ROTARY SCREW COMPRESSOR UNITS
ALL REFRIGERANTS
MODELS
852, 1179, 1395
RWH
Form 070.620-IOM (DEC 2012)
INSTALLATION - OPERATION - MAINTENANCE
File: SERVICE MANUAL - Section 70
Replaces: NOTHING
Dist: 3, 3a, 3b, 3c
Please check www.johnsoncontrols.com/frick for the latest version of this publication.
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.
RWH ROTARY SCREW COMPRESSOR UNITS
INSTALLATION - OPERATION - MAINTENANCE
070.620-IOM (DEC 12)
Page 2
Contents
MAINTENANCE
GENERAL INFORMATION ................................................. 23
NORMAL MAINTENANCE OPERATIONS ........................... 23
GENERAL MAINTENANCE ................................................ 23
COMPRESSOR SHUTDOWN and START-UP .....................23
GENERAL INSTRUCTIONS FOR REPLACING
COMPRESSOR UNIT COMPONENTS ......................... 23
OIL FILTER .......................................................................24
STRAINER - OIL PUMP ....................................................24
STRAINER - LIQUID INJECTION .......................................25
COALESCER FILTER ELEMENT(S)...................................... 25
CHANGING OIL ................................................................ 25
PUMP DISASSEMBLY .......................................................26
PUMP ASSEMBLY ............................................................27
THRUST BEARING ADJUSTMENT .....................................28
INSTALLATION OF CARBON GRAPHITE BUSHINGS .......... 28
TROUBLESHOOTING THE PUMP ...................................... 29
MAINTENANCE SCHEDULE .............................................. 30
PREVENTATIVE MAINTENANCE ......................................30
RECOMMENDED MAINTENANCE PROGRAM ....................30
VIBRATION ANALYSIS ......................................................30
OIL QUALITY AND ANALYSIS ..........................................31
OIL SAMPLING PROCEDURE ............................................ 31
OPERATING LOG .............................................................. 31
MOTOR BEARINGS .......................................................... 31
GREASE COMPATIBILITY .................................................. 31
NLGI GREASE COMPATIBILITY CHART ............................. 31
TROUBLESHOOTING GUIDE .............................................32
ABNORMAL OPERATION
ANALYSIS and CORRECTION ....................................32
PRESSURE TRANSDUCERS - TESTING ............................. 33
PRESSURE TRANSDUCERS - REPLACEMENT ...................34
CAPACITY LINEAR TRANSMITTER - SLIDE VALVE ........... 34
VOLUME RATIO CONTROL TRANSMITTER - SLIDE STOP
.. 34
TEMPERATURE SENSOR ..................................................35
OIL LEVEL TRANSMITTER ................................................ 35
TROUBLESHOOTING THE RWH COMPRESSOR ................ 37
THE PUMP SYSTEM ..................................................37
THE OIL SEPARATION SYSTEM .................................38
THE HYDRAULIC SYSTEM .........................................38
MOTOR and BARE COMPRESSOR REPLACEMENT ...........39
SAE STRAIGHT THREAD O-RING FITTINGS ASSEMBLY
PROCEDURE .............................................................39
SHUTDOWN DUE TO IMPROPER OIL PRESSURE
(HIGH STAGE and BOOSTER) ....................................39
COMPRESSOR PORT LOCATIONS .................................... 40
SAMPLE P & I DIAGRAM .................................................. 43
PROPER INSTALLATION OF ELECTRONIC EQUIPMENT IN
AN INDUSTRIAL ENVIRONMENT ...............................46
FORMS ............................................................................51
INDEX .............................................................................. 58
PREFACE............................................................................ 3
DESIGN LIMITATIONS ......................................................... 3
JOB INSPECTION ............................................................... 3
TRANSIT DAMAGE CLAIMS ............................................... 3
COMPRESSOR and UNIT IDENTIFICATION ......................... 3
COMPRESSOR IDENTIFICATION ........................................4
INSTALLATION
FOUNDATION ....................................................................5
RIGGING and HANDLING .................................................... 6
CHECKING MOTOR/COMPRESS OR ROTA TION .......................6
COMPRESSOR/MOTOR COUPLING INSTALLATION ............. 6
COUPLING ALIGNMENT PROCEDURE ................................. 7
HOT ALIGNMENT OF COMPRESSOR/MOTOR ...................... 9
OIL PUMP COUPLING ......................................................... 9
HOLDING CHARGE AND STORAGE.....................................9
OIL CHARGE ...................................................................... 9
OIL HEATER(S) ...................................................................9
OIL FILTER(S) ................................................................... 10
THERMOSYPHON OIL COOLING .......................................10
LIQUID INJECTION OIL COOLING (Optional) ...................... 11
LIQUID LINE SIZES/RECEIVER VOLUME ............................11
WATER-COOLED OIL COOLING (OPTION AL) .................... 11
ECONOMIZER - HIGH STAGE (OPTIONAL) .......................12
ECONOMIZER LOAD BALANCING ..................................... 13
ELECTRICAL ..................................................................... 13
MOTOR STARTER PACKAGE ............................................13
CURRENT TRANSFORMER (CT) RATIOS ........................... 15
MINI MUM BURDEN RATINGS ...........................................15
CONTROL POWER REGULATOR ....................................... 15
OPERATION
OPERATION and START-UP INSTRUCTIONS .................... 16
TDSH COMPRESSOR .......................................................16
COMPRESSOR LUBRICATION SYSTEM .............................16
CONTROL PUMP OIL SYSTEM ......................................... 16
FULL TIME PUMP SYSTEM ............................................... 17
COMPRESSOR OIL SEPARATION SYSTEM ....................... 17
DISCHARGE BUTTERFLY CONTROL OIL SYSTEM .............17
COMPRESSOR HYDRAULIC SYSTEM ...............................17
VOLUME RATIO CONTROL ............................................... 18
COMPRESSOR OIL COOLING SYSTEMS ........................... 18
SINGLE-PORT LIQUID INJECTION ................................... 18
DUAL-PORT LIQUID INJECTION ....................................... 18
QUANTUM™LX EZ-COOL™ LIQUID INJECTION
ADJUSTMENT PROCEDURE ......................................19
SUCTION CHECK VALVE BYPASS ..................................... 21
LOW AMBIENT OPERATION ............................................. 21
BALANCE PISTON PRESSURE REGULATOR ...................... 21
INITIAL START-UP ........................................................... 21
INITIAL START-UP PROCEDURE .......................................22
NORMAL START-UP PROCEDURE ....................................22
VFD SKIP FREQUENCIES ..................................................22
RWH ROTARY SCREW COMPRESSOR UNITS
GENERAL INFORMATION
070.620-IOM (DEC 12)
Page 3
PREFACE
This manual has been prepared to acquaint the owner and
serviceman with the INSTALLATION, OPERATION, and MAIN
TEN ANCE procedures as recommended by Johnson Controls
for Frick® RWH Rotary Screw Compres sor Units.
For information about the functions of the Quantum™LX
control panels, communications, specications, and wiring
diagrams, see publication series 090.022O, 090.020M,
090.020CS, and 090.020SPC.
It is most important that these units be properly applied to an
adequately controlled refrigeration system. Your authori zed
Frick® representative should be con sulted for their expert
guidance in this determination.
Proper performance and continued satisfaction with these
units is dependent upon:
CORRECT INSTALLATION
PROPER OPERATION
REGULAR, SYSTEMATIC MAINTENANCE
To ensure correct installation and application, the equip ment
must be properly selected and connected to a properly de
signed and installed system. The Engi neering plans, piping
layouts, etc. must be detailed in accor dance with the best
practices and local codes, such as those outlined in ASHRAE
literature.
A refrigeration compressor is a VAPOR PUMP. To be certain
that it is not being subjected to liquid refriger ant carryover
it is necessary that refriger ant controls are carefully selected
and in good operating condition; the piping is properly sized
and traps, if necessary, are provided with drains, liquid elimi
nation and permissives; the suction line has an accumula
tor or slugging protec tion; that load surges are known and
provisions made for control; operating cycles and de frost ing
periods are reasonable; and that high side condensers are
sized within system and compressor design limits.
It is recommended that the entering vapor temperature to
the compressor be superheated to 10°F above the refriger ant
saturation temperature. This assures that all refrigerant at
the compressor suction is in the vapor state.
DESIGN LIMITATIONS
The compressor units are designed for operation within
pressure and temperature limits determined by Frick. Refer
to applications brochure 070.500SPC.
JOB INSPECTION
Immediately upon delivery examine all crates, boxes and
exposed compressor and com ponent surfaces for dam age.
Unpack all items and check against shipping lists for any
discrepancy. Examine all items for damage in transit.
TRANSIT DAMAGE CLAIMS
All claims must be made by consignee. This is an ICC re
quirement. Request immediate inspection by the agent of
the carrier and be sure the proper claim forms are execut ed.
Report damage or shortage claims im mediately to Johnson
Controls Inc., Frick® Sales Ad ministration Depart ment, in
Waynes boro, PA.
COMPRESSOR and UNIT IDENTIFICATION
Each compressor unit has 2 identica tion data plates. The
compressor data plate containing compressor model and
serial number is mounted on the compressor body.
NOTICE
When inquiring about the compres sor or unit, or order-
ing repair parts, provide the MODEL, SERIAL, and FRICK®
SALES ORDER NUMBERS from these data plates.
UNIT DATA PLATE
Indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
Indicates a potentially hazardous situation or practice which, if not avoided, will result in death or
serious injury.
SAFETY PRECAUTION DEFINITIONS
Indicates a potentially hazardous situation or practice which, if not avoided, will result in damage
to equipment and/or minor injury.
Indicates an operating procedure, practice, etc., or portion thereof which is essential to highlight.
DANGER
WARNING
CAUTION
NOTICE
RWH ROTARY SCREW COMPRESSOR UNITS
GENERAL INFORMATION
070.620-IOM (DEC 12)
Page 4
COMPRESSOR IDENTIFICATION
Each compressor has an identication data plate (see below),
containing compressor model and serial number mounted on
the compressor body.
COMPRESSOR DATA PLATE
Rotary screw compressor serial numbers are dened by the
following information:
EXAMPLE: 10240A90000015Z
GLOBAL ADDITIONAL
PLANT DECADE MONTH YEAR SEQ NO. REMARKS
1024 0 A 9 0000015 Z
Month: A = JAN, B = FEB, C = MAR, D = APR, E = MAY, F =
JUN, G = JUL, H = AUG, K = SEP, L = OCT, M = NOV, N = DEC.
Additional Remarks: R = Remanufactured; Z = Deviation from
Standard Conguration.
Geometrical
Swept Volume
Drive Shaft End
Rotor Max
Compressor Diameter Rotor Speed CFM m³/h
Model mm L/D RPM ft³/ Rev m³/Rev 3550 RPM 2950 RPM
TDSH 408S 408 1.3 3,600 1.4118 0.03998 5,012 7,076
TDSH 408L 408 1.8 3,600 1.95481 0.05535 6,940 9,798
TDSH 408XL 408 2.13 3,600 2.31319 0.0655 8,212 11,594
GEOMETRICAL SWEPT VOLUME TABLE
RWH ROTARY SCREW COMPRESSOR UNITS
INSTALLATION
070.620-IOM (DEC 12)
Page 5
Installation
FOUNDATION
If RWH Rotary Screw Compressor Unit is shipped mounted
on a wood skid, it must be removed prior to unit installation.
WARNING
Allow space for servicing the unit per factory drawings.
The rst requirement of the compressor foundation is that
it must be able to support the weight of the compressor
package including coolers, oil, and refrigerant charge. Screw
compressors are capable of converting large quantities of
shaft power into gas compression in a relatively small space
and a mass is required to effectively dampen these relatively
highfrequency vibrations.
Firmly anchoring the compressor package to a suitable
foundation by proper application of grout and elimination of
piping stress imposed on the compressor is the best insur
ance for a troublefree installation. Use only the certied
general arrangement drawings from Frick to determine the
mounting locations and to allow for recommended clear
ances around the unit for ease of operation and servicing.
Foundations must be in compliance with local building codes
and materials should be of industrial quality.
Anchor bolts are required to rmly tie the unit to the foun
dation. Once the unit is rigged into place (See RIGGING and
HANDLING), the package must be level and raised at least
one inch for grouting. An expansiontype epoxy grout must
be worked under all areas of the base with no voids. The
base should be lled concrete and smoothed to allow water
runoff. Finish with a nonslip coating.
When installing on the upper oors of buildings, extra precau
tions should be taken to prevent normal package vibration
from being transferred to the building structure. It may be
necessary to use rubber or spring isolators, or a combination
of both, to prevent the transmission of compressor vibration
directly to the structure. However, this may increase package
vibration levels because the compressor is not in contact with
any damping mass. The mounting and support of suction
and discharge lines is also very important. Rubber or spring
pipe supports may be required to avoid exciting the build
ing structure at any pipe supports close to the compressor
package. It is best to employ a vibration expert in the design
of a proper mounting arrangement.
In any screw compressor installation, suction and discharge
lines should be supported in pipe hangers (preferably within 2
ft. of vertical pipe run) so that the lines won’t move if discon
nected from the compressor. See tables for Allowable Forces.
Table C.1 - Alowable Forces
Nozzle Nominal Size DN *
Force Nm 100 150 200 250 300 350 400
Fx 1,368 2,094 2,815 3,328 3,960 4,908 5,772
Fy 3,434 5,253 7,052 8,349 9,938 12,294 14,455
Fz 2,336 3,383 4,527 5,178 5,992 6,662 7,492
Fr 4,373 6,590 8,841 10,373 12,261 14,819 17,274
Nozzle Nominal Size NPS *
Force lbf 4 6 8 10 12 14 16
Fx 308 471 633 748 890 1,103 1,297
Fy 772 1,181 1,585 1,877 2,234 2,764 3,250
Fz 525 761 1,018 1,164 1,347 1,496 1,684
Fr 983 1,482 1,987 2,332 2,756 3,331 3,883
Table C.2 - Alowable Forces
Nozzle Nominal Size DN *
Force Nm 100 150 200 250 300 350 400
Mx 2,069 2,754 3,672 4,212 5,097 6,232 7,316
My 1,253 2,126 2,836 3,648 4,190 5,656 6,781
Mz 1,253 1,698 2,264 2,814 3,334 4,491 5,450
Mr 2,724 3,871 5,163 6,242 7,393 9,539 11,367
Nozzle Nominal Size NPS *
Force lbf 4 6 8 10 12 14 16
Mx 1,526 2,031 2,709 3,107 3,759 4,597 5,396
My 924 1,568 2,091 2,691 3,090 4,171 5,001
Mz 924 1,252 1,670 2,076 2,459 3,312 4,020
Mr 2,009 2,855 3,808 4,604 5,453 7,036 8,384
* Nozzle nominal size DN is expressed in millimeters; nozzle nominal size NPS is expressed in inches.
Figure 1 - Denition of Axes
RWH ROTARY SCREW COMPRESSOR UNITS
INSTALLATION
070.620-IOM (DEC 12)
Page 6
The resultant force, Fr, is given by Equation (C1):
where Fx, Fy, and Fz are the force components along the x,
y, and the zaxis, respectively
The resultant moment Mr, is given by Equation (C.2):
where Mx, My, and Mz are the force components along the
x, y, and the zaxis, respectively
Consult a licensed architect to determine the proper foun
dation requirements for any large engine or turbine drive.
When applying screw compressors at high pressures, the
customer must be prepared for package vibration and noise
higher than the values predicted for normal refrigeration duty.
Proper foundations and proper installation methods are vital;
and even then, sound attenuation or noise curtains may be
required to reduce noise to desired levels.
For more detailed information on Screw Compressor
Foundations, please request Frick® publication 070.210-IB.
RIGGING and HANDLING
WARNING
This screw compressor package may be top-heavy. Use
caution in rigging and handling.
The unit can be moved with rigging, using a crane and
spreader bars, by hooking into all lifting eyes on the package.
Ap propriate adjustment in the lifting point should be made to
compensate for the center of gravity. Refer to supplied engi
neering drawings to determine the package center of gravity.
CHECKING MOTOR/COMPRESS OR ROTA TION
WARNING
Make sure coupling hubs are tight-ened to the shaft
before rotatingthe motor to prevent them from ying
off and possibly causing serious injury or death.
WARNING
Injury may occur if loose clothing, etc, becomes en-
tangled on the spinning motor shaft.
COMPRESSOR ROTATION IS CLOCKWISE WHEN FACING
THE END OF THE COMPRESSOR SHAFT. Under NO condi
tions should the motor rotation be check ed with the coupling
center installed as damage to the com pressor may result.
BP SERIES COUPLING DATA TABLE
BP DISC PACK LOCKNUT HUB CLAMPING BOLTS KEYWAY SETSCREW
SERIES TORQUE (Lube*) SIZE UNF TORQUE SIZE UNF TORQUE SIZE NC
SIZE FT-LB NM FT-LB NM FT-LB NM
BP 38 17 23.1 5/16-24 41 55.6 3/8-24 22 29.8 3/8-16
BP 43 40 54.2 7/16-20 41 55.6 3/8-24 22 29.8 3/8-16
BP 48 40 54.2 7/16-20 41 55.6 3/8-24 53 71.9 1/2-13
BP 53 60 81.4 1/2-20 66 89.5 7/16-20 53 71.9 1/2-13
BP 58 120 162.7 5/8-18 101 137.0 1/2-20 53 71.9 1/2-13
BP 63 120 162.7 5/8-18 101 137.0 1/2-20 186 252.2 3/4-10
Bump the motor to check for correct compressor rotation.
After verication, install disc drive spacer, as applicable.
COMPRESSOR/MOTOR COUPLING INSTALLATION
The job coupling may be one of those described below or
it may be custom specied for the application. If the latter,
refer to the engineering prints and documents as well as
coupling manufacturer instructions as applicable, based on
the actual coupling supplied.
Figure 2 - BP Coupling
BP COUPLING INSTALLATION PROCEDURE
1. Install the motor and compressor coupling hubs and keys
on their respective shafts. Ensure that they can slide hori
zontally so that once the disc packs are installed, no axial
stress is transferred to the disc packs by a stuck coupling
hub. Use no lubricants.
2. Rotate both hubs so that the keys are 180° opposed (See
Figure 2). With the hubs mounted and the axial spacing set,
proceed to place the spacer between the two hub anges.
Care should be taken when handling the spacer. Be sure the
spacer is fully supported at this time. Damage to the unit
ized ex discs may result after they have been installed if
the spacer is not fully supported.
Install the unitized ex disc at this time. Start a bolt through
a bolt hole in the spacer. Put the unitized ex disc between
the hub and spacer until a bushing hole in the unitized ex
disc lines up with the bolt. Slide the bolt through the bushing
hole in the unitized ex disc. Install the locknut until it is snug.
Make sure that all bolt threads are clean and lightly oiled. Do
RWH ROTARY SCREW COMPRESSOR UNITS
INSTALLATION
070.620-IOM (DEC 12)
Page 7
Figure 3 - Angular Misalignment
Figure 4 - Dial Indicator Attached At 12 O'clock
Figure 5 - Dial Indicator At 6 O'clock
not torque any locknuts at this time. Now pivot the unitized
ex disc until the other bushing holes in the ex disc are in
line with the bolt holes in the spacer. Install the rest of the
spacer bolts at this time. The remaining bolts for this end of
the coupling can be installed through the hub bolt holes and
ex disc bushing holes.
Install the unitized ex disc in the other end of the coupling.
The unitized ex disc, as installed, should look at and parallel
with the mating hub and spacer anges.
Torque the disc pack locknuts as recommended in the BP
COUPLING DATA TABLE. The bolts should be held in place
while the locknuts are torqued.
3. Center the coupling between the shafts. Ensure that the
keys are fully engaged in their keyways.
4. Tighten the motor and compressor shaft clamping bolts
evenly. Torque to the recommended specication in the BP
coupling data table.
5. Torque the keyway setscrews as recommended in the BP
COUPLING DATA TABLE.
IMPORTANT
Only after the shaft clamping bolts are tightened to their
nal torque can the keyway set screws be tightened. If
the keyway set screws are tightened before the shaft
clamping bolts are tightened, then the hubs can be
cocked on the shaft.
COUPLING ALIGNMENT PROCEDURE
The life of the compressor shaft seal and bearings, as well
as the life of the motor bearings, is dependent upon proper
coupling alignment. Couplings may be aligned at the factory
but realignment MUST ALWAYS be done on the job site after
the unit is securely mounted on its founda tion. Initial align
ment must be made prior to startup and rechecked after
a few hours of operation. Final (HOT) eld alignment can
only be made when the unit is at operating tempera ture.
After nal (HOT) alignment has been made and found to be
satisfac tory for approximately one week, the motor may be
dowelled to maintain align ment.
NOTICE
The recommended cold aligning of the motor is .005"
high. This cold misalignment compensates for thermal
growth when the unit is at operating temperature.
An appropriate laser instrument or set of dial indicators are to
be used to measu re the angular and parallel shaft misalign
ment. Coupling alignment is attained by alternately measur
ing angular and parallel misalignment and repositioning the
motor until the misalignment is within specied tolerances.
WARNING
ALWAYS LOCK OUT MAIN MOTOR DISCONNECT BE-
FORE TOUCHING MOTOR SHAFT. MISALIGNMENT
MUST NOT EXCEED COUPLING MANUFACTURER'S
RECOMMENDATION.
ANGULAR ALIGNMENT
1. To check angular alignment, as shown in Figure 3, attach
dial indicator rigidly to the motor hub. Move indicator stem
so it is in contact with the outside face of compressor hub,
as shown in Figure 4.
2. Rotate both coupling hubs several revolutions until they
seek their normal axial positions.
Check the dial indicator to be sure that the indicator stem is
slightly loaded so as to allow movement in both direc tions.
3. Set the dial indicator at zero when viewed at the 12 o’clock
position, as shown in Figure 4.
4. Rotate both coupling hubs together 180° (6 o’clock posi
tion), as shown in Figure 5. At this position the dial indicator
will show TOTAL angular misalignment.
RWH ROTARY SCREW COMPRESSOR UNITS
INSTALLATION
070.620-IOM (DEC 12)
Page 8
NOTICE
The use of a mirror is helpful in reading the indicator
dial as coupling hubs are rotated.
5. Loosen motor anchor bolts and move or shim motor to
correct the angular misalignment.
After adjustments have been made for angular mis align ment
retighten anchor bolts to prevent inac curate read ings. Repeat
Steps 3 through 5 to check corrections. Further adjustments
and checks shall be made for angular misalignment until the
total in dicator reading is within the specied tolerance.
PARALLEL ALIGNMENT
6. To check parallel alignment, as shown in Figure 6, reposi
tion dial indicator so the stem is in contact with the rim of
the compressor hub, as shown in Figure 7.
Check the dial indicator to be sure that the indicator stem is
slightly loaded so as to allow movement in both directions.
7. Check parallel height misalignment by setting dial indica
tor at zero when viewed at the 12 o'clock position. Rotate
both coupling hubs together 180° (6 o'clock position). At this
position the dial indicator will show TWICE the amount of
parallel height misalignment.
8. Loosen motor anchor bolts and add or remove shims un
der the four motor feet until parallel height misalignment is
within specied tolerance when anchor bolts are retightened.
CAUTION
CARE MUST BE USED WHEN CORRECTING FOR PAR-
ALLEL MISALIGNMENT TO ENSURE THAT THE AXIAL
SPACING AND ANGULAR MISALIGNMENT IS NOT SIG-
NIFICANTLY DISTURBED.
9. After the parallel height misalignment is within tolerance,
repeat Steps 1 through 5 until angular misalignment is within
specied tolerance.
10. Check parallel lateral misalignment by positioning dial
indicator so the stem is in contact with the rim of the com
pressor hub at 3 o'clock, as shown in Figure 8.
Set indicator at zero and rotate both coupling hubs together
180° (9 o'clock position), as shown in Figure 7.
Adjust parallel lateral misalignment using the motor adjusting
screws until reading is within specied tolerance.
11. Recheck angular misalignment and realign if necessary.
12. Tighten motor anchor bolts and rotate both coupling hubs
together, checking the angular and parallel misalignment
through the full 360° travel at 90° increments. If dial read
ings are in excess of specied tolerance realign as required.
13. When the coupling hubs have been aligned to within
specied tolerance, a recording of the cold alignment must
be made for unit records and usage during hot alignment.
CAUTION
Install the coupling guard before operating the com-
pressor.
Figure 6 - Parallel Misalignment
Figure 7 - Dial Indicator Attached At 9 O'clock
Figure 8 - Dial Indicator At 3 O'clock
CAUTION
When installing drive spacer, make sure that hub spac-
ing is within limits shown on the Coupling Data Table
applicable to the coupling being installed and that the
clamping bolt(s) are properly torqued.
RWH ROTARY SCREW COMPRESSOR UNITS
INSTALLATION
070.620-IOM (DEC 12)
Page 9
COMPRESSOR UNIT OIL
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.
NOTICE
The Frick oil charge shipped with the unit is the best
suited lubricant for the conditions specied at the time
of purchase. If there is any doubt due to the refrigerant,
operating pressures, or temperatures, refer to Frick Oil
publication 160.802-SPC.
OIL CHARGE
The normal charging level is midway in the top sight
glass located midway along the oil separator shell. Nor-
mal operating level is midway between the top sight glass
and bottom sight glass. Refer to the engineering prints and
documents for the estimated lube oil charge.
Add oil by attaching the end of a suitable pressure type
hose to the oil drain valve, located in the separator pip
ing. Refer to the P & I drawing for exact location. Using
a pressuretype pump and the recommended Frick® oil,
open the drain valve and pump oil into the separator.
NOTICE
Evacuation of the oil separator will assist the ow of
oil into the unit. Also, ll slowly because oil will ll up
in the separator faster than it shows in the sight glass.
Oil distillers and similar equipment which act to trap
oil must be lled prior to unit operation to normal de
sign outlet levels. The same pump used to charge the
unit may be used for lling these auxiliary oil reservoirs.
NOTICE
The sight glass located in the coalescing end of the
separator near the discharge connection should remain
empty.
OIL HEATER(S)
Standard units are equipped with two or three 1000 watt oil
heaters, providing sufcient heat to maintain the oil tempera
ture for most indoor applications during shutdown cycles to
permit safe startup. Should insulation or additional heating
capacity be required because of low ambient temperature,
contact Johnson ControlsFrick®. The heaters are energized
only when the unit is not in operation.
WARNING
DO NOT ENERGIZE THE HEATERS when there is no oil
in the unit, the heat ers will burn out. The oil heat ers
will be energized whenever 120 volt control power is
applied to the unit and the com pressor is not run ning,
unless the 16 amp circuit breaker in the micro enclosure
is turned off.
HOT ALIGNMENT OF COMPRESSOR/MOTOR
WARNING
Hot alignments can only be made after the unit has
operated for several hours and all components are at
operating temperatures.
Shut down the unit (proper lockout/tagout procedures
should be followed) and QUICKLY afx dial indicator to
coupling motor hub, then take readings of both the face
and rim of the compressor hub. If these readings are within
tolerance, record reading, attach coupling guard and restart
unit. However, if the reading is not within limits, compare
the hot reading with the cold alignment and adjust for this
difference; i.e. if the rim at 0° and 180° readings indicates
that the motor rises .005" between its hot and cold state,
.005" of shims should be removed from under the motor.
After the initial hot alignment adjustment is made, restart unit
and bring to operating temperature. Shut down and recheck
hot alignment. Repeat procedure unit hot alignment is within
specied tolerance.
CAUTION
INSTALL COUPLING GUARD BEFORE OPERATING COM-
PRESSOR.
OIL PUMP COUPLING
Compressor units with direct motor/pump coupled pumps
need no pump/motor coupling alignment since this is main
tained by the closecoupled arrangement.
HOLDING CHARGE AND STORAGE
Each RWH compressor unit is pressure and leak tested at the
factory and then thoroughly evacuated and charged with dry
nitrogen to ensure the integrity of the unit during shipping
and short term storage prior to installation.
CAUTION
Care must be taken when entering the unit to ensure
that the nitrogen charge is safely released.
WARNING
Holding-charge shipping gauges on separator and
external oil cooler are rated for 30 PSIG and are for
checking the shipping charge only. They must be re-
moved before pressure testing the system and before
charging the system with refrigerant. Failure to remove
these gauges may result in catastrophic failure of the
gauge and uncontrolled release of refrigerant resulting
in serious injury or death.
All units must be kept in a clean, dry location to prevent
corrosion damage. Reasonable consideration must be given
to proper care for the solidstate components of the mi
croprocessor. Please contact Frick® service for long term
storage requirements.
RWH ROTARY SCREW COMPRESSOR UNITS
INSTALLATION
070.620-IOM (DEC 12)
Page 10
OIL FILTER(S)
NOTICE
Use of lter elements other than Frick® may cause war-
ranty claim to be denied.
The oil lter(s) and coalescer element(s) shipped with the
unit are best suited to ensure proper ltration and operation
of the system.
THERMOSYPHON OIL COOLING
Thermosyphon oil cooling is an economical, effective method
for cooling oil on screw compressor units. Ther mosyphon
cooling utilizes liquid refrigerant at condenser pressure and
temperature that is partially vaporized at the condenser tem
perature in a heat exchanger vessel, cooling the oil to within
35°F of that temperature. The vapor, at condensing pressure,
is vented to the condenser inlet and reliquied. This method
is the most cost effective of all currently applied cooling
systems since no compres sor capacity is lost or compressor
power penalties in curred. The vapor from the cooler need
only be con densed, not compressed. Refrigerant ow to the
cooler is automatic, driven by the thermosyphon principle
and cooling ow increases as the oil inlet temperature rises.
EQUIPMENT The basic equipment required for a ther
mosyphon system consists of:
1. A source of liquid refrigerant at condensing pressure and
temperature, located in close proximity to the unit to mini
mize piping pressure drop. The liquid level in the refrigerant
source must be 6 to 8 feet minimum above the center of the
oil cooler.
2. An oil cooler heat exchanger (often a plate and shell oil
cooler) designed for the purpose.
Due to the many variations in refrigeration system design
and physical layout, several systems for assuring the above
criteria are possible. Figure 9 illustrates a sample thermo
syphon oil cooling circuit.
Figure 9
SYSTEM OPERATION - Liquid refrigerant lls the cooler shell
side up to the Thermosyphon receiver liquid level.
Hot oil (above the liquid temperature) owing through the
cooler will cause some of the refrigerant to boil and vapor
ize. The vapor rises in the return line. The density of the
refrigerant liquid/vapor mixture in the return line is consid
erably less than the density of the liquid in the supply line.
This imbalance provides a differential pressure that sustains
a ow condi tion to the oil cooler. This relationship involves:
1. Liquid height above the cooler.
2. Oil heat of rejection.
3. Cooler size and piping pressure drops.
The liquid/vapor returned from the cooler is separated in the
receiver. The vapor is vented to the condenser inlet and need
only be reliquied since it is still at condenser pressure (Figure 8).
OIL TEMPERATURE CONTROL - Oil temperature will gen
erally run about 15 35°F above condensing tempera ture.
In many cases, an oil temperature control is not required if
condensing temperature is above 65°F as oil tempera ture can
be allowed to oat with condenser temperature.
Condensing Temperature: 65°F - 105°F
Oil Temperature: 80°F - 140°F
INSTALLATION The thermosyphon oil cooler with oilside
piping and a thermostatically controlled mixing valve are fac
tory mount ed and piped. The customer may need to supply
and generally install all piping and equip ment (depending
on the scope of the equipment supplied) located outside
of the shaded area on the piping diagram (Figure 10) with
consideration given to the following:
1. The refrigerant source, thermosyphon or system receiv er,
should be in close proximity to the unit to minimize piping
pressure drop.
2. The liquid level in the refrigerant source must be 6 to 8
feet minimum above the center of the oil cooler.
3. A safety valve should be installed if refrigerant isolation
valves are used for the oil cooler. A refrigerantside safety
valve is required in this location only when refrigerant iso
lation valves are installed between the cooler and thermo
syphon receiver. If no valves are used between the cooler
and TSOC receiver, the safety valve on the TSOC receiver
must be sized to handle the volume of both vessels. Then,
the safety valve on the cooler vent (liquid refrigerant side)
can be eliminated.
4. The system receiver must be below the thermosyphon
receiver in this arrangement.
NOTICE
The component and piping arrangement shown in Figure
10 is intended only to illustrate the operating principles
of thermosyphon oil cooling. Other component layouts
may be better suited to a specic installation. Refer to
publication 070.900-E for additional information on Ther-
mosyphon Oil Cooling.
RWH ROTARY SCREW COMPRESSOR UNITS
INSTALLATION
070.620-IOM (DEC 12)
Page 11
Figure 12 - Level Control
LIQUID LINE SIZES/RECEIVER VOLUME
Liquid line sizes and the additional receiver volume (quanti-
ty of refrigerant required for 5 minutes of liquid injection oil
cooling) can be found in CoolWare.
WATER-COOLED OIL COOLING (OPTION AL)
The watercooled oil cooler is mounted on the unit complete
with all oil piping. The customer must supply adequate water
connections. Determine the size of the watercooled oil
cooler supplied with the unit, as outlined on the Frick P&I
diagram and arrangement drawings. The water supply must
be sufcient to meet the required ow.
A closedloop system is recommended for the waterside of
the oil cooler. Careful attention to water treatment is es
sential to ensure adequate life of the cooler if cooling tower
water is used. It is imperative that the condition of cooling
water and closed-loop uids be analyzed regularly and
as necessary and maintained at a pH of 7.4, but not less
than 6.0 for proper heat exchanger life. After initial start
up of the compressor package, the strainer at the inlet of
the oil cooler should be cleaned several times in the rst 24
hours of operation.
In some applications, the plate and shell oil cooler may be
subjected to severe water conditions, including high tem
perature and/or hard water conditions. This causes acceler
ated scaling rates which will penalize the performance of the
heat exchanger. A chemical cleaning process will extend the
life of the PlateandShell heat exchanger. It is important to
establish regular cleaning schedules.
Cleaning a Plate-and-Shell Oil Cooler: A 3% solution of
Phosphoric or Oxalic Acid is recommended. Other cleaning
solutions can be obtained from your local distributor, but
they must be suitable for stainless steel. The oil cooler may
be cleaned in place by back ushing with recommended
solution for approximately 30 minutes. After back ushing,
rinse the heat exchanger with fresh water to remove any
remaining cleaning solution.
Figure 10 - TSOC Piping Arrangement
LIQUID INJECTION OIL COOLING (Optional)
The liquid injection system provided on the unit is self
contained but requires the connection of the liquid line sized
as per CoolWare.
It is IMPERATIVE that an uninterrupted supply of high pres
sure liquid refrigerant be provided to the injection system
at all times. Two items of EXTREME IMPOR TANCE are the
design of the receiver/liquid injection supply and the size of
the liquid line.
It is recommended that the receiver be oversized sufcient ly
to retain a preferential supply of refrig erant for oil cooling.
The evaporator supply must be secondary to this consider
ation. Two methods of accomplishing this are shown. For
large systems, a 5minute retention is used.
The dual dip tube method (Figure 11) uses two dip tubes in
the receiver. The liquid injection tube is below the evapor
ator tube to ensure continued oil cooling when the receiver
level is low.
Figure 11 - Dual Dip Tube
The level-control method (Figure 12) utilizes a level control
on the receiver to close a valve feeding the evaporator when
the liquid falls below that level. Liquid flows preferentially to
the liquid injection oil cooling circuit.
RWH ROTARY SCREW COMPRESSOR UNITS
INSTALLATION
070.620-IOM (DEC 12)
Page 12
ECONOMIZER - HIGH STAGE (OPTIONAL)
The economizer option provides an increase in system ca
pacity and efciency by cooling liquid from the condenser
through a heat exchanger or ash tank before it goes to the
evapora tor. The cooling is provided by ashing liquid in the
economizer cooler to an intermediate pressure level. The
intermediate pressure is provided by a port located part way
down the compres sion process on the screw compressor.
As the screw compressor unloads, the economizer port will
drop in pressure level, eventually being fully open to suc
tion. Because of this, an output from the microproces sor is
generally used to turn off the supply of ashing liquid on a
subcooler when the capacity falls below approximately 60%
70% capacity (85%90% slide valve position). This is done
because the compressor will be more efcient operating at
a higher slide valve position with the economizer turned off,
than it will at a low slide valve position with the economizer
turned on. Please note however that subcooler can be used
at low compressor capaciti es in cases where efcien cy is not
as important as assuring that the liquid supply is subcooled.
In such cases, the economi zer liquid control valve can be left
open whenever the com pressor is running.
Due to the tendency of the port pressure to fall with de creasing
compressor capacity, a backpressure regulator valve (BPR) is
generally required on a ash economizer system (Figure 14) in
order to maintain some preset pressure dif ference between
the subcooled liquid in the ash vessel and the evaporato rs.
If the backpressure regulator valve is not used on a ash
economizer, it is possible that no pressure difference will exist
to drive liquid from the ash vessel to the evaporators, since
the ash vessel pressure will approach suction pressure at a
decreased slide valve position. In cases where wide swings
in pressure are anticipated in the ash econo mizer vessel, it
may be necessary to add an outlet pressure regulator to the
ash vessel outlet to avoid overpressurizing the economizer
port, which could result in motor overload. Example: A sys
tem feeding liquid to the ash vessel in batches.
The recommended economizer systems are shown in Figures
1316. Notice that in all systems there should be a strainer
(STR) and a check valve (VCK) between the economizer ves
sel and the economizer port on the compressor. The strainer
prevents dirt from passing into the compressor and the check
valve prevents oil from owing from the compressor unit to
the econo mizer vessel during shutdown.
WARNING
Other than the isolation valve needed for strainer clean-
ing, it is essential that the strainer be the last device
in the economizer line before the compres sor. Also,
piston-type check valves are required for installation
in the economizer line, as opposed to disc-type check
valves. The latter are more prone to gas-pulsation-
induced failure. The isolation and check val ves and
strainer should be located as closely as possible to the
compressor, preferably within a few feet.
For refrigeration plants employing multiple compressors on
a common economizing vessel, regardless of economizer
type, each compressor must have a backpressure regulat
ing valve in order to balance the economizer load, or gas
ow, between compressors. The problem of balancing load
becomes most important when one or more compressors
run at partial load, exposing the economizer port to suction
pressure. In the case of a ash vessel, there is no need for
the redundancy of a backpressure regulating valve on the
vessel and each of the multiple compressors. Omit the BPR
valve on the ash economizer vessel and use one on each
compressor, as shown in Figure 16. It is also recommended
that the backpressure regulating valves, used on economizer
lines, should be specied with electric shutoff option. The
electric shutoff feature is necessary to prevent ow from the
common economizer vessel to the suction side of a stopped
compressor, through the suction check valve bypass line, if
the other compressors and the common economizer vessel
Figure 14 - Direct Expansion Economizer System
Figure 13 - Shell and Coil Economizer System
Figure 16 - Multiple Compressor Economizer System
Figure 15 - Flash Economizer System
HIGH
PRESSURE
LIQUID
INTERMEDIATE PRESSURE
GAS TO COMPRESSOR
SUCTION
STR VCK
SUBCOOLED
HIGH PRESSURE
LIQUID TO
EVAPORATOR
ECONOMIZER
COOLER
ECON1
HV-2
HIGH
PRESSURE
LIQUID
INTERMEDIATE PRESSURE
GAS TO COMPRESSOR
SUCTION
STR VCK
SUBCOOLED
HIGH PRESSURE
LIQUID TO
EVAPORATOR
ECONOMIZER
COOLER
WIRING
ECON2
HV-2
HIGH
PRESSURE
LIQUID
INTERMEDIATE PRESSURE
GAS TO COMPRESSOR
SUCTION
STR VCK
CONTROLLED
PRESSURE
SATURATED LIQUID
TO EVAPORATOR
ECONOMIZER
VESSEL
BPR
ECON3
HV-2
INTERMEDIATE PRESSURE
GAS TO COMPRESSOR
SUCTION
STR VCK BPR
CONTROLLED PRESSURE
SATURATED LIQUID TO EVAPORATOR
ECONOMIZER
VESSEL
ECON4
HV-2
RWH ROTARY SCREW COMPRESSOR UNITS
INSTALLATION
070.620-IOM (DEC 12)
Page 13
are still operating and the HV2 valve on the suction bypass
is open.
For refrigeration plants using a Packaged Refrigerant Recir
culation Unit and a direct expansion (DX) economizer system
it is necessary to operate the liquid feed solenoid on the unit
and the liquid feed solenoid on the DX vessel off of a common
signal to avoid liquid overfeed on the DX economizer system.
If multiple compressors are operated with a common
economizer vessel, it is necessary to install a backpressure
regulator valve with an electric shutoff option in the vapor
line piped to the compressor's economizer port.
ECONOMIZER LOAD BALANCING
The most energy efcient manner to operate an economizer
system, when using multiple compressors on a common
economizer vessel, is to take as much of the ash gas as
possible to the compressors that are fully loaded. This can
be done in at least two ways.
1. Use the economizer output from the microprocessor to
turn off a solenoid, or to actuate the electric shutoff option
on a backpressure regulator, based on percent of slide valve
travel. This will direct all the ash vapor to the other loaded
compressors.
2. A dualsetpoint, backpressure regulator valve can be
used in each of the individual economizer vapor lines. When
a compressor is running near full load, the BPR valve will
operate on the desired setpoint, or basically wide open, to
minimize pressure drop in the line. When one compressor
unloads below the slide valve position where the economizer
output on the microprocessor turns on, the dualsetpoint
feature of the regulator can be actuated by this output to
control the pressure, on the vessel side of the regulator, to
be a few psi higher. Consequently, the ash gas will be sent
to the loaded compressors rst, until they can’t handle all
the vapor and the pressure in the vessel starts to rise. Then,
some of the vapor will go to the unloaded compressor to
help maintain the vessel at the desired pressure. An example
of a backpressure regulator with electric shutoff and the
dualsetpoint feature is an R/S A4ADS.
ELECTRICAL
NOTICE
Before proceeding with electrical installation, read the
instructions in the section “Proper Installation of Elec-
tronic Equip ment in an Industrial Environment.”
RWH units are supplied with a Quantum™LX control system.
Care must be taken that the controls are not exposed to
physical damage during handling, storage, and installa tion.
The singlebox control door must be kept tightly closed to
prevent moisture and foreign mat ter from entry.
NOTICE
All customer connections are made in the single-box
control mounted on the oil separator. This is the ONLY
electrical enclosure and it should be kept tightly closed
whenever work is not being done in it.
VOLTAGE PROTECTION
Frick® does not advise nor support the use of UPS power
systems in front of the Quantum™LX panel. With a UPS power
system providing shutdown protection for the Quantum™LX,
the panel may not see the loss of the 3phase voltage on
the motor because the UPS could prevent the motor starter
contactor from dropping out. With the starter contactor still
energized, the compressor auxiliary will continue to feed
an “Okay” signal to the panel. This will allow the motor to
be subjected to a fault condition on the 3phase bus. Some
fault scenarios are:
1. The 3phase bus has power “on” and “off” in a continu
ous cyclic manner which may cause the motor to overheat
due to repeated excessive inrush currents.
2. Motor cycling may damage the coupling or cause other
mechanical damage due to the repeated high torque motor
“bumps”.
3. Prolonged low voltage may cause the motor to stall and
overheat before the motor contactor is manually turned off.
Under normal conditions, the loss of 3phase power will shut
down the Quantum™LX panel and it will restart upon power
return. If the panel was in:
• Auto – Compressor motor will return to running as pro
grammed.
• Remote – The external controller would reinitialize the
panel and proceed to run as required.
• Manual – The compressor will have to be restarted
manually after the 3phase bus fault has been cleared.
If the local power distribution system is unstable or prone
to problems, there are other recommendations to satisfy
these problems. If power spikes or low or high line voltages
are the problem, then we recommend the use of a Sola®
constant voltage (CV) transformer with a line suppression
feature. If a phase loss occurs, then you will typically get a
high motor amp shutdown. If problems continue to exist, then
an examination of the plant’s power factor may be in order.
Unless careful design failure analysis is considered in the
implementation of power systems, the alternative solutions
provide a safer and less expensive implementation. In either
case, only one Sola® may be used per compressor. Each
compressor needs to be individually isolated from each other
through a dedicated control transformer. Sharing a common
control power source is an invitation for ground loops and
the subsequent unexplainable problems.
MOTOR STARTER PACKAGE
Motor starter and interlock wiring require ments are shown in
the Starter Wiring Diagram. All of the equipment shown is
supplied by the installer unless a starter package is pur chased
separately from Johnson ControlsFrick. Starter packages
should consist of:
1. The compressor motor starter of the specied HP and
voltage for the starting method specied (acrosstheline,
wyedelta, or solidstate).
RWH ROTARY SCREW COMPRESSOR UNITS
INSTALLATION
070.620-IOM (DEC 12)
Page 14
NOTICE
If starting methods other than across-the-line are de-
sired, a motor/compressor torque analysis must be done
to ensure that sufcient starting torque is avail able,
particularly in booster applica tions. Contact Johnson
Controls-Frick if assistance is required.
2. If specied, the starter package can be supplied as a
combination starter with circuit breaker disconnect. Howev er,
the motor overcurrent protection/disconnection device can
be applied by others, usually as a part of an electrical power
distribution board.
3. The oil pump starter with fuses, or in the case where the
compressor motor is a different voltage from the oil pump
motor, with a circuit breaker disconnect suitable for sepa rate
power feed.
4. A properly sized control power transformer (CPT) to
supply 120 volt control power to the microprocessor control
system and separator oil heaters is included. If environ mental
condi tions require more than the usual 1000 watt oil heat
ers, an appropriately oversized control transformer will be
required. If frequent power uc tuations are anticipat ed or
extremely noisy power lines are encoun tered, a regulating
control transformer should be considered. Contact Johnson
ControlsFrick® for assistance.
5. For customersupplied acrosstheline starters, a shunt
ing device must be installed across the Current Transformer
(terminals 3 & 4).
WARNING
If the shunting device is not installed, the Analog I/O
board on the Quantum™LX panel may be severely dam-
aged at start-up. See Figure 17.
Figure 17 - Starter Wiring Diagram
6. One each normally open compressor motor and oil pump
motor starter auxiliary contact should be supplied. In addition
to the compressor and oil pump motor starter coils, the CT
and CPT secondaries should be wired as shown on the starter
package wiring diagram. The load on the control panel for
the compressor motor starter coil should not exceed a 2 amp
load. For larger starters, an interposing relay must be used
to switch the compres sor motor starter coil(s).
NOTICE
Do not install a compressor HAND/OFF/AUTO switch in
the starter package as this would bypass the compres-
sor safety devices.
7. The compressor motor Current Transformer (CT) is in
stalled on any one phase of the compressor leads.
NOTICE
The CT must see all the current of any one phase,
therefore in wye-delta applications BOTH leads of any
one phase must pass through the CT.
Figure 18 - Point-To-Point Wiring Diagram
RWH ROTARY SCREW COMPRESSOR UNITS
INSTALLATION
070.620-IOM (DEC 12)
Page 15
CURRENT TRANSFORMER (CT) RATIOS
The CT ratio for various motor sizes (with a 5 amp second ary) is given in the following table:
CT Factor
Voltage
HP 380 460 575 2300 3300 4000 4160 6000 6300 10,000 13,200
400 800:5 600:5 500:5 200:5 100:5 100:5 100:5 50:5 50:5 50:5 50:5
450 1000:5 800:5 600:5 200:5 200:5 100:5 100:5 100:5 100:5 50:5 50:5
500 1000:5 800:5 600:5 200:5 200:5 100:5 100:5 100:5 100:5 50:5 50:5
600 1200:5 1000:5 800:5 200:5 200:5 200:5 100:5 100:5 100:5 50:5 50:5
700 1200:5 1000:5 200:5 200:5 200:5 200:5 100:5 100:5 50:5 50:5
800 1000:5 300:5 200:5 200:5 200:5 100:5 100:5 100:5 50:5
900 1200:5 300:5 300:5 200:5 200:5 200:5 200:5 100:5 50:5
1000 300:5 300:5 200:5 200:5 200:5 200:5 100:5 100:5
1250 400:5 300:5 300:5 200:5 200:5 200:5 100:5 100:5
1500 500:5 400:5 300:5 300:5 200:5 200:5 100:5 100:5
2000 600:5 500:5 400:5 400:5 300:5 300:5 200:5 200:5
2500 700:5 600:5 500:5 400:5 300:5 300:5 200:5 200:5
3000 800:5 700:5 600:5 500:5 400:5 400:5 200:5 200:5
3500 900:5 800:5 700:5 500:5 500:5 400:5 300:5 200:5
4000 1000:5 1000:5 800:5 600:5 500:5 500:5 300:5 300:5
4500 1500:5 1200:5 800:5 800:5 600:5 600:5 300:5 300:5
5000 2000:5 1200:5 900:5 900:5 600:5 600:5 400:5 300:5
5500 2000:5 1500:5 1000:5 1000:5 700:5 700:5 400:5 300:5
6000 2000:5 1500:5 1200:5 1200:5 800:5 700:5 400:5 400:5
6500 2000:5 2000:5 1200:5 1200:5 800:5 800:5 500:5 400:5
MINI MUM BURDEN RATINGS
The following table gives the minimum CT burden ratings.
This is a function of the distance between the motor starting
package and the compressor unit.
BURDEN
RATING
MAXIMUM DISTANCE FROM
FRICK PANEL
ANSI VA USING # USING # USING #
14 AWG 12 AWG 10 AWG
B-0.1 2.5 15 ft 25 ft 40 ft
B-0.2 5 35 ft 55 ft 88 ft
B-0.5 12.5 93 ft 148 ft 236 ft
CONTROL POWER REGULATOR
Compressor units that will be used in areas that suffer brown
outs and other signicant power uctuations can be supplied
with a control power regulator. See Figure 19, Recommended
Regulator Installation.
Figure 19 - Recommended Regulator Installation
RWH ROTARY SCREW COMPRESSOR UNITS
OPERATION
070.620-IOM (DEC 12)
Page 16
Operation
OPERATION and START-UP INSTRUCTIONS
The Frick® RWH Rotary Screw Compressor Unit is an inte
grated system consisting of seven major subsystems:
1. Quantum™LX Control Panel
(See publications 090.022O, 090.020M & CS)
2. Compressor
3. Compressor Lubrication System
4. Compressor Oil Separation System
5. Compressor Hydraulic System
6. Compressor Oil Cooling System
7. Compressor EasyStart System
The information in this section of the manual provides the
logical stepbystep instructions to properly start up and
operate the RWH Rotary Screw Compressor Unit.
THE FOLLOWING SUBSECTIONS MUST BE READ AND
UNDERSTOOD BEFORE ATTEMPTING TO START OR OP-
ERATE THE UNIT.
TDSH COMPRESSOR
The Frick® RWH rotary screw compressor utilizes mating
asymmetrical prole helical rotors to provide a continuous
ow of refriger ant vapor and is designed for both high
pressure and lowpressure applica tions. The compressor
incorpor ates the following features:
1. Highcapacity roller bearings to carry radial loads at both
the inlet and outlet ends of the compres sor.
2. Heavyduty, fourpoint angularcontact ball bearings to
carry axial loads are mounted at the discharge end of com
pressor.
3. Balance pistons located in the inlet end of the compres sor
to reduce axial loads on the axial load bearings and increase
bearing life.
4. Movable slide valve to provide fully modulating capacity
control from 100% to approximately 10% of full load capacity.
5. Volume ratio control to allow innite ly variable volume
ratio from 2.2 to 5.0 during compres sor operation for all
models. Optional low Vi range is available.
6. A hydraulic unloader cylinder to operate the slide stop
and slide valve.
7. Bearing and casing design for 400 PSI discharge pres
sure for cast ductile iron casing 600 PSI for optional steel
casing. This PSI rating applies only to the compressor and
does not reect the design pressure of the various system
components.
8. All bearing and control oil vented to closed thread in the
compressor instead of suction port to avoid performance
penalties from superheating suction gas.
9. Shaft seal design to maintain operating pressure on seal
well below discharge pressure, for increased seal life.
10. Oil injected into the rotors to maintain good volumetric
and adiabatic efciency even at very high compression ratios.
11. Shaft rotation clockwise facing compressor, suitable for
all types of drives. SEE FOLLOWING WARNING.
WARNING
Compressor rotation is clockwise when facing the
compressor drive shaft. See Figure 20. The compressor
should never be operated in reverse rotation as bearing
damage will result.
Figure 20 - Shaft Rotation Direction
12. Dual compressor casing design for very low airborne noise
transmission.
13. Suction ange is 300 psig ANSI type (except RWH 852 is
CL 400 PLC).
COMPRESSOR LUBRICATION SYSTEM
The lubrication system on an RWH screw com pres sor unit
performs several functions:
1. Provides lubrication to bearings and seal.
2. Provides a cushion between the rotors to minimize noise
and vibrations.
3. Helps keep the compressor cool and prevents overheat ing.
4. Provides an oil supply to hydraulically actuate the slide
valve and slide stop.
5. Provides oil pressure to the balance pistons to help in
crease bearing life.
6. Provides an oil seal between the rotors to prevent rotor
contact or gas bypassing.
The compressor unit is equipped with either a full lube oil
pump or a prelube/control oil pump lubrication system.
Additionally, either system may contain dual oil lters and
liquid injection, watercooled, or thermosyphon oil cooler
for compressor oil cooling.
NOTICE
For alarm descriptions and shutdown or cutout param-
eters, see publication 090.022-O.
CONTROL PUMP OIL SYSTEM
The control oil pump is required to facilitate proper capac
ity control operation of the slide valve. It maintains control
(solenoid)oil pressure 30 to 50 PSI above discharge pressure.
It runs continuously and stops at time of shutdown. The
control oil pump works in conjunction with the discharge
buttery valve control. System pressure differential provides
for lubrication and cooling oil ow.
RWH ROTARY SCREW COMPRESSOR UNITS
OPERATION
070.620-IOM (DEC 12)
Page 17
FULL TIME PUMP SYSTEM
The full time pump system provides all oil ow requirements
for the compressor, including control oil pressure, as well as
lubrication and cooling oil ow. The pump runs continuously.
COMPRESSOR OIL SEPARATION SYSTEM
The RWH is an oil ooded screw compressor. Most of the oil
discharged by the compressor separates from the gas ow
in the oil charge reservoir. Some oil, however, is discharged
as a mist which does not separate readily from the gas ow
and is carried past the oil charge reser voir. One or more
coalescer lter elements then COALESCE the oil mist into
droplets which fall to the bottom of the coalescer section of
the oil separator. See Figure 21. The return of this oil to the
compressor is controlled by a throttling valve on both high
stage and booster applications.
NOTICE
Open throttling valve only enough to keep coalescer
end of separator free of oil.
The sight glass located near the bottom of the coales cer sec-
tion of the oil separator should remain empty during normal
operation. If an oil level develops and remains in the sight
glass, a problem in the oil return separation system or com-
pressor operation has developed. Refer to MAINTENANCE
for information on how to correct the prob lem.
NOTICE
The normal operating level is midway between the two
sight glasses located midway along the oil separator
shell.
Figure 21 - Oil Separation System
DISCHARGE BUTTERFLY CONTROL OIL SYSTEM
The valve can open when Compressor Start Output is
energized and immediately closes when the output is de
energized.
The Discharge Buttery Valve Solenoid output will only be
energized when the Discharge Pressure reaches the Con
densing Pressure. If the Solenoid needs to open when the
compressor starts, it can be controlled from the Compressor
Run Output.
The valve is controlled to maintain a minimum differential
pressure that will provide oil ow and keep the oil pressure
above the oil safeties. The Compressor Differential Pressure
Setpoint can be used to set a higher differential pressure
setting when necessary.
If the Lock Open Flag is set to True, after the valve opens
to 100% it will remain in this position until the compressor
is turned off. If the Lock Open Flag is set to False, the valve
will continue to modulate based on the compressor differ
ential pressure.
COMPRESSOR HYDRAULIC SYSTEM
The compressor hydraulic system moves the movable slide
valve (MSV) to load and unload the compressor. It also moves
the movable slide stop (MSS) to increase or decrease the
compressor’s volume ratio (Vi).
The hydraulic cylinder located at the inlet end of the SGC
compressor serves a dual purpose. It is separated by a xed
bulkhead into two sections. The movable slide valve (MSV)
sec tion is to the left of the bulkhead and the movable slide
stop (MSS) to the right. Both sections are considered double
acting hydraulic cylinders as oil pressure moves the pistons
in either direction.
Both sections are controlled by doubleacting, fourway
solenoid valves which are actuated when a signal from the
appropriate micropro cessor output energizes the solenoid
valve. Valves SV2, SV3, SC1, SC3, and T1 are always open.
NOTICE
The solenoid coils can be serviced or replaced without
evacuating the package. However, if the hydraulic so-
lenoid valves or manifold block needs to be serviced
or replaced, then the compressor package must be
evacuated.
SINGLE-ACTING MODE - High Stage
Close valve at SC2
Open valve at BP (bypass)
High stage compressor loading: The compressor loads when
MSV 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 MSV 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. 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, change
cycle time, proportional band, and dead band setpoints
with Quantum control. If additional control is needed,
throttle SC2 or BP.
DOUBLE-ACTING MODE - Booster
Open valve at SC2
Close valve at BP (bypass)
RWH ROTARY SCREW COMPRESSOR UNITS
OPERATION
070.620-IOM (DEC 12)
Page 18
Booster Compressor Loading: The compressor loads when
MSV 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
con tained in the unload side of the cylinder ows out cylinder
port SC1 through valve ports A and T to com pressor suction.
Booster Compressor Unloading: The compressor un loads
when MSV 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. Simultaneous ly,
oil contained in the load side of the cylinder ows out of
compressor port SC2 through valve ports B and T to com
pressor suction.
NOTICE
To control the rate of loading and unloading, change
cycle time, proportional band, and dead band setpoints
with Quantum control. If additional control is needed,
throttle SC2 or BP.
Figure 22
WARNING
NEVER open valve BP and valve SC2 at the same time
during compressor operation.
VOLUME RATIO CONTROL
NOTICE
See Figure 23 for port references.
Open valve at SC3
Open valve at T1
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 compres
sor port SC3, enters the increase side of the cylinder and
overcomes the decrease spring tension. Simultaneously, oil
ows from T1 port through valve ports B and T to compres
sor suction. The inboard side of the slide stop piston is at
suction pressure.
Compressor Vi decrease: The volume ratio Vi is decreased
when MSS solenoid valve YY4 is energized and oil ows from
the oil manifold through valve ports P and B to compressor
port T1, enters the decrease side of the cylinder. Simultane
ously, oil ows form SC3 port through valve ports A and T
to compressor suction. On these models, YY4 is energized
which permits oil to vent from port A to T with assistance
from the unloader spring.
TO CONTROL THE RATE OF VI CHANGE, THROTTLE THE
NEEDLE VALVE AT SC3 PORT.
COMPRESSOR OIL COOLING SYSTEMS
The RWH unit can be equipped with one of several systems
for controlling the compressor oil tempera ture. They are
single or dualport liquid injection and thermo syphon, air
cooled or watercooled oil coolers. Each system is autom
ati cally controlled, independent of compressor loading or
unloading.
Oil cooling systems should maintain oil temperature within
the following ranges for R717:
Liquid Injection External*
Oil Cooling Oil Cooling
130 170°F 120 160°F
* Thermosyphon oil cooling (TSOC), aircooled, or water
cooled oil cooling (WCOC).
SINGLE-PORT LIQUID INJECTION
The singleport liquid injection system is desig ned to permit
liquid refrigerant injection into one port on the compressor
at any given moment and operates as outlined.
The liquid injection control valve is enabled by the micro
processor when the temperature sensor, in stalled in the
compressor discharge, exceeds the setpoint. Highpressure
liquid refriger ant is then expanded through the tempera
ture control valve (TCV) and cools the compressor. Refer to
P & I DIAGRAMS section for piping and instrumentation
drawings.
DUAL-PORT LIQUID INJECTION
The dualport liquid injection system is design ed to obtain
the most efcient compressor performance at high and low
compression ratios by permitting injection of liquid refriger ant
into one of two ports optimally located on the com pressor.
This minimizes the performance penalty incurred with liquid
injection oil cooling.
The dualport system contains all the com ponents of the
singleport system with the addition of a directional valve
and operates as follows:
The liquid injection solenoid valve is energized by the
micro processor when the temperature sensor, in stalled in
the oil manifold, exceeds the setpoint. Liquid refrigerant is
then passed through the tempera ture control valve (TCV)
to the directional solenoid valve. Depending on the com
pressor’s operating volume ratio (Vi), the micropro cessor
will select the ow of the liquid refrigerant to the optimum
com pressor port.
RWH ROTARY SCREW COMPRESSOR UNITS
OPERATION
070.620-IOM (DEC 12)
Page 19
Figure 23 - Port Locations
QUANTUM™LX EZ-COOL™ LIQUID INJECTION ADJUSTMENT PROCEDURE
Figure 24 - Analog Output Calibration
Use the following directions to set up and tune the EZ-Cool
LIOC with a Quantum™LX Control Panel. Also refer to publi-
cation 090.022-O, Quantum™LX Operation, for an overview
of PID control.
First, complete calibration of the analog output used for
EZ-Cool
™
LIOC. Typically, this will be analog output #1 for PID #1.
• Power down the panel and remove the two control
wires for the valve from terminals 1 & 2 of the P11A
terminal strip of analog board #1.
RWH ROTARY SCREW COMPRESSOR UNITS
OPERATION
070.620-IOM (DEC 12)
Page 20
• Place the leads of a calibrated, quality meter to ter
minal one (positive) and terminal two (negative). Set
the meter to read mA DC and power up the panel.
• Set operating session to session [2] and go to the
screen shown in Figure 24 by pressing [Menu] >[Cali-
bration] > [Analog Outputs] > [Output Calibration].
• Press #1 on the keypad to drive the output to the
low end. Using numbers 4, 7 and 0 on the keypad
to increase and decrease the output and change the
“Delta For Changing Output Percentage” setpoint, set
the output to 4mA.
• If the read value is less than the objective of 4 or 20mA
use 7 on the keypad, increase the output by the Delta.
If the read value is more than the objective, use 4 to
decrease the value by the Delta.
• Use the 0 key to change the Delta from 10 to 1, .10
or .01% to tune the output to the objective of 4 or
20mA.
• Press #3 on the keypad to set the output to the high
end and repeat the process in the preceding steps to
set the output to 20mA.
• Power down the panel, remove the meter and recon
nect the control wires for the EZCool LIOC valve as
they were removed to terminals 1 & 2 of the P11A
terminal strip of analog board #1.
Description of Proportional Band and Gain setpoints:
• Proportional Band – This setpoint determines the size
of a region either above or below the Control Setpoint.
Within this region the Proportional component of the
PID Output value is the number between 0% and 100%
that directly corresponds to the difference between
the Control Input (Actual) and the Control Setpoint
(Setpoint). Outside of this region the Proportional
component is either 100% or 0%. If the PID Action
is Forward, the Proportional Band extends above the
Control Setpoint. If the PID Action is Reverse, the
Proportional Band extends below the Control Setpoint.
• Proportional Gain This value is calculated from the
Proportional Band setpoint and is the same value that
was entered as a Proportional Gain setpoint in the
Quantum. The control setpoint will not be achieved
with proportional control only. Integral control is
needed to further correct the control input to achieve
the setpoint.
• Integral Gain This setpoint controls the inuence the
Integral component exerts on the PID Output value.
The Integral component works to push the Control
Input toward the Control Setpoint by tracking the
difference between the Control Input and the Control
Setpoint over time.
• Derivative Gain This setpoint controls the inuence
the Derivative component exerts on the PID Output
value. The Derivative component reacts to rapid
changes in the value of the Control Input by predicting
the direction the Control Input is traveling and then
turning it back toward the Control Setpoint.
Example of Proportional Only Control:
Control Input: Discharge Temperature
Control Setpoint: 150°F
Dead Band: 0°F
Proportional Band: 25
Action: Forward
NOTES:
1. Set the “Liquid Slugging” Alarm and Shutdown setpoints
to 90 to prevent nuisance shutdowns during the tuning
process. Be sure to return these setpoints to their original
values when nished.
2. While the discharge temperature will be the Control Point,
it reacts quickly to adjustments. Be sure to allow an adjust
ment to the proportional band or integral gain setpoints the
opportunity to counter and correct the control input (dis
charge temperature) before making additional adjustments.
3. Tune the output by making small adjustments of 15 to
the Proportional Band and .1.5 of the Integral Gain setpoints.
Adjust only one at a time, allowing each adjustment time to
settle out.
Figure 25 - PID Setup
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