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 - Identication 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)
Page 5
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)
Page 6
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 specic
application.


     
     

OUTLINE DIMENSIONS
for reference only
      
534E1237.



070.250-IOM (APR 11)
Page 8
408 MM ROTARY SCREW COMPRESSOR
INSTALLATION
COMPRESSOR PORT LOCATIONS - 408 MM
A
B
A
C
C
B
SC-1 SC-3
SC-5
SC-7
SM-1
SC-9
SV-1
SC-9
ST-2
SC-6
ST-1
SC-10
SC-11
VIEW C-C

070.250-IOM (APR 11)
Page 9
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