
YY1 YY2 YY3 YY4
(UNLOAD) YY1
(INCREASE VI) YY3
SC3
2
1
NORMAL START-UP PROCEDURE
070.250-IOM (APR 11)
Page 18
408 MM ROTARY SCREW COMPRESSOR
MAINTENANCE
MAINTENANCE
GENERAL INFORMATION
WARNING
THIS SECTION MUST BE READ AND UNDERSTOOD BE-
FORE ATTEMPTING TO PERFORM ANY MAINTENANCE
OR SERVICE TO THE UNIT.
CAUTION
Cylinder assembly under high spring load. Consult
manual before disassembly. Improper disassembly may
cause injury due to spring tension release.
NORMAL MAINTENANCE OPERATIONS
STOP
GENERAL MAINTENANCE
1. Keep oil clean and dry, avoid moisture contamination.
2. Keep suction strainer clean.
3. Keep oil lters clean.
4. Avoid slugging the compressor with liquids (oil).
5. Protect the compressor during long periods of
shutdown.
6. Preventive maintenance inspection
CHANGING OIL
WARNING
DO NOT MIX OILS of different brands, manufacturers,
or types. Mixing of oils may cause excessive oil foam-
ing, nuisance oil level cutouts, oil pressure loss, gas or
oil leakage and catastrophic compressor failure.
RECOMMENDED MAINTENANCE PROGRAM
VIBRATION ANALYSIS
070.250-IOM (APR 11)
Page 19
408 MM ROTARY SCREW COMPRESSOR
MAINTENANCE
MAINTENANCE SCHEDULE
This schedule should be followed to ensure trouble-free operation of the compressor unit.
FREQUENCY OR HOURS OF OPERATION (MAXIMUM)
MAINTENANCE
200
1000
5000
8000
10,000
15,000
20,000
25,000
30,000
35,000
40,000
45,000
50,000
55,000
60,000
65,000
70,000
75,000
80,000
85,000
90,000
95,000
Change Oil As Directed By Oil Analysis
Oil Analysis nEvery 6 Months
Replace Oil Filters n n n n n n n n n n n
Clean Oil Strainers n n n n n n n n n n n
Clean Liquid Strainers n n n n n n n n n n n
Replace Coalescers n n n
Check and Clean Suction Strainer n n n n n n n n n n n
Vibration Analysis nEvery 6 Months, More Frequently If Levels Increase
Replace Shaft Seal When Leak Rate Exceeds 7 - 8 Drops Per Minute
OIL QUALITY AND ANALYSIS
OPERATING LOG
TROUBLESHOOTING GUIDE
ABNORMAL OPERATION ANALYSIS AND CORRECTION
070.250-IOM (APR 11)
Page 20
408 MM ROTARY SCREW COMPRESSOR
MAINTENANCE
CAPACITY LINEAR TRANSMITTER REPLACEMENT - SLIDE
VALVE
END VIEW
DIN CONNECTOR
STAINLESS STEEL WELL
HEAT ISOLATOR
CAST ALUMINUM HOUSING
COMPRESSOR UNLOAD CYLINDER
SHADED AREA SHOWS
CAPACITY LINEAR TRANSMITTER
Figure 12 - Capacity Linear Transmitter
VOLUMIZER TRANSMITTER REPLACEMENT - SLIDE STOP
Figure 13 - Volumizer Transmitter
NOTICE
For calibration of the Volumizer unit, refer to the Analog
Calibration instructions in publication 090.040-O.
BARE COMPRESSOR REPLACEMENT
SHUTDOWN DUE TO
IMPROPER OIL PRESSURE
(High Stage and Booster)
The compressor must not operate with incorrect oil
pressure.
This manual suits for next models
2
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