Frick SBTP 4018, SBTP 4021 Installation Operation & Maintenance

Form 070.655-IOM (MAY 2019)
INSTALLATION - OPERATION - MAINTENANCE
File:
Replaces:
Dist:
SERVICE MANUAL - Section 070
NOTHING
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)
Page 2
SBTP 408 ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
Contents
GENERAL INFORMATION
OPERATION
Preface .............................................................................. 3
Design limitations .............................................................. 3
Job inspection ................................................................... 3
Standard bare compressor ................................................ 3
Transit damage claims ....................................................... 3
Compressor identification ................................................. 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
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
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 filter(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
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
SAFETY PRECAUTION DEFINITIONS
DANGER
Indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
a potentially hazardous situation or practice which, if not avoided, will result in death or
WARNING Indicates
serious injury.
CAUTION
Indicates a potentially hazardous situation or practice which, if not avoided, will result in damage
to equipment and/or minor injury.
NOTICE
Indicates an operating procedure, practice, etc., or portion thereof which is essential to highlight.
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.
070.655-IOM (MAY 19)
Page 3
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 requirement. Request immediate inspection by the agent of
the carrier and be sure the proper claim forms are executed. Report damage or shortage claims immediately to
Johnson Controls-FRICK Sales Administration Department,
Waynesboro, PA.
It is most important that these compressors be properly
applied to an adequately controlled refrigerant or gas system. Your authorized Johnson Controls-FRICK representative should be consulted for expert guidance in this determination.
Each compressor has an identification data plate, containing
compressor model and serial number mounted on the
compressor body.
Proper performance and continued satisfaction with these
units is dependent upon:
NOTICE
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.
COMPRESSOR IDENTIFICATION
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
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.
ROTARY SCREW COMPRESSOR
MODEL NO.
PART NO.
SERIAL NO.
MAX DRIVER SPEED
RPM
It is required that the discharge temperature be kept high
enough to prevent condensation of any moisture in the
compressor and oil separator.
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.
BARG
ASSEMBLED IN
FROM FOREIGN AND DOMESTIC MATERIALS
DESIGN LIMITATIONS
FRICK 408 mm compressors are designed for operation
within the pressure and temperature limits which are
specified by Johnson Controls-FRICK and our CoolWare™
selection software. They are primarily used for compressing
refrigerant gas and most hydrocarbon gasses.
MAX ALLOWABLE PRESSURE
PSIG
Figure 1: Identification data plate
Rotary screw compressor serial numbers are defined by the
following information:
Example: 10240A90000015Z
Plant
1024
Decade
0
Month
A
Year
9
Global
seq. no.
0000015
Additional
remarks
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 Configuration.
070.655-IOM (MAY 19)
Page 4
SBTP 408 ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
Table 1: Compressor specifications
Compressor
model
4013
4018
4021
Rotor
diameter
mm
408
408
408
Rotor
L/D
1.3
1.8
2.13
Max
speed
rpm
3,600
3,600
3,600
Theoretical
displacement
ft³/ rev
(m³/rev)
1.41180
(0.03998)
1.95481
(0.05535)
2.31319
(0.06550)
The name plates in Figure 2 show which refrigerants are
compatible with the compressor as manufactured.
COMPRESSOR OPERATES ON AND IS
COMPATIBLE WITH THE FOLLOWING
REFRIGERANTS
R290, R1270, NATURAL GAS
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.
Displacement at
3550 rpm
driver speed
ft³/rev (m³/rev)
5,012
(8,515)
6,940
(11,790)
8,212
(13,952)
Displacement at
2950 rpm
driver speed
ft³/rev
(m³/h)
4,165
(7,076)
5,767
(9,798)
6,824
(11,594)
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 flooded 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 specific 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
4018
4013
120 gallons
115 gallons
100 gallons
After the compressor is oil charged, pressurize compressor
to 5 psig to 15 psig with nitrogen.
Table 2: Compressor and packaged equipment storage log
Model
Serial No.
Compressor and packaged equipment storage log
Compressor, motor
oil pump and
refrigerant pump
Rotor
Visual
shaft rotation
Housing
Charge
Inspection
1½ Turn
Charge
added
Per qai-3
Charge
Checked by
Date
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 profile helical rotors to provide a continuous
flow 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 infinitely
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 efficiency even at very high compression
ratios.
9. S
haft 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 flanges are ANSI B16.1 Class 300
for all models.
070.655-IOM (MAY 19)
Page 5
11.The 408 mm compressors must be fitted 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
overheating.
the
compressor
cool
and
prevents
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 flow back to
the oil separator until the proper oil conditions are verified.
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.
070.655-IOM (MAY 19)
Page 6
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 profile.
The five-lobed male rotor is directly connected to the
driver. The seven-lobed female rotor is driven by the male
on a thin oil film.
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
flows 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 efficient unloading method available for part-load
operation of a screw compressor.
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 specific
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 ControlsFRICK sales.
070.655-IOM (MAY 19)
Page 7
070.655-IOM (MAY 19)
Page 8
SBTP 408 ROTARY SCREW COMPRESSOR
INSTALLATION
COMPRESSOR PORT LOCATIONS - SBTP 408 MM
A
A
ST-1
C
SC-5
SC-15
SM-1
SD-1
SC-9
SV-1
ST-2
SC-6
B
Figure 3: Compressor port locations
AXIAL BEARING RTD
AXIAL BEARING RTD
AXIAL BEARING RTD
AXIAL BEARING RTD
SC-11
SC-10
VIEW C-C
Figure 4: Compressor port locations, view C-C
B
C
SBTP 408 ROTARY SCREW COMPRESSOR
INSTALLATION
070.655-IOM (MAY 19)
Page 9
COMPRESSOR PORT LOCATIONS - SBTP 408 MM
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.
SE-2
SB-2
PROXIMITY SENSOR
AXIAL PROBE
SC-5
SC-7
SC-1
SB-3
SE-1
2X PROXIMITY SENSOR
PHASE PROBE
4X PROXIMITY SENSOR
VERT. PROBE
PROXIMITY SENSOR
AXIAL PROBE
SP-1
SP-2
4X RADIAL BEARING RTD
4X PROXIMITY SENSOR
HORIZ. PROBE
VIEW A-A
Figure 5: Compressor port locations, view A-A
SC-4
SC-12
SC-4
SC-8
VIEW B-B
Figure 6: Compressor port locations, view B-B
070.655-IOM (MAY 19)
Page 10
SBTP 408 ROTARY SCREW COMPRESSOR
INSTALLATION
COMPRESSOR PORT LOCATIONS - SBTP 408 MM
P
T
VIEW D-D
SL-1
SC-3
D
SC-2
SL-2
DISCHARGE
D
Figure 7: Compressor port locations, view D-D
SBTP 408 ROTARY SCREW COMPRESSOR
INSTALLATION
070.655-IOM (MAY 19)
Page 11
COMPRESSOR PORT LOCATIONS - SBTP 408 MM
Table 3: Compressor port information
Port
SB-2
SB-3
SC-1
SC-2
SC-3
SC-4
SC-5
SC-6
SC-7
SC-8
SC-9
SC-10
SC-11
SC-12
P
T
SD-1
SE-1
SE-2
SL-1
SL-2
SM-1
SP-1
SP-2
ST-1
ST-2
SV-1
Size
O-ring
Description
1"-300# ANSI, 5/8-11 UNC, 1.37 DP.
1"-600# ANSI, 5/8-11 UNC, 1.37 DP.
2"-300# ANSI, 5/8-11 UNC, 1.75 DP.
2"-300# ANSI, 5/8-11 UNC, 1.75 DP.
9/16-18 UNF-2B straight thread o-ring
9/16-18 UNF-2B straight thread o-ring
9/16-18 UNF-2B straight thread o-ring
9/16-18 UNF-2B straight thread o-ring
3/4-16 UNF-2B straight thread o-ring
3/4-16 UNF-2B straight thread o-ring
3/4-16 UNF-2B straight thread o-ring
1/8-27 NPTF
1 7/8-12 UN-2B straight thread o-ring
2 1/2-12 UN-2B straight thread o-ring
1 5/8-12 UN-2B straight thread o-ring
3/4-16 UNF-2B straight thread o-ring
3/4-16 UNF-2B straight thread o-ring
3/4-16 UNF-2B straight thread o-ring
1 1/16-12 UN-2B straight thread o-ring
DIN connector
DIN connector
1 1/2-300# ANSI, 3/4-10 UNC, 1.75 DP.
980A0013K58
980A0013K58
980A0013K58
980A0013K58
980A0013K60
980A0013K60
980A0013K60
980A0013K70
980A0013K69
980A0013K69
980A0013K60
980A0013K60
980A0013K60
980A0013K64
-
Inlet bearings (4018, 4021)
Inlet barings (4013)
Outlet bearings (4018, 4021)
Outlet barings (4013)
Slide valve
Slide valve
Slide stop
Cylinder drain
Suction pressure
Discharge pressure
Oil pressure
Seal weepage
Closed thread pressure
Slide valve tool/discharge pressure
Drain/discharge pressure
Drain/suction pressure
Cylinder pressure (manifold block pressure)
Cylinder vent (manifold block tank)
Coalescer bleed/suction pressure
Slide valve
Slide stop
Low Vi liq injection (4018, 4021)
1 1/2-600# ANSI, 3/4-10 UNC, 1.75 DP.
-
Low Vi liq injection (4013)
1 1/2-300# ANSI, 3/4-10 UNC, 1.75 DP.
1 1/2-600# ANSI, 3/4-10 UNC, 1.75 DP.
3-300# ANSI, 3/4-10 UNC, 1.63 DP.
3-600# ANSI, 3/4-10 UNC, 1.63 DP.
1/4-28 UNF-2B, .68 DP.
1/4-28 UNF-2B, .68 DP.
1 1/16-12 UN-2B straight thread o-ring
1 1/16-12 UN-2B straight thread o-ring
4-300# ANSI, 3/4-10 UNC, 1.63 DP.
3-600# ANSI, 3/4-10 UNC, 1.88 DP.
980A0013K64
980A0013K64
-
High Vi liq injection (4018, 4021)
High Vi liq injection (4013)
Main oil injection (4018, 4021)
Main oil injection (4013)
Suction accelerometer
Discharge accelerometer
Suction temperature
Discharge temperature
Vapor injection (4018, 4021)
Vapor injection (4013)
* While liquid injection oil cooling is an option for anti-friction FRICK screw compressors, it is not recommended for compressors
supplied with tilting pad thrust bearings.
070.655-IOM (MAY 19)
Page 12
SBTP 408 ROTARY SCREW COMPRESSOR
INSTALLATION
HOLDING CHARGE AND STORAGE
FOUNDATION
Every 408 mm compressor is pressure and leak tested at the
Johnson Controls–FRICK factory and then thoroughly evacuated and charged with dry nitrogen to ensure its integrity
during shipping and short term storage prior to installation.
Each 408 mm rotary screw compressor is shipped mounted
on a wooden skid, which must be removed prior to unit
installation.
All compressors must be kept in a clean, dry location to
prevent corrosion damage. Compressors that will be stored
for more than two months must have their nitrogen charge
checked periodically (see pages in General Information for
complete instructions).
CAUTION
Allow proper spacing for servicing (see Dimensional
Outline Drawing).
The first requirement of the compressor foundation is that
it must be able to support the weight.
4013
4018
4021
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 maintenance
manual for additional information.
Escaping gas may cause injury
RIGGING AND HANDLING
The compressor can be moved with rigging, using a crane
or forklift, by hooking into the two lifting rings on the rotor
housing. The compressor lifting rings shall only be used to
lift the compressor itself. See Figures 8.
LIFTING RINGS
15,733 lb
17,342 lb
18,592 lb
(7,136 kg)
(7,866 kg)
(8,433 kg)
Screw compressors are capable of converting large
quantities of shaft power into gas compression in a relatively
small space. The compression process creates relatively
high frequency vibrations that require sufficient mass in the
base to effectively dampen them.
The best insurance for a trouble-free installation is to firmly
anchor the compressor to a suitable foundation using
proper bolting and by preventing piping stress from being
imposed on the compressor (refer to Screw Compressor
Foundations, 070.210-IB). Once the compressor is rigged
into place, its feet must be shimmed to level it. There must
be absolutely no stresses introduced into the compressor
body due to bolting of the feet and flanges.
In any screw compressor installation, suction and discharge
lines should be supported in pipe hangers (preferably within
2 feet of vertical pipe run) so that the lines won’t move if
disconnected from the compressor. See Table 4 for
allowable flange loads.
Table 4: Allowable flange loads
Noz. Moments (ft-lbf)
Load (lbf)
size Axial Vert.
Lat.
Axial Vert.
MC
ML
P
VC
NPS MR
1
25
25
50
40
250
175
175
425
400
400
1.25
25
2
100
4
400
1.5
3
5
6
1,000
10
1,500
8
12
14
16
25
70
200
750
25
25
40
50
50
50
100
75
75
50
125
125
200
300
400
400
750
225
400
650
1,000
1,500
1,800
1,500
1,600
1,500
2,250
1,800
2,000
50
150
1,000
2,000
50
70
1,500
1,200
Lat.
VL
1,200
1,800
2,000
250
450
650
900
250
450
650
900
1,500
1,200 1,200
1,700
2,000 2,000
1,700
1,400 1,200
2,200 2,000
CUSTOMER CONNECTIONS
Figure 8: Lifting rings - not model specific
As a minimum you must connect the lube oil system to the
following locations in addition to suction and discharge:
SB-2
SB-3
SM-1
SC-13
Inlet Bearings
Discharge Bearings and Shaft Seal
Main oil injection
Manifold block pressure (on manifold block)
SBTP 408 ROTARY SCREW COMPRESSOR
INSTALLATION
Other connections are available for instrumentation and
service as noted on the dimensional outline drawing. The
electrical connections for the slide stop and the slide valve
transmitters and the solenoid valve coils must be connected
to your control system.
The oil supply system for the compressor must be designed
for a total pressure drop of no more than 15 psi with a new
oil filter element. This is critical as excessive pressure drop
in the oil circuit can prevent proper operation of the slide
valve and slide stop pistons.
COMPRESSOR OIL
WARNING
Only FRICK approved oil is recommended. No additives are approved. Do not mix oils of different brands,
manufacturers, or types. Mixing of oils can cause excessive oil foaming, nuisance oil level cutouts, oil pressure loss, gas or oil leakage and catastrophic compressor failure. CoolWare will select a specific FRICK oil for
the refrigerant being used. Depending on the application, a different oil can be selected provided it is of the
proper viscosity and is compatible with the refrigerant
and compressor elastomers.
OIL PUMP
All SBTP 408 mm compressor applications require an oil
pump and it is recommended that a strainer be mounted
upstream to protect it. FRICK supplied pumps are a positive
displacement gear or screw type that must have a safety
relief valve to ensure that the maximum oil pressure will not
be exceeded
COMPRESSOR
COMPRESSOR ROTATION IS CLOCKWISE WHEN FACING
THE END OF THE COMPRESSOR SHAFT
Confirm motor will rotate the compressor clockwise before
installing the coupling.
MOTOR MOUNTING (FOOT MOUNTED ONLY)
1. Thoroughly clean the motor feet and mounting pads of
grease, burrs, and other foreign matter to ensure firm
seating of the motor.
2. Attach the motor to the base using bolts and motor
raising blocks, if required.
3. Weld the four kick bolts (not included with compressor)
into place so that they are positioned to allow movement of the motor feet.
4. After the motor has been set, check to see that the
shafts are properly spaced for the coupling being used.
Check the appropriate Dimensional Outline drawing
for the minimum clearance required between the shaft
ends to change the shaft seal.
COMPRESSOR/MOTOR COUPLING REQUIREMENTS.
FRICK 408 mm compressors are arranged for direct motor
drive and require a flexible drive coupling to connect the
compressor to the motor.
070.655-IOM (MAY 19)
Page 13
If you are using the Johnson Controls–FRICK motor mount,
the mount is machined to ensure that motor to compressor
alignment is in specification. See motor mounting section
for details.
With a foot-mounted motor, it is essential that the coupling
be properly aligned to ensure proper bearing and seal
performance.
1. Coupling must be selected and installed so that it
doesn’t transmit any axial load to the compressor shaft.
2. Set up the minimum distance between compressor shaft
and motor shaft to allow for seal removal (see Outline
drawings).
3. Coupling must be able to take up any misalignment between motor and compressor. It is critical to the life of
the shaft seal that misalignment is kept to the minimum
possible value. Be sure to follow the coupling manufacturer’s guidelines for checking and correcting any misalignment. See the next section for Johnson Controls–
FRICK requirements.
COUPLING ALIGNMENT REQUIREMENTS
Coupling alignment must be performed prior to start-up.
After the compressor has been installed on the job site,
alignment must be checked again and if necessary corrected
prior to start-up. After a few hours operation, the alignment
must be checked while the package is still hot. Correct hot
alignment is critical to ensure the life of the shaft seal and
compressor bearings.
The maximum radial runout is .004” total indicator reading.
The maximum axial runout is .004” total indicator reading.
A dial indicator or another appropriate measuring device is
to be used to determine the total indicator runout.
Indicator bracket sag must be checked as all brackets have
some flexibility. The best way to measure this is to attach
the dial indicator and bracket on a pipe at the coupling span
distance. Zero the indicator in the 12:00 position, and rotate
the pipe so the indicator is in the 6:00 position. The reading
on the indicator in the 6:00 position is the bracket sag. This
value must be included in the dial indicator readings when
affixed to the coupling for an accurate alignment.
OIL HEATER(S)
Your package must be equipped with oil heaters that provide
sufficient heat to prevent condensation from occurring
during shutdown cycles. In addition, heat tracing is strongly
recommended for all of the lube oil lines including oil filters
and the oil cooler. The heat tracing should be activated
during compressor shutdown to ensure that all of the lube
system is up to the proper temperature prior to startup.
OIL FILTER(S)
Use of filter elements other than Johnson Controls-FRICK
must be approved in writing by Johnson Controls-FRICK
engineering or a warranty claim may be denied. Typical oil
filter specification β5 = 75 according to ISO 4572 is required
to obtain the recommended oil cleanliness class 16/14/11
according to ISO 4406.
070.655-IOM (MAY 19)
Page 14
SBTP 408 ROTARY SCREW COMPRESSOR
INSTALLATION
OIL COOLING REQUIREMENTS
Compressor oil needs to be cooled to control the discharge
temperature, maintain proper oil viscosity and to preserve
the life of the oil. Normally the discharge temperature will
be in the 170° - 180°F range (see CoolWare™).
One application that typically requires higher discharge
temperatures (as high as 250°F) is natural gas gathering at
the wellhead. Moisture is normally present in the gas and
it is imperative that the discharge temperature be at least
30°F higher than the discharge dew point temperature for
the gas. Run CoolWare™ with the Water Saturated block
checked to get the discharge dew point temperature for
your application. Oil temperatures as high as 170°F can
be used to achieve the necessary discharge temperature
to prevent moisture from condensing in the oil separator.
Contact Johnson Controls–FRICK for additional information
for natural gas compression.
Figure 9: Slide stop transmitter
The main oil injection line that is connected to port SM1
must have a regulating valve to permit adjustment of the
oil flow to maintain the desired discharge temperature at
all times.
The use of a three-way mixing valve is recommended to
keep the oil temperature in the normal range of 120° 140°F. The valve will provide warm oil to the compressor
quickly, reducing the pressure drop caused by cold, viscous
oil. This ensures proper oil flow and temperature over the
full range of operating conditions.
While liquid injection oil cooling is an option for antifriction FRICK screw compressors, it is not recommended
for compressors supplied with tilting pad thrust bearings.
Acceptable methods of oil cooling would use either water,
air, or refrigerant cooled oil coolers.
DEHYDRATION / EVACUATION TEST
Evacuate the system to 1000 microns. Valve off the vacuum
pump and hold vacuum for one hour.
Pass –Vacuum cannot rise more than 500 microns during
one hour hold period.
Fail –Vacuum rise is more than 500 microns during one
hour hold period. Identify and repair any system
leaks. Repeat vacuum test until requirements are
met.
Figure 10: Wiring diagram for slide stop transmitter
CAPACITY SLIDE VALVE TRANSMITTER
The slide valve transmitter (Figure 7) measures the position
of the slide valve (SV) and sends a 4 to 20 mA signal to your
control system (See Figure 12). The controller will adjust
the position of the SV according to the motor load setpoint.
The correct position is important to properly load the
compressor and motor. It is important not to overload the
compressor and motor. Observe the maximum power input
and ensure design limitations are not exceeded. Connect to
+/- and signal as shown in the wiring diagram, Figure 12.
Refer to FRICK compressor panel instructions 090.040-O
for calibration procedure.
END VIEW
SHADED AREA SHOWS
CAPACITY LINEAR TRANSMITTER
STAINLESS STEEL WELL
DIN CONNECTOR
ELECTRICAL INSTALLATION
SLIDE STOP TRANSMITTER
The slide stop transmitter (See Figure 9) measures the
position of the slide stop (SS) using a 20 to 4 mA signal to
cover the range of minimum to maximum Vi. The signal is
sent to your control system so that it can adjust the position
of SS according to system pressures. The correct SS position
is important to achieve the most efficient compressor
operation. Connect to +/- and signal as shown in the wiring
diagram in Figure 10. Refer to FRICK compressor panel
instructions 090.040-O for calibration procedure.
HEAT ISOLATOR
COMPRESSOR UNLOAD CYLINDER
CAST ALUMINUM HOUSING
Figure 11: Capacity slide valve transmitter
SBTP 408 ROTARY SCREW COMPRESSOR
INSTALLATION
Figure 12: Wiring diagram for slide valve transmitter
DIRECTIONAL CONTROL VALVES
Solenoids YY1, YY2, YY3 and YY4 must be wired to give the
correct function. A description of their function is given in
the Operation section. For control system information refer
to FRICK Compressor Control Panel 090-020 O. See wiring
diagram in Figure 9.
Figure 13: Directional control valve wiring diagram
070.655-IOM (MAY 19)
Page 15
070.655-IOM (MAY 19)
Page 16
SBTP 408 ROTARY SCREW COMPRESSOR
OPERATION
OPERATION
OPERATION AND START-UP INSTRUCTIONS
The FRICK 408 mm Rotary Screw Compressor will be a
component in an integrated system. As such the compressor
requires some specific operation and conditions to ensure
trouble-free running.
The information in this section of the manual provides the
logical step-by-step instructions to properly start up and
operate the 408 mm Rotary Screw Compressor in your unit.
Only matters which may influence the proper operation of
the 408 mm compressor are included.
Booster compressor loading: The compressor loads when
SV solenoid YY2 is energized and oil flows from the oil
manifold through valve ports P and B to cylinder port SC2
and enters the load side of the cylinder. Simultaneously, oil
contained in the unload side of the cylinder flows out
cylinder port SC1 through valve ports A and T to compressor
suction.
Booster compressor unloading: The compressor unloads
when SV solenoid YY1 is energized and oil flows from the
oil manifold through valve ports P and A to cylinder port
SC1 and enters the unload side of the cylinder.
Simultaneously, oil contained in the load side of the cylinder
flows out of compressor port SC2 through valve ports B and
T to compressor suction.
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)
The compressor hydraulic system actuates the movable slide
valve (SV) to load and unload the compressor. It also actuates
the movable slide stop (SS) to increase or decrease the
compressor’s volume ratio (Vi). The hydraulic cylinder
located at the inlet end of the 408 mm compressor serves a
dual purpose. It is separated by a fixed bulkhead into two
sections. The SV section is on the forward side of the
bulkhead and the SS is aft of the bulkhead when viewed from
the non-drive end of the compressor. Both operations are
controlled by solenoid valves, which are actuated when a
signal from the appropriate microprocessor output energizes
the solenoid valve.
NOTICE
To control the rate of loading and unloading, throttle
valves SC1 and SC2. Optional flow control valves are
available (FC1 and FC2) for finer speed adjustment.
NOTICE
To slow all valve movements - loading, unloading,
and Vi change - a optional customer supplied throttle
valve can be utilized upstream of connection P.
SINGLE-ACTING MODE - High Stage
Open valve at SC1
Close valve at SC2
Open valve at BP (bypass)
See Figure 15 for details.
High stage compressor loading: The compressor loads
when SV solenoid YY2 is energized and oil flows from the
unload side of the cylinder out port SC1, through valve
ports A and T to compressor suction. Simultaneously,
discharge pressure loads the slide valve.
High stage compressor unloading: The compressor
unloads when SV solenoid YY1 is energized and oil flows
from the oil manifold through valve ports P and A to
cylinder port SC1 and enters the unload side of the cylinder.
Simultaneously, gas on the load side of the cylinder is
vented through port SC2 and valve BP to compressor
suction.
NOTICE
To control the rate of loading and unloading, throttle
the needle valve at SC1 port.
DOUBLE-ACTING MODE - Booster (low differential)
Open valve at SC1
Open valve at SC2
Close valve at BP (bypass)
See Figure 15 for details.
Figure 14: Solenoid valve block
Special throttling control valve blocks are available with
needle valves and check valves on each port direction. This
can be ordered through FRICK sales on new orders or parts
on aftermarket.
CAUTION
NEVER open valve BP and valve SC2 at the same time
during compressor operation.
VOLUMIZER VOLUME RATIO CONTROL
Open valve at SC3
Compressor Vi increase: The volume ratio Vi is increased
when MSS solenoid valve YY3 is energized and oil flows
from the oil manifold through valve ports P and A to
compressor port SC3, enters the increase side of the
cylinder and overcomes spring tension.
Compressor Vi decrease: The volume ratio Vi is decreased
when MSS solenoid valve YY4 is energized and oil flows
from SC3 through valve ports A and T to compressor port
T1.
To control the rate of Vi change, throttle the needle valve at
SC3 port.
SBTP 408 ROTARY SCREW COMPRESSOR
OPERATION
SC-2
T1
CAPACITY - LOAD (SLIDE VALVE)
OIL PRESSURE OUT (INTERNAL)
SC-1
070.655-IOM (MAY 19)
Page 17
SC-3
VOLUME RATIO (VI) - INCREASE (SLIDE STOP)
CAPACITY - UNLOAD (SLIDE VALVE)
OPTIONAL FLOW CONTROL VALVE
OPTIONAL FLOW CONTROL VALVE
2
FC1
2
FC2
1
2
2
1
SC3
2
1
SC2
SC1
1
1
A
BP
B
YY1
YY2
P
HYDRAULIC VALVE
TOP VIEW
2
1
YY3
T
1
A
B
P
T
2
P
OIL PRESSURE IN
SC3
YY4
BP
T
SC2
OIL PRESSURE OUT
SC1
Figure 15: Hydraulic schematic
LOW AMBIENT OPERATION
It is recommended that package oil separators be insulated
as a minimum requirement to preserve the heat generated
by the oil heaters, to prevent condensation and secure
lubrication at start-up.
INITIAL START-UP
Prior to the start-up, the prestart check must be
accomplished.
INITIAL START-UP PROCEDURE
Having performed the prestart check, the compressor unit
is ready for start-up. It is important that an adequate gas
load be available to load test the unit at normal operating
conditions. The following points should be kept in mind
during initial start-up.
1.For proper and safe operation, the compressor must be
run at the proper speed and discharge pressure.
Exceeding design conditions creates a potential hazard.
2. After 1 to 3 hours of operation adjust oil cooling system.
3.
Pull and clean suction strainer after 24 hours of
operation. If it is excessively dirty, repeat every 24 hours
until system is clean. Otherwise, follow the normal
maintenance schedule.
4. Perform vibration analysis if equipment is available.
NORMAL START-UP PROCEDURE
1.Confirm system
compressor.
conditions
permit
starting
the
2. Start.
3.Observe the compressor unit for mechanical tightness
of the external piping, bolts and valves. Ensure that the
machine has no oil and vapor leaks. If any of these
occur, shut down the compressor and correct the
problem as necessary using good safety practices.
070.655-IOM (MAY 19)
Page 18
SBTP 408 ROTARY SCREW COMPRESSOR
MAINTENANCE
MAINTENANCE
have an accumulator, and all refrigerant and oil lines
should drain away from the compressor
GENERAL INFORMATION
• Protect the compressor during long periods of
shutdown: If the compressor will be sitting for long
periods without running, it is advisable to evacuate to low
pressure and charge with dry nitrogen or oil. This is
particularly true on systems known to contain water
vapor.
This section provides instructions for normal maintenance,
a recommended maintenance program, and troubleshooting
and correction guides.
WARNING
THIS SECTION MUST BE READ AND UNDERSTOOD BEFORE 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
When performing maintenance you must take several
precautions to ensure your safety:
1. If unit is running, press STOP key.
2. Stop motor and lock out starter before performing any
maintenance.
3. Wear proper safety equipment when compressor unit is
opened to atmosphere.
• Preventive
maintenance
inspection:
This
is
recommended any time a compressor exhibits a noticeable
change in vibration level, noise, or performance.
CHANGING OIL
Shut down the unit when changing oil. At the same time all
oil filter cartridges must be changed and all oil strainer
elements removed and cleaned.
WARNING
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.
The procedure is as follows:
1. Stop the compressor unit.
2. Lock out the motor starter.
3. Close the suction and discharge service valves.
4. Ensure adequate ventilation.
4. Using appropriate equipment, lower the compressor
pressure to 0 psig.
5. Take necessary safety precautions required for the gas
being used.
5. Open the drain valve(s) and drain oil into a suitable
container.
GENERAL MAINTENANCE
6. Drain the oil filter(s) and the oil coolers.
Proper maintenance is important in order to assure long and
trouble-free service from your screw compressor. Some areas
critical to good compressor operation are:
7. Remove the old filter cartridges, and install new ones.
• Keep oil clean and dry, avoid moisture contamination:
After servicing any portion of the refrigeration system,
evacuate to remove moisture before returning to service.
Water vapor condensing in the compressor while running,
or more likely while shutting down, can cause rusting of
critical components and facilitate the formation of acids,
thereby reducing the life of the unit.
10. Open the suction service valve and pressurize the unit
to system suction pressure. Close the suction valve and
leak test.
• Keep suction strainer clean: Check periodically,
particularly on new systems where welding slag or pipe
scale could find its way to the compressor suction.
Excessive dirt in the suction strainer could cause it to
collapse, dumping particles into the compressor.
14. Start the unit.
• Keep oil filters clean: If filters show increasing pressure
drop, indicating dirt or water, stop the compressor and
change filters. Running a compressor for long periods
with high filter pressure drop can starve the compressor
of oil and lead to premature bearing failure. Dual oil filters
are recommended so that the filters can be changed
without shutting down the package.
• Avoid slugging the compressor with liquids (oil): While
screw compressors are probably the most tolerant of any
compressor type available today about ingestion of some
liquid, they are not liquid pumps. Make certain a properly
sized suction accumulator is used to avoid dumping liquid
into compressor suction. The economizer line should
8. Remove, clean, and reinstall elements in the strainers.
9. Evacuate the unit.
11. Add oil.
12. Open the suction and discharge service valves.
13. Remove the lockout from the motor starter.
RECOMMENDED MAINTENANCE PROGRAM
In order to obtain maximum compressor performance and
ensure reliable operation, a regular maintenance program
should be followed. The compressor unit should be checked
regularly for leaks, abnormal vibration, noise, and proper
operation. A log should also be maintained. Oil analysis
should be performed on a regular basis. It is a valuable tool
that can identify the presence of moisture, acid, metallics
and other contaminants that will shorten compressor life if
not corrected. In addition, an analysis of the compressor
vibration should be made periodically.
VIBRATION ANALYSIS
Periodic vibration analysis can be useful in detecting bearing
wear and other mechanical failures. If vibration analysis is
used as a part of your preventive maintenance program,
take the following guidelines into consideration.
SBTP 408 ROTARY SCREW COMPRESSOR
MAINTENANCE
1.Always take vibration readings from exactly the same
places and at exactly the same percentage of load.
2.Use vibration readings taken from the new unit at startup as the baseline reference.
070.655-IOM (MAY 19)
Page 19
contaminants. In order to ensure the quality of the oil in the
compressor unit:
1.
Only use FRICK oil or high quality oils approved by
Johnson Controls-FRICK for your application.
3.Evaluate vibration readings carefully as the instrument
range and function used can vary. Findings can be easily
misinterpreted.
2.Only use FRICK filter elements. Substitutions must be
approved in writing by Johnson Controls-FRICK
engineering or warranty claim may be denied.
4.Vibration readings can be influenced by other equipment
operating in the vicinity or connected to the same piping
as the unit.
3.Participate in a regular, periodic oil analysis program to
maintain oil and system integrity.
OPERATING LOG
5.
If using proximity probes, collect data and evaluate
periodically in the same manner as vibration readings.
The use of an operating log as included in this manual
permits thorough analysis of the operation of a system by
those responsible for its maintenance and servicing.
Continual recording of gauge pressures, temperatures, and
other pertinent information, enables the observer and
OIL QUALITY AND ANALYSIS
High quality and suitable oil is necessary to ensure
compressor longevity and reliability. Oil quality will rapidly
deteriorate in systems containing moisture and air or other
MAINTENANCE SCHEDULE
This schedule should be followed to ensure trouble-free operation of the compressor unit.
95,000
90,000
85,000
80,000
75,000
70,000
65,000
60,000
55,000
50,000
45,000
40,000
35,000
30,000



 Every 6 months









25,000
20,000
15,000
10,000
8000
1000
Change oil
Oil analysis
Replace oil filters
Clean oil strainers
Clean liquid strainers
Replace coalescers
Check and clean suction strainer
Vibration analysis
Replace shaft seal
200
Maintenance
5000
Frequency or hours of operation (maximum)
As directed by oil analysis


























 Every 6 months, more frequently if levels increase
When leak rate exceeds 20 drops per minute
serviceman to be constantly familiar with the operation of
the system and to recognize immediately any deviations
from normal operating conditions. It is recommended that
readings be taken at least daily.
TROUBLESHOOTING GUIDE
Successful problem solving requires an organized approach
to define the problem, identify the cause, and make the
proper correction. Sometimes it is possible that two
relatively obvious problems combine to provide a set of
symptoms that can mislead the troubleshooter. Be aware of
this possibility and avoid solving the “wrong problem”.
ABNORMAL OPERATION ANALYSIS AND CORRECTION
Four logical steps are required to analyze an operational
problem effectively and make the necessary corrections:









1. Insufficient or excessive refrigerant or gas load.
2. Excessively high suction pressure.
3. Excessively high discharge pressure.
4. Excessively high or low temperature coolant to the oil
cooler.
5. Excessive liquid entering the compressor (slugging).
6. Insufficient oil cooling.
7. Excessive oil cooling
8. Incorrect gas line sizing.
9. Improper system piping.
10. Wrong operation of hydraulic operated slide valve.
11. Problems in electrical service to compressor.
12. Moisture present in the system.
4. Make the necessary corrections.
Make a list of all deviations from normal compressor
operation. Delete any items, which do not relate to the
symptom and separately list those items that might relate
to the symptom. Use the list as a guide to further investigate
the problem.
The first step in effective problem solving is to define the
limits of the problem. The following list of abnormal system
conditions can cause abnormal operation of the 408 mm
compressor:
The second step in problem solving is to decide which
items on the list are possible causes and which items are
additional symptoms. High discharge temperature and high
oil temperature readings on a display may both be symptoms
1. Define the problem and its limits.
2. Identify all possible causes.
3. Test each cause until the source of the problem is found.
070.655-IOM (MAY 19)
Page 20
SBTP 408 ROTARY SCREW COMPRESSOR
MAINTENANCE
of a problem and not causally related.
The third step is to identify the most likely cause and take
action to correct the problem. If the symptoms are not
relieved, move on to the next item on the list and repeat the
procedure until you have identified the cause of the
problem. Once the cause has been identified and confirmed
make the necessary corrections.
CAPACITY LINEAR TRANSMITTER REPLACEMENT SLIDE VALVE
The Capacity Linear Transmitter is located on the end of the
compressor cylinder (see Figure 12). The linear transmitter
with hermetic enclosure is based on the inductive measuring
principle. It features removable electronics (from the sensor
well) eliminating the need to evacuate the compressor for
replacement. This type of transmitter is dedicated to
capacity control and is not adjustable.
1. Shut off control power.
2. Remove DIN connector plug from transmitter.
3. Loosen cap screws.
The linear transmitter, with hermetic, enclosure is based on
the inductive measuring principle. It features removable
electronics (from the sensor well) eliminating the need to
evacuate the compressor for replacement. This type of
transmitter is dedicated to volume ratio control and has no
user adjustments.
1. Shut off control power.
2. Remove DIN connector plug from transmitter.
3. Loosen setscrews.
4. Remove transmitter unit.
5. Install new transmitter unit.
6. Tighten setscrews.
7. Apply DIN connector plug to transmitter.
8. Turn on control power.
NOTICE
For calibration of the Volumizer unit, refer to the Analog
Calibration instructions in publication 090.040-O.
4. Remove transmitter unit.
5. Install new transmitter unit.
6. Tighten cap screws.
BARE COMPRESSOR REPLACEMENT
7. Apply DIN connector plug to transmitter.
The following procedure is required only when a bare
compressor is replaced in the field.
8. Turn on control power.
1. Verify that the starter is locked out.
END VIEW
SHADED AREA SHOWS
CAPACITY LINEAR TRANSMITTER
STAINLESS STEEL WELL
DIN CONNECTOR
2. Remove all tubing, piping, and wiring that is connected
to the compressor.
3. Disconnect the coupling from the motor shaft.
4. While supporting the compressor assembly with a
crane, remove the bolts at the compressor feet.
5. Thoroughly clean the compressor feet and mounting
pads of burrs and other foreign matter to ensure firm
seating of the compressor.
HEAT ISOLATOR
6. Thoroughly clean the new compressor and remove all
cover plates and protection etc.
7. Install new gaskets and sealing in all connections.
COMPRESSOR UNLOAD CYLINDER
CAST ALUMINUM HOUSING
Figure 16: Capacity Linear Transmitter
8. Set the new compressor in place and shim feet where
required.
9. Reattach the drive coupling.
10. Check the shaft alignment and perform cold alignment.
VOLUMIZER TRANSMITTER REPLACEMENT - SLIDE STOP
11. Complete tubing, piping, and wiring.
The Volumizer Transmitter is located on the right side of
the compressor (facing shaft) at the inlet end (see Figure
13).
12. Restart unit, and run until steady state conditions are
met. Shut down, lock out motor starter, and perform hot
alignment.
SHUTDOWN DUE TO
IMPROPER OIL PRESSURE
(High Stage and Booster)
The compressor must not operate with incorrect oil
pressure.
• Refer to CONTROL SETUP
Figure 17: Volumizer transmitter
SBTP 408 ROTARY SCREW COMPRESSOR
MAINTENANCE
070.655-IOM (MAY 19)
Page 21
TROUBLESHOOTING THE 408 MM COMPRESSOR
Symptom
Probable causes and corrections
Slide valve and/or slide stop
will not move
4-way hydraulic control valve failed. Repair or replace.
Slide stop indicator rod stuck. Contact Johnson Controls–FRICK Service for assistance.
Check both S.V. and S.S. feedback devices for wiring and resistance.
Compressor must be running with sufficient oil pressure.
Unloader piston stuck. Contact Johnson Controls–FRICK service for assistance.
Piston Seals worn out or damaged. Contact Johnson Controls-FRICK Service for
assistance.
NOTICE
Unless the Service Technician has been certified by Johnson Controls–FRICK to rebuild our compressors,
troubleshooting the compressor is limited to identifying the probable cause. If a mechanical problem is suspected,
contact Johnson Controls–FRICK Service. Do not attempt to disassemble compressor.
TROUBLESHOOTING THE HYDRAULIC SYSTEM
Symptom
Probable causes and corrections
Slide valve will not load or
unload
Solenoid coils burned out. Replace.
Valve closed. Open hydraulic service valves.
Solenoid spool stuck or centering spring broken. Replace.
Check LED on coil. If lit, there is power to the coil. Check coil.
Solenoid may be actuated mechanically by inserting a piece of 3/16” rod against
armature pin and pushing spool to opposite end. Push A side to confirm unload
capability. If valve works, problem is electrical.
Slide valve will load but will
not unload
A side solenoid coil may be burned out. Replace.
Dirt inside solenoid valve preventing valve from operating both ways. Clean.
Check LED on coil. If lit, valve is functioning mechanically. Problem is electrical.
Solenoid may be actuated mechanically by inserting a piece of 3/16” rod against
armature pin and pushing spool to opposite end. Push A side to confirm unload
capability. If valve works, problem is electrical.
Slide valve will unload but will
not load
A side solenoid coil may be burned out. Replace.
Dirt inside solenoid valve preventing valve from operating both ways. Clean.
Check LED on coil. If lit, valve is functioning mechanically. Problem is electrical.
Solenoid may be actuated mechanically by inserting a piece of 3/16” rod against
armature pin and pushing spool to opposite end. Push A side to confirm unload
capability. If valve works, problem is electrical.
Slide stop will not function
either direction
Solenoid coils may be burned out. Replace.
Solenoid service valves may be closed. Open.
Manually actuate solenoid. If slide stop will not move, mechanical problems are
indicated. Consult Johnson Controls-FRICK Service.
Note: See Compressor Hydraulic System section for additional information
070.655-IOM (MAY 19)
Page 22
SBTP 408 ROTARY SCREW COMPRESSOR
MAINTENANCE
TROUBLESHOOTING THE OIL PUMP AND SYSTEM
Symptom
Probable causes and corrections
Pump will not produce enough
oil pressure at start-up
Check that service valves are open.
Filter cartridges may be blocked. Check PSID across filters.
Strainer may be blocked. Clean.
Oil pressure regulator set too low or stuck open. Readjust or repair.
Pump worn out. Repair or replace.
Oil pressure rapidly drops off
when compressor starts
Main oil injection throttling valve too wide open or oil pressure regulating valve
improperly adjusted. Readjust both valves.
Noise and vibration
Pump strainer blocked. Clean.
Pump worn out. Repair or replace.
Oil pressure drops as head
pressure increases
Normal behavior. Set main oil injection and oil pressure for maximum head pressure
condition.
Main unit filter psid is too high
Filters clogged with dirt. Replace.
Oil is too cold. Allow oil to warm up and check again.
Service valve on filter outlet is partially closed. Open valves fully.
SBTP 408 ROTARY SCREW COMPRESSOR
FORMS
070.655-IOM (MAY 19)
Page 23
DRIVE TRAIN ALIGNMENT
Ambient Temperature at Time of Alignment
Oil Separator Temperature at Time of Alignment
Motor Coupling Type
Distance Between Coupling Hub Faces
Soft Foot Check:
Size
OK as Found
Indicator Readings in:
in./1000
Indicator Readings Facing:
Compressor
Compressor Coupling Hub Runout
Initial Cold Alignment
Face
Rim
Thickness of Shims Added
Shimming Required
mm
Motor
Amount of Shims used to Correct
Indicator Clamped to
Magnetic Center Checked
Motor Coupling Hub Runout
Initial Hot Alignment
Face
Rim
Thickness of Shims Added
OPERATING LOG SHEET
Date
Time
Hour meter reading
Equip. Room temp.
Suction pressure
Suction temperature
Suction superheat
Discharge pressure
Discharge temperature
Corresponding temperature
Oil pressure
Oil temperature
Oil filter pressure drop
Separator temperature
Slide valve position
Volume ratio (vi)
Motor amps / fla %
Capacity control setpoint
Oil level
Oil added
Seal leakage (drops/min.)
Motor
Compressor
Marked
N/A
Final Hot Alignment
Face
Rim
Thickness of Shims Added
070.655-IOM (MAY 19)
Page 24
SBTP 408 ROTARY SCREW COMPRESSOR
FORMS
VIBRATION DATA SHEET
Date:
Sales Order Number:
End User:
Installing Contractor:
Address:
Service Technician:
Final Hot Alignment
Equipment ID (As in Microlog):
Compressor Serial Number:
Unit Serial Number:
National Board Number:
Running Hours:
Manufacturer and Size of Coupling:
Motor Manufacturer:
Motor Serial Number:
RPM:
Frame Size:
Refrigerant:
Ambient Room Temperature:
Operating Conditions:
Suction
Face
Rim
Total Thickness of Shims Added
Soft Foot
Soft Foot
Soft Foot
Soft Foot
H.P.
°F
Discharge
Oil
Separator
Press
#
Press
#
Press
#
Temp
°F
Temp
°F
Temp
°F
Temp
Slide Valve Position
°F
F.L.A.
Figure 18: Casing Accelerometers (if equipped)
Compressor Non Drive-End
Horizontal Direction
____.____ IPS Overall
Compressor Drive-End
Horizontal Direction
_______ . ______ IPS Overall
Compressor Drive-End
Axial Direction
____.____ IPS Overall
Compressor Non Drive-End
Vertical Direction
____.____ IPS Overall
Compressor Drive-End
Vertical Direction
____.____ IPS Overall
%
Vi Ratio
%
SBTP 408 ROTARY SCREW COMPRESSOR
FORMS
070.655-IOM (MAY 19)
Page 25
Figure 19: Proximity Probes (if equipped)
Compressor Non Drive-End
Male
X and Y
X ____.____ mil pk-pk
Y ____.____ mil pk-pk
Compressor Non Drive-End
Female
X and Y
X ____.____ mil pk-pk
Y ____.____ mil pk-pk
Compressor Drive-End
Male
X and Y
X ____.____ mil pk-pk
Y ____.____ mil pk-pk
Compressor Drive-End
Female
X and Y
X ____.____ mil pk-pk
Y ____.____ mil pk-pk
Male Axial Displacement
Push-Pull
____ inch
070.655-IOM (MAY 19)
Page 26
SBTP 408 ROTARY SCREW COMPRESSOR
INDEX
A
L
accumulator, 3
allowable flange loads, 12
antifriction bearings, 6
ASHRAE, 3
lifting rings, 12
linear transmitter, 20
load surges, 3
long term storage, 4
lubrication system, 5
B
bare compressor, 20
booster, 16
C
capacity control, 6
capacity linear transmitter, 20
compressor oil, 13
compressor port locations, 8
compressor rotation, 5
compressor shaft seal, 6
condensation, 3
CoolWare™, 3
corrosion, 4, 12
coupling, 20
customer connections, 12
D
dimensions, 7
DIN connector plug, 20
discharge pressure, 6, 16, 19
discharge temperature, 3
drive coupling, 20
drive train alignment, 23
dry nitrogen, 12
E
evacuation lines, 4
F
female rotor, 6
foundation, 12
M
maintenance, 18
maintenance
maintenance schedule, 19
male rotor, 6
male rotor shaft, 5
motor, 20
motor, 23
MSS solenoid, 16
N
needle valve, 16
O
oil analysis, 18
oil cooler, 19
oil cooling system, 17
oil filter cartridges, 18
oil filters, 18
oil filter(s), 13
oil heater(s), 13
oil manifold, 16
oil pump, 13
oil quality, 19
oil seal, 5
oil strainer elements, 18
oil supply, 5
operating log, 19
operating log sheet, 23
over-compression, 6
P
gaskets, 20
gas load, 19
pipe hangers, 12
piping layouts, 3
piping stress, 12
pressure ratio, 6
H
R
hermetic enclosur, 20
hermetic enclosure, 20
holding charge, 12
hydraulic cylinder, 5, 16
hydrocarbon gasses, 3
rigging and handling, 12
rotor housing, 6
G
I
identification data plate, 3
installation, 7
insulated, 17
S
seal life, 5
seal well, 5
serial number, 3
shaft alignment, 20
shaft rotation, 5
shipping gauges, 12
shutdown, 18
slide stop, 6
SBTP 408 ROTARY SCREW COMPRESSOR
INDEX
slide valve, 5, 6, 14, 19
slide valve transmitter, 14
solenoids, 15
solenoid valves, 16
start-up, 17
storage, 12
suction accumulator, 18
suction line, 3
suction pressure, 19
suction strainer, 17, 18
system piping, 19
T
thermal stability, 6
transmitter unit, 20
traps, 3
troubleshooting, 18
troubleshooting, 21
filter cartridges, 22
hydraulic control valve, 21
oil pressure, 22
oil pressure regulator, 22
piston seals, 21
pressure regulating valve, 22
pump, 22
pump strainer, 22
service valves, 22
slide stop, 21
slide stop indicator rod, 21
slide valve, 21
solenoid coils, 21
solenoid spool, 21
strainer, 22
unloader piston, 21
U
under-compression, 6
unloading, 6
V
vacuum, 4
vacuum, 14
vacuum pump, 14
valve ports, 16
vapor pump, 3
Vi, 16
vibration analysis, 17, 18
vibration level, 18
volume ratio, 16
W
water vapor, 18
water vapor, 18
070.655-IOM (MAY 19)
Page 27
Form 070.655-IOM (2019-05)
Supersedes: NOTHING
Subject to change without notice
Published in USA • 05/19 • PDF
© 2019 Johnson Controls Int’l PLC - ALL RIGHTS RESERVED
JOHNSON CONTROLS
100 Cumberland Valley Avenue
Waynesboro, PA 17268-1206 USA
Phone: 717-762-2121 • FAX: 717-762-8624
www.jci.com/FRICK