Frick SBTP Rotary Screw Compressor Installation Operation and Maintenance Guide

Brand: Frick

Model: SBTP Rotary Screw Compressor

Type: Installation Operation and Maintenance Guide

This manual contains installation, operation, 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 incorrect operation.

Rotary Screw Compressor

SBTP 355 and 408 Series

Form 070.655-IOM (FEB 2022)

Installation – Operation – Maintenance

File: Service Manual – Section 070

Replaces: 070.655-IOM (MAY 2019)

Distribution: 3, 3a, 3b, 3c

Revised: October 28, 2022

Check www.FrickCold.com for the latest version of this publication.

070.655-IOM (FEB 22)

Page 2

SBTP Rotary Screw Compressor

Installation - Operation - Maintenance

Contents

General information

Design limitations ............................................................. 3

Job inspection .................................................................. 3

Standard bare compressor ............................................... 3

Transit damage claims ...................................................... 3

Compressor identification ................................................ 3

Description ........................................................................4

Frick SBTP compressor ............................................... 4

Compressor lubrication system ................................... 4

Oil pump ....................................................................... 5

Construction details...................................................... 5

Installation

Design limits ..................................................................... 7

Outline dimensions ........................................................... 7

Holding charge and storage ............................................ 15

Rigging and handling ....................................................... 15

Lifting instructions ...................................................... 15

Foundation ..................................................................... 15

Customer connections .................................................... 16

Compressor oil ................................................................ 16

Oil pump ......................................................................... 16

Compressor ..................................................................... 16

Mounting the motor: foot mounted only ....................16

Connecting the compressor to the motor .................. 17

Aligning the coupling .................................................. 17

Oil heaters ......................................................................17

Oil filters ........................................................................17

Oil cooling requirements ................................................. 17

Natural gas applications .............................................17

Dehydration or evacuation test ....................................... 18

Installing electrical components ...................................... 18

Slide stop transmitter .................................................18

Capacity slide valve transmitter .................................. 18

Directional control valves .......................................... 18

Operation

Operation and start-up instructions ............................... 19

Compressor hydraulic system ........................................19

Volumizer volume ratio control ......................................20

Low ambient operation .................................................. 20

Initial start-up ................................................................20

Initial start-up procedure ..........................................20

Normal start-up procedure ........................................20

Maintenance

General information .......................................................21

General maintenance ................................................21

Maintenance schedule .....................................................22

Changing the oil ......................................................... 22

Maintenance program ............................................... 22

Vibration analysis ............................................................ 23

Oil quality and analysis ................................................... 23

Operating log .................................................................23

Troubleshooting guide .................................................... 23

Abnormal operation analysis and correction ............. 23

Replacing the capacity linear transmitter: slide valve 23

Replacing the

volumizer transmitter: slide stop.............24

Replacing the bare compressor ......................................25

Long-term storage .......................................................... 25

Preparing the compressor for storage............................. 25

Maintaining the compressor ............................................ 25

Shutdown due to incorrect oil pressure: high stage and

booster ................................................................... 25

Troubleshooting the SBTP compressor .......................... 26

Troubleshooting the oil pump and system ....................... 26

Troubleshooting the hydraulic system ............................. 27

Forms

Compressor prestart checklist .........................................28

Drive train alignment ....................................................... 29

Operating log sheet ........................................................29

Vibration data sheet ........................................................30

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

injury.

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

serious injury.

Safety precaution denitions

Indicates a potentially hazardous situation or practice, which if not avoided, results in damage to

equipment and/or minor injury.

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

WARNING

CAUTION

DANGER

NOTICE

070.655-IOM (FEB 22)

Page 3

SBTP Rotary Screw Compressor

Installation - Operation - Maintenance

General information

Note: The information in this document is subject to

change without notice.

This manual has been prepared to acquaint the owner and

servicer with the Installation, operation, and maintenance

procedures as recommended by Johnson Controls-Frick®

for SBTP Rotary Screw Compressors.

It is most important that these compressors are correctly

applied to an adequately controlled refrigerant or gas

system. Consult your authorized Johnson Controls-Frick

representative for expert guidance in this determination.

Effective performance and continued satisfaction with

these units depends on the following factors:

• Correct installation

• Correct operation

• Regular, systematic maintenance

To ensure correct installation and application, select

the appropriate equipment and connect to a correctly

designed and installed system. The engineering plans,

piping layouts, and other system design materials must be

detailed in accordance with the best practices and local

codes, such as those outlined in ASHRAE and API litera-

ture.

A screw compressor is a vapor pump. To ensure that

working uid in the liquid state is not being ingested, per-

form the following checks:

• Select controls carefully. Make sure they are in good

operating condition.

• Size piping and arrange traps correctly, if they are

necessary.

• Check that the suction line has an accumulator or slug-

ging protection.

• Know the load surges and make provisions for control.

• Check that operating cycles and stand still periods are

reasonable.

• Size high-side components within system and com-

pressor design limits.

It is necessary to keep the discharge temperature high

enough to prevent condensation of any moisture in the

compressor and oil separator.

Design limitations

Frick compressors are designed for operation within the

pressure and temperature limits which are specied by

Johnson Controls-Frick and our CoolWare™ selection soft-

ware. They are primarily used for compressing refrigerant

gas and most hydrocarbon gasses.

If your application is for sour gas, there are special re-

quirements to protect the compressor. Contact Johnson

Controls-Frick Compressor Engineering for application

details.

Job inspection

Immediately upon delivery, examine all crates, boxes, and

exposed compressor and component surfaces for damage.

Unpack all items and check against shipping lists for any

discrepancy. Examine all items for damage in transit.

Standard bare compressor

Items not included with bare compressor that are available

as sales order options include a solenoid valve block, and

solenoid valves.

Transit damage claims

All claims must be made by consignee. This is an ICC

requirement. Request immediate inspection by the agent

of the carrier and be sure the correct claim forms are ex-

ecuted. Report damage or shortage claims immediately to

Johnson Controls-Frick Sales Administration Department,

Waynesboro, PA.

Compressor identification

Each compressor has an identication data plate, contain-

ing compressor model and serial number mounted on the

compressor body.

NOTICE

When inquiring about the compressor or unit, or

ordering repair parts, provide the model, serial, and

Frick sales order numbers from the data plate. See

Figure 1.

Figure 1: Identication data plate

100 CUMBERLAND VALLEY AVENUE

WAYNESBORO, PA 17268

ROTARY SCREW COMPRESSOR

MODEL NO.

MAX DRIVER SPEED MAX ALLOWABLE PRESSURE

PART NO.

RPMPSIG BARG

ASSEMBLED IN

FROM FOREIGN AND DOMESTIC MATERIALS

SERIAL NO.

070.655-IOM (FEB 22)

Page 4

SBTP Rotary Screw Compressor

Installation - Operation - Maintenance

Rotary screw compressor serial numbers are dened by

the following information:

Example: 10240A90000015Z

Plant Decade Month Year Global

seq. no.

Additional

remarks

1024 0 A 9 0000015 Z

Month:

A = JAN, B = FEB, C = MAR, D = APR, E = MAY, F = JUN,

G = JUL, H = AUG, K = SEP, L = OCT, M = NOV, N = DEC

Additional remarks

R = Remanufactured

Z = Deviation from Standard Conguration

The name plates in Figure 2 show which refrigerants are

compatible with the compressor as manufactured.

Figure 2: Refrigerant name plates

R290, R1270, NATURAL GAS

COMPRESSOR OPERATES ON AND IS

COMPATIBLE WITH THE FOLLOWING

REFRIGERANTS

Compressor

model

Rotor

diameter

Rotor

L/D

Max

speed

rpm

Theoretical

displacement

ft³/rev (m³/rev)

Displacement at

3550 rpm

driver speed

ft³/rev (m³/rev)

Displacement at

2950 rpm

driver speed

ft³/rev (m³/h)

3511 355 1.1 3,600 0.82248 (0.02329) 2,929 (4,976) 2,434 (4,135)

3515 355 1.5 3,600 1.12124 (0.03175) 3,994 (6,786) 3,319 (5,639)

3519 355 1.9 3,600 1.42748 (0.04042) 5,058 (8,594) 4,203 (7,141)

3524 355 2.4 3,600 1.80329 (0.05106) 6,390 (10,857) 5,310 (9,022)

4013 408 1.3 3,600 1.41180 (0.03998) 5,012 (8,515) 4,165 (7,076)

4018 408 1.8 3,600 1.95481 (0.05535) 6,940 (11,790) 5,767 (9,798)

4021 408 2.13 3,600 2.31319 (0.06550) 8,212 (13,952) 6,824 (11,594)

Table 1: Compressor specications

Description

Frick SBTP compressor

Frick SBTP rotary screw compressors use mating asym-

metrical prole helical rotors to provide a continuous ow

of vapor and are designed for both high-pressure and

low-pressure applications. The compressor incorporates

the following features:

• High-capacity sleeve bearings to carry radial loads at

both the inlet and outlet ends of the compressor.

• Heavy-duty, tilt-pad thrust bearings mounted at the

discharge end of the compressor to carry axial loads.

• Moveable slide valve to provide fully modulating

capacity control from 100% to approximately 15%,

condition dependent, of full load capacity.

• Volumizer volume ratio control to allow innitely vari-

able volume ratio between minimum and maximum

values during compressor operation.

• A hydraulic cylinder to operate the slide stop and slide

valve.

• Housings are designed for 600 psig pressure.

• Shaft seal housing is designed to maintain operating

pressure on seal well below discharge pressure for

increased seal life.

• Oil injected into the rotors to maintain good volumetric

and adiabatic efciency even at very high compression

ratios.

• The shaft rotation clockwise facing compressor from

the drive end, suitable for all types of drives. See the

following warning.

WARNING

Compressor rotation is clockwise when facing the

compressor drive shaft. Never operate the compres-

sor in reverse rotation because this can result in

bearing damage.

• ANSI B16.1 Class 300 suction and discharge anges for

all models.

• Specified #60 mesh x 0.0065 in. diameter stainless

steel wire or better strainer, to prevent damage to the

compressor from particles entering the suction area.

Compressor lubrication system

The lubrication system on an SBTP screw compressor per-

forms several functions:

• Provides lubrication to bearings and seal.

• Provides a cushion between the rotors to minimize

noise and vibrations.

• Helps keep the compressor cool and prevents over-

heating.

• Provides an oil supply to hydraulically actuate the slide

valve and slide stop.

• Provides an oil seal between the rotors to prevent ro-

tor contact or gas bypassing.

070.655-IOM (FEB 22)

Page 5

SBTP Rotary Screw Compressor

Installation - Operation - Maintenance

Oil pump

A full-time lube oil pump is required for all sleeve bear-

ing 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 before starting the compressor to

ensure adequate oil pressure and temperature is being

supplied to the machine. Do this by using an automated

diverting valve that bypasses oil ow back to the oil sepa-

rator until the correct oil conditions are veried. After this

the diverter valve switches to direct oil to the compressor,

at which point you can start the compressor. At shutdown,

the oil pump must continue to run until the compressor

has stopped rotating. Failure to provide adequate oil pres-

sure and temperature to the compressor while it is running

may lead to equipment damage.

Construction details

Housing: all SBTP screw compressor castings are steel

to ensure structural integrity and mechanical and thermal

stability under all operating conditions.

Rotors: the rotors are machined from AISI-1141 or Y40Mn

steel to the exacting tolerances of the latest Frick prole.

The male rotor is directly connected to the driver while

the female rotor is driven by the male on a thin oil lm.

Bearings:

SBTP compressor models use API compliant

journal bearings and tilting pad thrust bearings to absorb

radial and axial loads respectively. The cylindrical sleeve

bearings are oil grooved for optimal lubrication and higher

radial load capability. The tilting pad thrust bearing uses

offset pads and directed lubrication to minimize power

loss and maintain lower bearing temperatures at lower oil

ows for maximum bearing life

Shaft seal: the compressor is supplied with a single-

face type mechanical shaft seal with metallic stationary

and rotating faces. Materials vary to suit the application.

Tandem style seals can also be supplied at additional cost

if required The seal is capable of withstanding static pres-

sure up to 700 psig.

Volumizer variable volume ratio control: the Frick com-

pressor includes a method of varying the internal volume

ratio to match the system pressure ratio. Control of the in-

ternal 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 por-

tion 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 capac-

ity 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 by-

passed back to suction through a recirculation slot before

compression begins and any work is expended, providing

the most efcient unloading method available for part-

load operation of a screw compressor.

070.655-IOM (FEB 22)

Page 6

SBTP Rotary Screw Compressor

Installation - Operation - Maintenance

This page is intentionally left blank.

070.655-IOM (FEB 22)

Page 7

SBTP Rotary Screw Compressor

Installation

Design limits

General information for all of the models is provided in the

following sections. See CoolWare™ to determine the limits

for a specic application.

Do not exceed the rotor and bearing design set limitations

of any compressor. Refer to CoolWare™ for more

information.

Outline dimensions

See Figure 3 to Figure 12 for port locations. Drawings are

for reference only. Refer to outline drawing 534E1598

for 355 series and 534E1279 for 408 series for complete

dimensions and access connections. If you do not have

this drawing, you can request it by contacting Johnson

Controls-Frick sales.

070.655-IOM (FEB 22)

Page 8

SBTP Rotary Screw Compressor

Installation

Figure 3: SBTP 355 compressor port locations

Figure 4: SBTP 355 compressor port locations, view A-A

Suction

3511 compressor

10 - 300# ANSI ange

1 in. - 8 UNC-2B x 2.13 DP

Proximity sensor

phase probe

4X radial bearing RTD

4X proximity sensor

vertical probe

4X proximity sensor

horizontal probe

Proximity

sensor

female axial

probe

Proximity sensor

male axial probe

View A-A

070.655-IOM (FEB 22)

Page 9

SBTP Rotary Screw Compressor

Installation

Figure 5: SBTP 355 compressor port locations, view B-B

Figure 6: SBTP 355 compressor port locations, view C-C

Axial bearing RTD

2x Axial bearing RTD

View B-B

View C-C

070.655-IOM (FEB 22)

Page 10

SBTP Rotary Screw Compressor

Installation

SC-15

SC-5

ST-1

SM-1

SC-9

SV-1

SC-6

ST-2

Figure 8: SBTP 408 compressor port locations

SD-1

Discharge

10 in. - 300# ANSI ange

1 in. - 8 UNC-2B x 2.25 DP

Standard piping arrangement

View D-D

View E-E

Figure 7: SBTP 355 compressor port locations, view D-D and E-E

070.655-IOM (FEB 22)

Page 11

SBTP Rotary Screw Compressor

Installation

SE-1

SC-1

SB-2 SC-5

SP-1

SP-2

SB-3

SC-7

SE-2

View A-A

Proximity sensor

axial probe

4X proximity sensor

horizontal probe

4X radial bearing RTD

4X proximity sensor

vertical probe

2X proximity sensor

phase probe

Suction compressors

4018 and 4021

16 in. - 400# ANSI ange

1 1/4-7 UNC-2B x 2.56 DP

20X on 22.500 B.C.

Compressor 4013

12 in. - 400# ANSI ange

1 1/4-7 UNC-2B x 2.18 DP

16X on 17.750 B.C.

Proximity sensor

axial probe

Figure 9: SBTP 408 compressor port locations, view A-A

SC-4

View B-B

SC-12

SC-8

Figure 10: SBTP 408 Compressor port locations, view B-B

070.655-IOM (FEB 22)

Page 12

SBTP Rotary Screw Compressor

Installation

SC-10

SC-11

Axial bearing RTD

View C-C

Figure 11: SBTP 408 compressor port locations, view C-C

Axial bearing RTD

View E-E

View D-D

SL-1 SC-3

SC-2

SL-2

Discharge

Figure 12: SBTP 408 compressor port locations, view D-D and E-E

070.655-IOM (FEB 22)

Page 13

SBTP Rotary Screw Compressor

Installation

Port Size O-ring Description

SB-2 1 in. -300# ANSI, 5/8-11 UNC, 1.38 DP - Oil feed inlet bearings

SB-3 2 in. -300# ANSI, 5/8-11 UNC, 1.25 DP - Oil feed outlet bearings and seal

SC-1 9/16-18 UNF-2B straight thread o-ring 980A0013K58 Slide valve

SC-3 3/4-16 UNF-2B straight thread o-ring 980A0013K60 Slide stop

SC-4 3/4-16 UNF-2B straight thread o-ring 980A0013K60 Cylinder drain

SC-5 1 1/16-12 UN-2B straight thread o-ring 980A0013K64 Suction pressure

SC-6 1 1/16-12 UN-2B straight thread o-ring 980A0013K64 Discharge pressure/slide valve tool

SC-7 3/4-16 UNF-2B straight thread o-ring 980A0013K60 Oil pressure

SC-8 1/8-27 NPTF - Seal weepage

SC-11 1 1/16-12 UN-2B straight thread o-ring 980A0013K64 Drain/discharge pressure

SC-12 3/4-16 UNF-2B straight thread o-ring 980A0013K60 Drain/suction pressure

SC-13 1 1/16-12 UN-2B straight thread o-ring 980A0013K64 Inlet bearing drain/suction pressure

P 3/4-16 UNF-2B straight thread o-ring 980A0013K60 Cylinder pressure (manifold block pressure)

T 3/4-16 UNF-2B straight thread o-ring 980A0013K60 Cylinder vent (manifold block tank)

SD-1 1 1/16-12 UN-2B straight thread o-ring 980A0013K64 Coalescer bleed/suction pressure

SE-1 DIN connector - Slide valve

SE-2 DIN connector - Slide stop

SM-1 1 1/2 in. -300# ANSI, 3/4-10 UNC, 1.75 DP - Main oil injection

SP-1 1/4-28 UNF-2B, 0.68 DP - Suction accelerometer

SP-2 1/4-28 UNF-2B, 0.68 DP - Discharge accelerometer

ST-2 1 1/16-12 UN-2B straight thread o-ring 980A0013K64 Discharge temperature

SV-1 2 1/2-300# ANSI, 3/4-10 unc, 1.75 DP - Vapor injection (3511 compressor)

3-300# ANSI, 3/4-10 UNC, 1.75 DP - Vapor injection (3515, 3519, 3524 compressors)

Note: While liquid injection oil cooling is an option for anti-friction Frick screw compressors, Frick does not suggest it for

compressors supplied with tilting pad thrust bearings.

Table 2: 355 series port information

070.655-IOM (FEB 22)

Page 14

SBTP Rotary Screw Compressor

Installation

Port Size O-ring Description

SB-2 1 in. -300# ANSI, 5/8-11 UNC, 1.37 DP - Inlet bearings (4018, 4021)

1 in.-600# ANSI, 5/8-11 UNC, 1.37 DP - Inlet bearings (4013)

SB-3 2 in.-300# ANSI, 5/8-11 UNC, 1.75 DP - Outlet bearings (4018, 4021)

2 in.-300# ANSI, 5/8-11 UNC, 1.75 DP - Outlet bearings (4013)

SC-1 9/16-18 UNF-2B straight thread o-ring 980A0013K58 Slide valve

SC-2 9/16-18 UNF-2B straight thread o-ring 980A0013K58 Slide valve

SC-3 9/16-18 UNF-2B straight thread o-ring 980A0013K58 Slide stop

SC-4 9/16-18 UNF-2B straight thread o-ring 980A0013K58 Cylinder drain

SC-5 3/4-16 UNF-2B straight thread o-ring 980A0013K60 Suction pressure

SC-6 3/4-16 UNF-2B straight thread o-ring 980A0013K60 Discharge pressure

SC-7 3/4-16 UNF-2B straight thread o-ring 980A0013K60 Oil pressure

SC-8 1/8-27 NPTF - Seal weepage

SC-9 1 7/8-12 UN-2B straight thread o-ring 980A0013K70 Closed thread pressure

SC-10 2 1/2-12 UN-2B straight thread o-ring 980A0013K69 Slide valve tool/discharge pressure

SC-11 1 5/8-12 UN-2B straight thread o-ring 980A0013K69 Drain/discharge pressure

SC-12 3/4-16 UNF-2B straight thread o-ring 980A0013K60 Drain/suction pressure

P 3/4-16 UNF-2B straight thread o-ring 980A0013K60 Cylinder pressure (manifold block pressure)

T 3/4-16 UNF-2B straight thread o-ring 980A0013K60 Cylinder vent (manifold block tank)

SD-1 1 1/16-12 UN-2B straight thread o-ring 980A0013K64 Coalescer bleed/suction pressure

SE-1 DIN connector - Slide valve

SE-2 DIN connector - Slide stop

SL-1 1 1/2-300# ANSI, 3/4-10 UNC, 1.75 DP - Low Vi liquid injection (4018, 4021)

1 1/2-600# ANSI, 3/4-10 UNC, 1.75 DP - Low Vi liquid injection (4013)

SL-2 1 1/2-300# ANSI, 3/4-10 UNC, 1.75 DP - High Vi liquid injection (4018, 4021)

1 1/2-600# ANSI, 3/4-10 UNC, 1.75 DP - High Vi liquid injection (4013)

SM-1 3-300# ANSI, 3/4-10 UNC, 1.63 DP - Main oil injection (4018, 4021)

3-600# ANSI, 3/4-10 UNC, 1.63 DP - Main oil injection (4013)

SP-1 1/4-28 UNF-2B, 0.68 DP - Suction accelerometer

SP-2 1/4-28 UNF-2B, 0.68 DP - Discharge accelerometer

ST-1 1 1/16-12 UN-2B straight thread o-ring 980A0013K64 Suction temperature

ST-2 1 1/16-12 UN-2B straight thread o-ring 980A0013K64 Discharge temperature

SV-1 4-300# ANSI, 3/4-10 UNC, 1.63 DP - Vapor injection (4018, 4021)

3-600# ANSI, 3/4-10 UNC, 1.88 DP - Vapor injection (4013)

Note: While liquid injection oil cooling is an option for anti-friction Frick screw compressors, it is not recommended for com-

pressors supplied with tilting pad thrust bearings.

Table 3: 408 series port information

070.655-IOM (FEB 22)

Page 15

SBTP Rotary Screw Compressor

Installation

Holding charge and storage

Every SBTP compressor is pressure and leak tested at the

Johnson Controls–Frick factory and then thoroughly evacu-

ated and charged with dry nitrogen to ensure its integrity

during shipping and short-term storage before installation.

When storing the units, ensure the following:

• Keep all compressors in a clean, dry location to prevent

corrosion damage.

• When storing compressors for more than two months,

check their nitrogen charge periodically.

• When storing compressors for more than six months,

See Long-term storage for instructions and refer

to 020.050-W Limited Warranty Screw Compressor

Purchased for Long-Term Storage for Frick Bare Screw

Compressors.

WARNING

Holding-charge shipping gauges, if mounted, are

rated for 30 psig and are for checking the shipping

charge only. Remove them 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 you must replace them with

steel plugs when the package is assembled.

CAUTION

This equipment has been pressurized with nitrogen

gas. Temporary valves and gauges have been installed.

1. Relieve pressure before opening lines or making

eld connections.

2. Remove charging valves or gauges before pressur-

izing system.

Refer to installation operation and maintenance

manual for additional information.

Escaping gas may cause injury

Rigging and handling

You can move the compressor with rigging using a crane

or forklift by hooking into the two lifting rings at each end

of the main housings. Only use the compressor lifting rings

to lift the compressor itself. See the following figure:

Figure 13: Lifting rings: not model specic

LIFTING RINGS

Lifting instructions

Lifting rings are located to facilitate the rigging and lift-

ing of the bare compressor. See Figure 14. Ensure only a

qualied operator performs the lifting and that they follow

the necessary precautions.

• Lift rings are intended for lifting the bare compressor

only.

• Examine the lift rings for damage before lifting the

compressor. Replace any damaged rings

• Fully screw in the lift rings and seat them rmly against

the contact surface before lifting.

• Load the lift rings in the vertical direction only; that is,

ensure the load is parallel to the threaded portion of

the lift ring. See Figure 14. This may require the use

of a spreader beam. Loading the lift rings at an angle

reduces their load capacity.

• Ensure that the load is level and stable before lifting

more than a few inches.

• Lift the compressor slowly.

• Remove the lift rings from the compressor before

operation. The vibration of a running compressor can

cause the lift rings to loosen and become damaged.

Figure 14: Lifting rings orientation

Foundation

Note: For more detailed information on screw compressor

foundations, refer to Screw Compressor Founda-

tions, 070.210-IB.

Each

SBTP

rotary screw compressor is shipped mounted on

a wooden skid. Remove the skid before installing the unit.

CAUTION

Allow appropriate spacing for servicing. See the rel-

evant dimensional outline drawing.

The first requirement of the compressor foundation is that

it must be able to support the weight of the compressor

package.

Lifting rings

070.655-IOM (FEB 22)

Page 16

SBTP Rotary Screw Compressor

Installation

Table 4: Compressor weight

Model Weight

lb kg

3511 8,847 4,013

3515 9,701 4,400

3519 10,704 4,855

3524 11,852 5,376

4013 15,733 7,136

4018 17,342 7,866

4021 18,592 8,433

Screw compressors are capable of converting large quan-

tities of shaft power into gas compression in a relatively

small space. The compression process creates relatively

high-frequency vibrations that require sufcient 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 the correct bolting and by preventing piping stress

from being imposed on the compressor.

After rigging the compressor into place, shim its feet to

level it. There must be absolutely no stresses introduced

into the compressor body due to bolting the feet and

anges.

In any screw compressor installation, ensure suction and

discharge lines are supported in pipe hangers, preferably

within 2 ft of vertical pipe run, so that the lines won’t

move if disconnected from the compressor. See Table 5

for allowable ange loads.

Table 5: Allowable ange loads

Noz.

size

NPS

Moments (ft-lbf) Load (lbf)

Axial Vert. Lat. Axial Vert. Lat.

MR MC ML P VC VL

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

As a minimum, you must connect the lube oil system

to the following locations in addition to the suction and

discharge:

Table 6: Necessary port connections

Port Description

SB-2 Inlet bearings

SB-3 Discharge bearings and

shaft seal

SM-1 Main oil injection

SC-13 Manifold block pressure,

on manifold block

Other connections are available for instrumentation and

service as noted on the dimensional outline drawings.

NOTICE

You must connect the electrical connections for the

slide stop and the slide valve transmitters, and the

solenoid valve coils to your control system.

The oil supply system for the compressor must be de-

signed for a total pressure drop of no more than 15 psi

with a new oil lter element. This is critical because an

excessive pressure drop in the oil circuit can prevent the

slide valve and slide stop pistons from operating correctly.

Compressor oil

WARNING

Only Frick approved oil is recommended. No ad-

ditives 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 selects

a specic Frick oil for the refrigerant being used.

Depending on the application, a different oil can be

selected provided it is of the correct viscosity and

is compatible with the refrigerant and compressor

elastomers.

Oil pump

All SBTP compressor applications require an oil pump, and

Frick suggests mounting a strainer 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 unit does not exceed maximum oil pressure.

Compressor

Note: Compressor rotation is clockwise when facing the

end of the compressor shaft.

Conrm the motor can rotate the compressor clockwise

before installing the coupling.

Mounting the motor: foot mounted only

1. Thoroughly clean the motor feet and mounting pads of

grease, burrs, and other foreign matter to ensure rm

seating of the motor.

2. Attach the motor to the base using bolts and motor

raising blocks, if required.

070.655-IOM (FEB 22)

Page 17

SBTP Rotary Screw Compressor

Installation

3. Weld the four kick bolts, which are not included with

compressor, into place so that they are positioned to

allow movement of the motor feet.

4. After setting the motor, check to see that the shafts

are spaced correctly 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.

Connecting the compressor to the motor

Frick SBTP compressors are arranged for direct motor drive

and require a exible drive coupling to connect the compres-

sor to the motor.

If you are using the Johnson Controls–Frick motor mount,

the mount is machined to ensure that motor to compressor

alignment is in specication. See Mounting the motor: foot

mounted only for details.

With a foot-mounted motor, it is essential that the coupling

is correctly aligned to ensure the correct bearing and seal

performance:

• Select and install the coupling so that it doesn’t trans-

mit any axial load to the compressor shaft.

• Set up the minimum distance between compressor

shaft and motor shaft to allow for seal removal. See

the relevant outline drawings in Figure 3 to Figure 12.

• The 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 mini-

mum possible value. Ensure you follow the coupling

manufacturer’s guidelines for checking and correcting

any misalignment.

Aligning the coupling

You must perform a coupling alignment before start-up:

1. After installing the compressor on the job site, check

the alignment again and correct if necessary before

start-up.

2. After a few hours operation, check the alignment while

the package is still hot. Correct hot alignment is criti-

cal to ensure the life of the shaft seal and compressor

bearings.

Note: The maximum radial runout is 0.004 in. total indica-

tor reading. The maximum axial runout is 0.004 in.

total indicator reading.

3. Use a dial indicator or another appropriate measuring

device to determine the total indicator runout.

4. Check the indicator bracket sag because all brackets

have some exibility. The best way to measure this is

as follows:

a. Attach the dial indicator and bracket on a pipe at the

coupling span distance.

b. Zero the indicator in the 12:00 position.

c. 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.

You must include this value in the dial indicator readings

when afxed to the coupling for an accurate alignment.

Oil heaters

Your package must be equipped with oil heaters that

provide sufcient heat to prevent condensation from oc-

curring during shutdown cycles. In addition, Frick strongly

suggests heat tracing for all of the lube oil lines includ-

ing oil lters and the oil cooler. Activate the heat tracing

during compressor shutdown to ensure that all of the lube

system is up to the correct temperature before startup.

Oil filters

Using lter 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 lter specication β5 = 75 according to ISO 4572 is

required to obtain the recommended oil cleanliness class

16/14/11 according to ISO 4406.

Oil cooling requirements

Compressor oil needs to be cooled to control the discharge

temperature, maintain the appropriate oil viscosity, and to

preserve the life of the oil. Normally the discharge tempera-

ture is between 170°F to 180°F. See CoolWare™ to determine

your conguration.

The main oil injection line that is connected to port SM1 must

have a regulating valve to permit adjustment of the oil ow to

maintain the appropriate discharge temperature at all times.

Frick suggests using a three-way mixing valve to keep the

oil temperature in the normal range of 120°F to 140°F.

The valve provides warm oil to the compressor quickly, re-

ducing the pressure drop caused by cold, viscous oil. This

ensures the correct oil ow and temperature over the full

range of operating conditions.

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.

Acceptable methods of oil cooling would use either water,

air, or refrigerant cooled oil coolers.

Natural gas applications

One application that usually 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.

1. Open CoolWare and from the Wet/Dry Mode list, se-

lect Water Saturated.

2. Select Calculate to get the discharge dew point tem-

perature 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.

070.655-IOM (FEB 22)

Page 18

SBTP Rotary Screw Compressor

Installation

Dehydration or evacuation test

Evacuate the system to 1000 microns. Valve off the

vacuum pump and hold vacuum for 1 h.

Pass: vacuum cannot rise more than 500 microns during

1 h hold period.

Fail: vacuum rise is more than 500 microns during 1 h

hold period. Identify and repair any system leaks. Repeat

vacuum test until requirements are met.

Installing electrical components

Slide stop transmitter

The slide stop transmitter measures the position of the

slide stop (SS) using a 20 to 4 mA signal to cover the

range of minimum to maximum Vi. See Figure 15. 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 ef-

cient compressor operation. Connect to ± and signal as

shown in Figure 16. Refer to the latest Quantum Control-

ler Operations manual for calibration procedure, currently

090.070-O. Contact Frick for the most up-to-date version.

Figure 15: Slide stop transmitter

Figure 16: Wiring diagram for slide stop transmitter

Capacity slide valve transmitter

The slide valve transmitter measures the position of the

slide valve (SV) and sends a 4 to 20 mA signal to your

control system. See Figure 17 and Figure 18. The control-

ler adjusts the position of the SV according to the mo-

tor load setpoint. The position is important in order to

correctly 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

Figure 18. For compressor panel instructions, refer to the

latest Quantum Controller Operations, currently

090.070-O. Contact Frick for the most up-to-date version.

Figure 17: Capacity slide valve transmitter

ENDVIEW

DIN CONNECTOR

STAINLESS STEEL WELL

HEAT ISO LATO R

CAST ALUM INUM HOUSING

COMPRESSO R UNLOAD CYLINDER

SHADED AREA SHOW S

CAPACITY LINEAR TRANSMITTER

Note: Shaded are shows capacity linear transmitter.

Figure 18: Wiring diagram for slide valve transmitter

Directional control valves

You must wire solenoids YY1, YY2, YY3 and YY4 to give

the correct function. See the Compressor hydraulic system

section for a description of their function. For control

system information, refer to the latest Quantum Control-

ler Operations, currently 090.070-O. Contact Frick for the

most up-to-date version. See the following figure.

Figure 19: Directional control valve wiring diagram

Cast aluminum housing

DC isolated to ground

Supply 12 VDC

Out 20-4 mA

PCB

GND

Stroke

DIN connector 43650-A

Printed circuit board

Cast aluminum housing

Stainless steel

sensor well

DIN connector

Heat isolator

End view

Stainless steel well

Compressor unload cylinder

Cast aluminum housing

Stroke

GND

Out 4-20 mA

Supply 12 VDC to 24 VDC

PCB

Slide valve load

NeutralHot

Slide valve unload

Slide stop increase

Slide stop decrease

070.655-IOM (FEB 22)

Page 19

SBTP Rotary Screw Compressor

Operation

Operation and start-up instructions

The Frick SBTP rotary screw compressor is a compo-

nent in an integrated system. As a result, the compressor

requires some specic operation and conditions to ensure

trouble-free running.

The information in this section provides logical step-

by-step instructions to correctly start up and operate

the SBTP rotary screw compressor in your unit. It only

includes matters that may inuence the correct operation

of the SBTP compressor.

Read and ensure you understand the following sections

before attempting to start or operate the unit.

WARNING

The compression process creates noise and operating

screw compressors are loud. Wear the correct hearing

protection when near the compressor during operation.

If people are expected to be in the vicinity of the running

compressor for extended time periods, provide warnings.

Compressor hydraulic system

Note: 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 de-

crease the compressor’s volume ratio (Vi).

The hydraulic cylinder located at the inlet end of the SBTP

compressor serves a dual purpose. It is separated by a xed

bulkhead into two sections: the SV section is on the for-

ward 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 micropro-

cessor output energizes the solenoid valve.

Single-acting mode: high stage

Valve opens at SC1

Valve closes at SC2

Valve opens at bypass (BP)

See Figure 21 for details.

High-stage compressor loading: the compressor loads

when SV solenoid YY2 is energized and oil ows 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 ows

from the oil manifold through valve ports P and A to cylin-

der port SC1 and enters the unload side of the cylinder. Si-

multaneously, 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.

CAUTION

You must use single-acting mode for compressors

with differential pressures above 200 psid in order to

prevent failure of the slide valve piston retaining nut.

Double-acting mode: booster, low differential

Valve opens at SC1

Valve opens at SC2

Valve closes at BP

See Figure 21 for details.

Booster compressor loading: The compressor loads when

SV solenoid YY2 is energized and oil ows 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 ows out

cylinder port SC1 through valve ports A and T to compres-

sor suction.

Booster compressor unloading: The compressor unloads

when SV solenoid YY1 is energized and oil ows from the

oil manifold through valve ports P and A to cylinder port

SC1 and enters the unload side of the cylinder. Simultane-

ously, oil contained in the load side of the cylinder ows

out of compressor port SC2 through valve ports B and T to

compressor suction.

NOTICE

To control the rate of loading and unloading, throttle

valves SC1 and SC2. Optional ow control valves are

available (FC1 and FC2) for ner speed adjustment.

NOTICE

To slow all valve movements - loading, unload-

ing, and Vi change - a optional customer supplied

throttle valve can be used upstream of connection P.

Figure 20: Solenoid valve block

Special throttling control valve blocks are available with

needle valves and check valves on each port direction.

You can order 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.

070.655-IOM (FEB 22)

Page 20

SBTP Rotary Screw 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 ows

from the oil manifold through valve ports P and A to com-

pressor 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 ows

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.

Low ambient operation

Frick suggests insulating package oil separators as a mini-

mum requirement to preserve the heat generated by the

oil heaters, to prevent condensation, and secure lubrica-

tion at start-up.

Initial start-up

Before start-up, you must complete the prestart checklist.

See Compressor prestart checklist.

Initial start-up procedure

After completing 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. Keep the following points in mind during initial

start-up:

1. For effective and safe operation, the compressor must

be run at the correct speed and discharge pressure.

Exceeding design conditions creates a potential hazard.

2. After 1 h to 3 h of operation adjust oil cooling system.

3. Pull and clean suction strainer after 24 h of operation.

If it is excessively dirty, repeat every 24 h until system

is clean. Otherwise, follow the normal maintenance

schedule.

4. Perform a vibration analysis if equipment is available.

Normal start-up procedure

1. Conrm system conditions permit starting the com-

pressor.

NOTICE

Ambient temperatures need to be high enough to

prevent excessive condensing; otherwise, initiate oil

heaters and heat tracing 24 h before start-up.

2. Start the unit.

3. Observe the compressor unit for mechanical tight-

ness 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.

Oil pressure in

Oil pressure out

SC1

YY1 YY2 YY3 YY4

SC-1

SC-2

SC-3

SC2

A A

P PT T

B B

2 2

SC3

FC1 FC2

Optional ow control valve Optional ow control valve

Volume ratio (VI) - Increase (slide stop)

Oil pressure out (internal)

Capacity - unload (slide valve)

Capacity - load (slide valve)

Hydraulic valve

top view

SC2 SC1

SC3

Figure 21: Hydraulic schematic

Page is loading ...

Frick SBTP Rotary Screw Compressor Installation Operation and Maintenance Guide

Brand: Frick

Model: SBTP Rotary Screw Compressor

Type: Installation Operation and Maintenance Guide

Download PDF

report

Frick SBTP Rotary Screw Compressor Installation Operation and Maintenance Guide

Frick SBTP Rotary Screw Compressor Installation Operation and Maintenance Guide

Related papers

Other documents