Transcript
S70-101 IOM/JAN 2000
File:
Replaces:
Dist:
SERVICE MANUAL - Section 70
S70-101 IOM/APR 96
3, 3a, 3b, 3c
Installation - Operation - Maintenance
ROTARY SCREW COMPRESSOR UNITS
WITH
MICROPROCESSOR CONTROL
ALL REFRIGERANTS
THIS MANUAL CONTAINS RIGGING, ASSEMBLY, START-UP, AND
MAINTENANCE INSTRUCTIONS. READ THOROUGHLY BEFORE
BEGINNING INSTALLATION. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DAMAGE OR IMPROPER OPERATION OF THE UNIT.
S70-101 IOM
Page 2
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
INSTALLATION - OPERATION - MAINTENANCE
TABLE OF CONTENTS
GENERAL INFORMATION
Preface .............................................................................. 3
Design Limitations ............................................................ 3
Job Inspection ................................................................... 3
Transit Damage Claims ..................................................... 3
Compressor/Unit Identification .......................................... 3
INSTALLATION
Foundation ........................................................................ 4
Handling and Moving ........................................................ 4
Skid Removal .................................................................... 5
Motor Mounting ................................................................. 5
Compressor/Motor Coupling Installation .......................... 5
Coupling Alignment Procedure ......................................... 6
Hot Alignment of Compressor/Motor ................................ 8
Checking Motor/Compressor Rotation .............................. 8
Holding Charge and Storage ............................................ 8
Compressor Oil ................................................................. 8
Oil Charge ......................................................................... 8
Oil Heater .......................................................................... 8
Liquid Injection Oil Cooling ............................................... 9
Dual Dip Tube Method ....................................................... 9
Level Control Method ........................................................ 9
Water-Cooled Oil Cooling ............................................... 10
Thermosyphon Oil Cooling ............................................. 10
Economizer - High Stage ................................................ 12
Electrical ......................................................................... 13
Motor Starter Package .................................................... 13
Current Transformers (CT) Ratios ................................... 14
Minimum Burden Ratings ................................................ 14
Battery Backup ............................................................... 14
OPERATION
General Information ........................................................ 15
Microprocessor Control Panel ......................................... 15
Keys and Key Functions ................................................. 16
To Change The Adjustable Setpoints .............................. 18
How To Determine Adjustable Setpoints ......................... 18
Temperature-Pressure Control Program ......................... 22
Lead-Lag (Option) ........................................................... 24
Communications Troubleshooting ................................... 24
How The Microprocessor Works - Summary .................. 25
Multiple Compressor Sequencing ................................... 26
Microprocessor Telecommunications .............................. 27
Communications Protocol Specifications ....................... 27
RXB Compressor ............................................................ 30
Compressor Lubrication System ..................................... 30
Full-Lube Oil System ...................................................... 30
Compressor Oil Separation System ............................... 30
Compressor Hydraulic System ....................................... 31
Compressor Oil Cooling Systems ................................... 32
Single-Port Liquid Injection ............................................. 32
Dual-Port Liquid Injection ................................................ 33
Liquid Injection Adjustment Procedure ........................... 33
Prestart Checklist ............................................................ 34
Initial Start-up Procedure ................................................ 35
Normal Start-up Procedure ............................................. 35
Restarting Unit After Power Failure ................................. 35
MAINTENANCE
Normal Maintenance Operations .................................... 36
Compressor Shutdown and Start-up .............................. 36
General Instructions For Replacing
Compressor Unit Components .................................... 36
Suction Check Valve Bypass Valve ................................. 36
Oil Filter, Single ............................................................... 36
Oil Filter, Dual ................................................................. 37
Strainer, Oil Return ......................................................... 37
Strainer, Oil Pump (Optional) .......................................... 37
Strainer, Liquid Injection ................................................. 37
Coalescer Filter Element ................................................ 38
Changing Oil ................................................................... 38
Recommended Maintenance Program ........................... 38
Vibration Analysis ........................................................... 39
Oil Quality and Analysis .................................................. 39
Motor Bearings ............................................................... 39
Operating Log ................................................................. 39
Maintenance Schedule ................................................... 40
Troubleshooting Guide .................................................... 41
Abnormal Operation Analysis and Correction ................ 41
Troubleshooting The Microprocessor .............................. 42
EPROM Memory I/C Chip Replacement ........................ 45
SBC Board Replacement ................................................ 45
Microprocessor Display Replacement ............................ 45
Output Fuse Replacement .............................................. 45
Pressure Transducers - Testing ....................................... 45
Pressure Transducer Conversion Data ........................... 45
Pressure Transducers - Replacement ............................. 46
Volumizer Potentiometer - Replace/Adjust ..................... 47
Temperature/Pressure Adjustment ................................. 47
Bare Compressor Mounting ............................................ 47
Troubleshooting The RXB PLUS:
Compressor ................................................................. 48
Oil Separator System .................................................. 48
Hydraulic System ........................................................ 48
Full-Time Pump Systems ............................................ 49
Liquid Injection Oil Cooling ......................................... 49
Thermal Expansion Valves ............................................. 50
Temperature Control Valve .............................................. 51
Wiring Diagrams ............................................................. 52
P and I Diagrams ............................................................ 58
PROPER INSTALLATION OF ELECTRONIC
EQUIPMENT ............................................................... 61
SPARE PARTS LIST ....................................................... 64
OPERATING LOG .......................................................... 65
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
GENERAL INFORMATION
S70-101 IOM
Page 3
PREFACE
COMPRESSOR and UNIT IDENTIFICATION
This manual has been prepared to acquaint the owner and
serviceman with the INSTALLATION, OPERATION, and
MAINTENANCE procedures as recommended by Frick for
RXB PLUS Rotary Screw Compressor Units.
Each compressor unit has 2 identification data plates. The
compressor data plate, containing compressor model and
serial number, is mounted on the compressor body. The unit
data plate, containing unit model, serial number, and Frick
sales order number, is mounted on the side of the motor
base.
It is most important that these units be properly applied to
an adequately controlled refrigeration system. Your authorized Frick representative should be consulted for his expert guidance in this determination.
NOTE: When inquiring about the compressor or unit, or
ordering repair parts, provide the MODEL, SERIAL, and
FRICK SALES ORDER NUMBERS from these data plates.
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 equipment
must be properly selected and connected to a properly designed and installed system. The Engineering plans, piping
layouts, etc. must be detailed in accordance 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 refrigerant carryover, it
is necessary that refrigerant controls are carefully selected
and in good operating condition; the piping is properly sized
and traps, if necessary, are correctly arranged; the suction
line has an accumulator or slugging protection; that load
surges are known and provisions made for control; operating cycles and defrosting 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 10OF above the refrigerant saturation temperature. This ensures that all refrigerant
at the compressor suction is in the vapor state.
COMPRESSOR DATA PLATE
DESIGN LIMITATIONS
The compressor units are designed for operation within the
pressure and temperature limits as shown in Frick Pub.
E70-100 SED.
JOB INSPECTION
Immediately upon arrival examine all crates, boxes and exposed compressor and component surfaces for damage.
Unpack all items and check against shipping lists for any
possible shortage. Examine all items for damage in transit.
TRANSIT DAMAGE CLAIMS
All claims must be made by consignee. This is an ICC requirement. Request immediate inspection by the agent of
the carrier and be sure the proper claim forms are executed.
Report damage or shortage claims immediately to Frick ,
Sales Administration Department, in Waynesboro, PA.
UNIT DATA PLATE
S70-101 IOM
Page 4
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
INSTALLATION
FOUNDATION
ALLOWABLE FLANGE LOADS
MOMENTS (ft-lbf)
LOAD (lbf)
Each RXB PLUS Rotary Screw Compressor Unit is shipped
mounted on a wood skid which must be removed prior to unit
installation. CAUTION: Allow space for servicing both ends
of the unit. A minimum of 24 inches is recommended.
NOZ.
SIZE
NPS
(in.)
AXIAL
VERT.
LAT.
AXIAL
VERT.
LAT.
MR
MC
ML
P
VC
VL
The first 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 high frequency vibrations.
1
1.25
1.5
2
3
4
5
6
8
10
12
14
25
25
50
100
250
400
425
1000
1500
1500
1500
2000
25
25
40
70
175
200
400
750
1000
1200
1500
1800
25
25
40
70
175
200
400
750
1000
1200
1500
1800
50
50
100
150
225
300
400
650
1500
1500
1500
1700
50
50
75
125
250
400
450
650
900
1200
1500
2000
50
50
75
125
250
400
450
650
900
1200
1500
2000
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 insurance
for a trouble free installation. Use only the certified general
arrangement drawings from Frick to determine the mounting foot locations and to allow for recommended clearances
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.
The floor should be a minimum of 6 inches of reinforced concrete and housekeeping pads are recommended. Anchor bolts
are required to firmly tie the unit to the floor. Once the unit is
rigged into place (See HANDLING and MOVING), the feet must
then be shimmed in order to level the unit. The shims should
be placed to position the feet roughly one inch above the housekeeping pad to allow room for grouting. An expansion-type
epoxy grout must be worked under all areas of the base with
no voids and be allowed to settle with a slight outward slope so
oil and water can run off of the base.
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 S70-210 IB.
When installing on a steel base, the following guidelines should
be implemented to properly design the system base:
1. Use I-beams in the skid where the screw compressor will be
attached to the system base. They should run parallel to the
package feet and support the feet for their full length.
2. The compressor unit feet should be continuously welded to
the system base at all points of contact, or bolted.
3. The compressor unit should not be mounted on vibration
isolators in order to hold down package vibration levels.
4. The customer’s foundation for the system base should fully
support the system base under all areas, but most certainly
under the I-beams that support the compressor package.
When installing on the upper floors of buildings, extra precautions 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 building 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 disconnected
from the compressor. See table for Allowable Flange Loads.
A licensed architect should be consulted to determine the
proper foundation requirements for any large engine or turbine drive.
FIG. 1 - RECOMMENDED LIFTING METHOD
HANDLING AND MOVING
THIS UNIT MAY BE TOP HEAVY.
USE CARE WHILE HANDLING.
Spreader bars should be used on
both the length and width of the package to prevent
bending of oil lines and damage to the package.
The unit can be moved with rigging, using a crane or forklift.
The recommended method is to insert lengths of 2" pipe
through the lifting holes in the vertical supports (see FIG. 1).
Alternatively, hooks may be used in rigging, inserting them
in the lifting holes (see FIG. 2).
Use CAUTION in locating the lifting ring. If no motor is
mounted, the lifting ring should be moved off center to the
compressor side of the unit because 60 percent of the weight
is toward the compressor end. If a motor is mounted, appropriate adjustment in the lifting point should be made to
compensate for motor weight. Adjustment of the lifting point
must also be made for any additions to the standard package, such as an external oil cooler, etc., as the center of
balance will be affected.
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
INSTALLATION
S70-101 IOM
Page 5
1. Inspect the shaft of the motor and compressor to ensure
that no nicks, grease, or foreign matter is present.
2. Inspect the bores in the coupling hubs to make sure that
they are free of burrs, dirt, and grit.
3. Check that the keys fit the hubs and shafts properly.
CH COUPLING – The T.B. Woods Elastomeric CH Coupling
is used in most applications. It consists of two drive hubs
and a loose, gear-type Hytrel Drive Spacer. The split hub is
clamped to the shaft by tightening the clamp screws. Torque
is transmitted from the motor through the elastomeric gear
which floats freely between the hubs. Install as follows:
FIG. 2 - ALTERNATIVE LIFTING METHOD
IT IS MANDATORY THAT THE COUPLING CENTER BE REMOVED
AND THE DIRECTION OF MOTOR
ROTATION BE CONFIRMED BEFORE RUNNING THE
COMPRESSOR. Proper rotation of the compressor shaft
is clockwise looking at the end of the compressor shaft.
FAILURE TO FOLLOW THIS STEP COULD RESULT IN
BACKWARD COMPRESSOR ROTATION WHICH CAN
CAUSE COMPRESSOR FAILURE OR EXPLOSION OF
THE SUCTION HOUSING.
The unit can be moved with a forklift by forking under the
skid, or it can be skidded into place with pinch bars by pushing against the skid. NEVER MOVE THE UNIT BY PUSHING OR FORKING AGAINST THE SEPARATOR SHELL
OR ITS MOUNTING SUPPORTS.
SKID REMOVAL
If the unit is rigged into place the skid can be removed by
taking off the nuts and bolts that are fastening the unit mounting supports to the skid before lowering the unit onto the
mounting surface.
1. Slide one hub onto each shaft as far as possible. It may
be necessary to use a screwdriver as a wedge in the slot to
open the bore before the hubs will slide onto the shafts.
If the unit is skidded into place, remove the cross members
from the skid and remove the nuts anchoring the unit to the
skid. Using a 5-ton jack under the separator, raise the unit at
the compressor end until it clears the two mounting bolts.
Spread the skid to clear the unit mounting support, then lower
the unit to the surface. Repeat procedure on opposite end.
2. Hold the elastomeric gear between the hubs and slide
both hubs onto the gear to fully engage the mating teeth.
Make sure that the keys on the compressor and motor halves
of the coupling are offset 180O (see FIG. 3). Center the gear
and hub assembly so there is equal engagement on both
shafts. Adjust the space between hubs as specified in the
CH Coupling Data Table below.
MOTOR MOUNTING
The following procedure is required only when the motor is
mounted at the job site.
3. Torque the clamping bolts in both hubs to the torque value
given in the CH Data Table. DO NOT USE ANY LUBRICANT ON THESE BOLTS.
1. Thoroughly clean the motor feet and mounting pads of
grease, burrs, and other foreign matter to ensure firm seating of the motor.
4. Proceed to Coupling Alignment.
2. Attach the motor to the base using the bolts and motorraising blocks, if required. Bolt snugly through the base.
3. Weld the four kick bolts into place so that they are positioned to allow movement of the motor feet.
4. Now that the motor has been set, check that the shafts
are properly spaced for the coupling being used. Refer to
the coupling data table for the applicable dimension.
COMPRESSOR/MOTOR COUPLING
INSTALLATION
RXB PLUS units are arranged for direct motor drive and
require a flexible drive coupling to connect the compressor
to the motor. Before installing, perform the following:
DRIVE COUPLING
FIG. 3 - COUPLING/SHAFT KEYS INSTALLATION
CH COUPLING DATA TABLE
CH
COUPLING
SIZE
6
7
8
9C
COUPLING HUB
SHAFT ENGAGEMENT
BETWEEN SHAFT SPACING
MIN *
in.
3
3
3-13/16
3-9/16
MIN
MAX
FACE SPACING
MAX
mm
in.
mm
in.
mm
76.2
76.2
96.8
90.5
3-1/4
3-7/16
4
5-7/16
101.6
138.1
161.9
149.2
3/4
1
1
1-1/4
19.0
25.4
25.4
31.8
in.
15/16
1-3/8
1-13/16
2-3/8
mm
23.8
34.9
46.0
60.3
in.
7/8
1-1/16
1-1/8
1-7/16
mm
22.2
27.0
28.6
36.5
MAXIMUM
TOTAL
INDICATOR
READING
CLAMP
BOLT
TORQUE
KEYWAY
SETSCREW
TORQUE
in.
mm
ft-lb
Nm
ft-lb
Nm
.004
.004
.004
.004
.104
.104
.104
.104
10
20
35
35
13.6
27.1
47.5
47.5
13
13
13
13
17.6
17.6
17.6
17.6
S70-101 IOM
Page 6
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
INSTALLATION
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 foundation. Initial alignment must be made prior to start-up and rechecked
after a few hours of operation. Final (HOT) field alignment
can only be made when the unit is at operating temperature. After final (HOT) alignment has been made and found
to be satisfactory for approximately one week, the motor
may be dowelled to maintain alignment.
NOTE: Frick recommends cold aligning the motor .005"
high. This cold misalignment compensates for thermal
growth when the unit is at operating temperature.
FIG. 1 - ANGULAR MISALIGNMENT
Use dial indicators to measure the angular and parallel shaft
misalignment. Coupling alignment is attained by alternately
measuring angular and parallel misalignment and repositioning the motor until the misalignment is within specified
tolerances. The following procedure is recommended.
MISALIGNMENT MUST NOT EXCEED .004" FOR ALL CH COUPLINGS.
ANGULAR ALIGNMENT
1. To check angular alignment, as shown in Fig. 1., 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 Fig. 2.
2. Rotate both coupling hubs several revolutions until they
seek their normal axial positions.
FIG. 2 - DIAL INDICATOR ATTACHED (AT 12 O'CLOCK)
Check the dial indicator to be sure that the indicator stem is
slightly loaded so as to allow movement in both directions.
3. Set the dial indicator at zero when viewed at the 12 o’clock
position, as shown in Fig. 2.
4. Rotate both coupling hubs together 180O (6 o’clock position), as shown in Fig. 3. At this position the dial indicator
will show TOTAL angular misalignment.
NOTE: 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 misalignment
retighten anchor bolts to prevent inaccurate readings. Repeat Steps 3 through 5 to check corrections. Further adjustments and checks shall be made for angular misalignment
until the total indicator reading is within the specified tolerance.
FIG. 3 - DIAL INDICATOR AT 6 O'CLOCK
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
INSTALLATION
S70-101 IOM
Page 7
PARALLEL ALIGNMENT
6. To check parallel alignment, as shown in Fig. 4, reposition dial indicator so the stem is in contact with the rim of the
compressor hub, as shown in Fig. 5.
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 indicator at zero when viewed at the 12 o'clock position. Rotate
both coupling hubs together 180O (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 under
the four motor feet until parallel height misalignment is within
specified tolerance when anchor bolts are retightened.
FIG. 4 - PARALLEL MISALIGNMENT
CARE MUST BE USED WHEN
CORRECTING FOR PARALLEL
MISALIGNMENT TO ENSURE
THAT THE AXIAL SPACING AND ANGULAR MISALIGNMENT IS NOT SIGNIFICANTLY DISTURBED.
9. After the parallel height misalignment is within tolerance,
repeat Steps 1 through 5 until angular misalignment is within
specified tolerance.
10. Check parallel lateral misalignment by positioning dial
indicator so the stem is in contact with the rim of the compressor hub at 3 o'clock, as shown in Fig. 6.
Set indicator at zero and rotate both coupling hubs together
180O (9 o'clock position), as shown in Fig. 5.
FIG. 5 - DIAL INDICATOR ATTACHED (AT 9 O'CLOCK)
Adjust parallel lateral misalignment using the motor adjusting screws until reading is within specified 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 360O travel at 90O increments. If dial readings are in excess of specified tolerance, realign as required.
13. When the coupling hubs have been aligned to within
specified tolerance, a recording of the cold alignment must
be made for unit records and usage during hot alignment.
14. Bump the motor to check for correct compressor rotation. COMPRESSOR ROTATION IS CLOCKWISE WHEN
FACING COMPRESSOR SHAFT (see "CHECKING MOTOR/COMPRESSOR ROTATION", page 8). After verification, install gear or disk drive spacer, as applicable.
15. Install the coupling guard before operating the compressor.
When installing drive spacer, make
sure that hub spacing is within limits shown on the Coupling Data
Table applicable to the coupling being installed and that
the clamping bolt(s) are properly torqued.
FIG. 6 - DIAL INDICATOR AT 3 O'CLOCK
S70-101 IOM
Page 8
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
INSTALLATION
HOT ALIGNMENT OF COMPRESSOR/MOTOR
COMPRESSOR UNIT OIL
Hot alignments can only be made after the unit has operated for several hours and all components are at operating
temperatures.
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.
Shut down the unit and quickly affix 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 0O and 180O 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 specified tolerance.
Use of oils other than Frick Oil must
be approved in writing by Frick engineering or warranty claim may be
denied.
Use of filter elements other than
Frick must be approved in writing
by Frick engineering or warranty
claim may be denied.
The oil charge shipped with the unit is the best suited lubricant for the conditions specified at the time of purchase. If
there is any doubt due to the refrigerant, operating pressures, or temperatures; refer to Frick Pub. E160-802 SPC
for guidance.
INSTALL COUPLING GUARD BEFORE OPERATING COMPRESSOR.
CHECKING MOTOR/COMPRESSOR
ROTATION
COMPRESSOR ROTATION IS CLOCKWISE WHEN FACING THE END OF THE COMPRESSOR SHAFT. Under NO
conditions should the motor rotation be checked with the
coupling center installed as damage to the compressor may
result.
COMPRESSOR
OIL CHARGE
The normal charging level is midway in the top sight glass
located midway along the oil separator shell. Normal operating level is between the top sight glass and bottom sight
glass. The following table gives the approximate oil charge
quantity.
TABLE - BASIC OIL CHARGE (Gal)
MODEL
BASIC CHARGE* (GAL.)
12
15
19
24
30
39
50
10
10
14
14
17
17
21
* Add oil volume for external oil cooler, according to cooler
size selected: 6 x 5 TSOC - 4 gal.; 6 x 5 WCOC - 5 gal.; 8 x
5 TSOC - 6-1/2 gal.; and 8 x 5 WCOC - 8 gal.
HOLDING CHARGE AND STORAGE
Each compressor unit is pressure and leak tested at the
Frick 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.
NOTE: Care must be taken when entering the unit to
ensure that the nitrogen charge is safely released.
All units must be kept in a clean, dry location to prevent
corrosion damage. Reasonable consideration must be given
to proper care for the solid state components of the microprocessor. Unit which will be stored for more than two
months must have the nitrogen charge checked periodically.
Add oil by attaching the end of a suitable pressure type
hose to the oil charging valve, located on the top of the oil
separator on the compressor end of the separator. Using a
pressure-type pump and the recommended Frick oil, open
the charging valve and pump oil into the separator.
Oil distillers and similar equipment which act to trap oil must
be filled prior to unit operation to normal design outlet levels. The same pump used to charge the unit may be used
for filling these auxiliary oil reservoirs.
NOTE: The sight glass, located near the bottom of the
separator shell at the discharge end, should remain
empty when the unit is in operation. The presence of oil
in this end of the vessel during operation indicates liquid carryover or malfunction of the oil return.
OIL HEATER
Standard units are equipped with a 500 watt oil heater, providing sufficient heat to maintain the oil temperature for most
indoor applications during shutdown cycles to permit safe
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
INSTALLATION
start-up. Should additional heating capacity be required
because of unusual environmental condition, contact Frick
Company. The heater is energized only when the unit is not
in operation.
DO NOT ENERGIZE THE HEATER
WHEN THERE IS NO OIL IN THE
UNIT, OTHERWISE THE HEATER
WILL BURN OUT. THE OIL HEATER WILL BE ENERGIZED
WHENEVER 120 VOLT CONTROL POWER IS APPLIED
TO THE UNIT AND THE COMPRESSOR IS NOT RUNNING
UNLESS THE 10 AMP FUSE (1FU) IN THE CONTROL
PANEL IS REMOVED.
S70-101 IOM
Page 9
Where low compression ratios (low condensing pressures)
are anticipated, thermosyphon or water-cooled oil cooling
should be used. It is IMPERATIVE that an uninterrupted
supply of high pressure liquid refrigerant be provided to the
injection system at all times. Two items of EXTREME IMPORTANCE are the design of the receiver/liquid injection
supply and the size of the liquid line. It is recommended that
the receiver be oversized sufficiently to retain a 5 minute
supply of refrigerant for oil cooling. The evaporator supply
must be secondary to this consideration. Two methods of
accomplishing this are shown.
DUAL DIP TUBE METHOD
LIQUID INJECTION OIL COOLING
The liquid injection system provided on the unit is self-contained but requires the connection of the liquid line sized as
shown in the table and careful insertion of the expansion
valve bulb into the thermowell provided in the separator. High
pressure gas is connected through the regulator to the external port on the liquid injection valve to control oil temperature. Refer to the liquid injection piping diagram.
The dual dip tube method uses two dip tubes in the receiver. The liquid injection tube is below the evaporator tube to
ensure continued oil cooling when the receiver level is low.
NOTE: For booster applications, the high pressure gas
connection must be taken from a high side source (highstage compressor discharge). This should be a minimum
3/8" line connected into the solenoid valve provided. This
gas is required by the expansion valve external port to
control oil temperature.
High-stage compressor units may be supplied with singleport (low Vi) or dual-port (low Vi and high Vi), liquid injection
oil cooling. Single port will be furnished for low compression
ratio operation and dual port for high compression ratio operation. Booster compressor units use single-port, liquid injection oil cooling due to the typically lower compression
ratios.
The control system on high-stage units with dual-port, liquid
injection oil cooling switches the liquid refrigerant supply to
the high port when the compressor is operating at higher
compression ratios (3.5 Vi and above) for best efficiency.
The following table gives the condensing temperature(s) with
the corresponding maximum evaporator temperature limit
for liquid injection usage and the minimum evaporator temperature for a single-port application.
TABLE - EVAPORATOR TEMPERATURE with
SINGLE-PORT LIQUID INJECTION
CONDENSING
TEMP
75OF
85OF
95OF
105OF
MAXIMUM
EVAPORATOR
TEMPERATURE FOR
LIQUID INJECTION
USAGE
MINIMUM *
EVAP TEMP
FOR
SINGLE PORT
(LOW Vi)
R-717
R-717 & R-22
+10OF
+25OF
+35OF
+40OF
R-22
+5OF
+15OF
+25OF
+35OF
-23OF
-17OF
-11OF
- 4OF
* Dual Injection Kit will be shipped by Frick
below these temperatures.
LEVEL CONTROL METHOD
The level control method utilizes a float level control on the
receiver to close a solenoid valve feeding the evaporator
when the liquid falls below that amount necessary for 5 minutes of liquid injection oil cooling.
S70-101 IOM
Page 10
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
INSTALLATION
Liquid line sizes and the additional receiver volume (quantity of refrigerant required for 5 minutes of liquid injection oil
cooling) are given in the following table:
LIQ. LINE SIZE*
PIPE
SCH 80
TUBING
OD
FLOW
RATE
(lb.)
5 MIN
HIGH
STAGE
R-717
12
15
19
24
30
39
50
1/2
1/2
1/2
1/2
1/2
1/2
3/4
–
–
–
–
–
–
–
10
12.5
15
20
25
30
40
.3
.4
.4
.6
.7
8
1.1
HIGH
STAGE
R-22
12
15
19
24
30
39
50
3/4
3/4
3/4
3/4
3/4
3/4
1
5/8
5/8
5/8
7/8
7/8
7/8
1
30
37.5
45
60
75
95
125
.4
.5
.6
.8
1.0
1.3
1.7
BOOSTER
R-717
12
15
19
24
30
39
50
1/2
1/2
1/2
1/2
1/2
1/2
1/2
–
–
–
–
–
–
–-
2
2.5
3.5
4.5
5.5
6.5
8.5
.1
.1
.1
.1
.2
.2
.3
BOOSTER
R-22
12
15
19
24
30
39
50
3/4
3/4
3/4
3/4
3/4
3/4
3/4
1/2
1/2
1/2
1/2
1/2
1/2
5/8
6
7
9
12
14.5
18
24
.1
.1
.1
.2
.2
.3
.3
REF
RXB
MODEL
LIQUID
VOLUME
CU.FT.
* 100 ft. liquid line. For longer runs, increase line size accordingly.
WATER-COOLED OIL COOLING (OPTIONAL)
The shell and tube-type, water-cooled oil cooler is mounted
on the unit complete with all oil piping. The customer must
supply adequate water connections and install the two-way
water regulating valve. It is recommended that (local codes
permitting) the water regulator be installed on the water outlet
connection. Insert the water regulator valve bulb and well in
the chamber provided on the oil outlet connection. Determine the size of the water-cooled oil cooler supplied with
the unit, then refer to table for the water connection size
and water flow range (GPM). The water supply must be
sufficient to meet the required flow.
It is imperative that the condition of cooling water and closed
loop fluids be analyzed and maintained regularly and as
necessary to prevent corrosion of heat exchanger surfaces.
The oxygen content of river water and some other cooling
water sources will oxidize steel tubes and cause premature
failure. Careful attention to water treatment is essential to
ensure adequate life of steel cooler tubes if cooling tower
water is used. The condition of heat exchanger tubes should
be checked semiannually to prevent hazard.
OIL COOLER DATA TABLE
SIZE - Inches
COOLER
WATER CONN
APPROX
WATER FLOW
RANGE (GPM)
5 Foot Lengths
6" DIA.
8" DIA.
1 NPT
1-1/4 NPT
10 – 23
35 – 60
NOTE: The water regulating valve shipped with the unit
will be sized to the specific flow for the unit.
THERMOSYPHON OIL COOLING (OPTIONAL)
Thermosyphon oil cooling is an economical, effective method
for cooling oil on screw compressor units. Thermosyphon
cooling utilizes liquid refrigerant at condenser pressure and
temperature which is partially vaporized at the condenser
temperature in a shell and tube- or plate-type vessel cooling the oil to within 15OF of that temperature. The vapor, at
condensing pressure, is vented to the condenser inlet and
reliquified. This method is the most cost effective of all currently applied cooling systems since no compressor capacity is lost or compressor power penalties incurred. The vapor from the cooler need only be condensed, not compressed. Refrigerant flow to the cooler is automatic, driven
by the thermosyphon principle, and cooling flow increases
as the oil inlet temperature rises.
EQUIPMENT - The basic equipment required for a thermosyphon system consists of:
1. A source of liquid refrigerant at condensing pressure and
temperature located in close proximity to the unit to minimize piping pressure drop. The liquid level in the refrigerant
source must be 6 to 8 feet above the center of the oil cooler.
2. A shell and tube- or plate-type oil cooler with a 300 psi
minimum design working pressure on both the oil and refrigerant sides.
Due to the many variations in refrigeration system design
and physical layout, several systems for ensuring the above
criteria are possible.
SYSTEM OPERATION - Liquid refrigerant fills the cooler
tube side up to the Thermosyphon receiver liquid level.
Water or hot oil (above the liquid temperature) flowing
through the cooler will cause some of the refrigerant to boil
and vaporize in the tubes. The vapor rises in the return line.
The density of the refrigerant liquid/vapor mixture in the return line is considerably less than the density of the liquid in
the supply line. This imbalance provides a differential pressure that sustains a flow condition 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.
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
INSTALLATION
Current thermosyphon systems are using two-pass oil coolers and flow rates based on 4:1 overfeed.
The liquid/vapor returned from the cooler is separated in the
receiver. The vapor is vented to the condenser inlet and need
only be reliquified since it is still at condenser pressure.
S70-101 IOM
Page 11
TSOC AND WCOC OPTIONAL OIL SIDE SAFETY RELIEF
- Compressor units, which have valves in the oil piping to
isolate the oil cooler from the oil separator for servicing,
may have factory installed piping to relieve the shell side
(oil side) safety valve directly into the oil separator, as shown
in the P & I diagrams on pages 58 through 60.
INSTALLATION - The shell and tube-type thermosyphon oil
cooler with oil-side piping and a thermostatically controlled
mixing valve (if ordered) are factory mounted and piped. The
customer must supply and install all piping and equipment
located outside of the shaded area on the piping diagram
with consideration given to the following:
This arrangement uses a special UV stamped safety valve
rated for liquid and vapor relief. The safety valve is designed
for 500 psi DWP and is set to relieve at 75 psi delta P. The
safety valve piping contains flanged connections should the
valve require maintenance or replacement.
1. The refrigerant source, thermosyphon or system receiver, should be in close proximity to the unit to minimize piping
pressure drop.
Extra caution should be used when servicing an oil separator with this arrangement. If the oil cooler is valved off
from an oil separator which has been evacuated for servicing, then the oil cooler could relieve into the separator vessel if the 75 psi delta p setpoint is exceeded.
2. The liquid level in the refrigerant source must be 6 to 8
feet above the center of the oil cooler.
3. A safety valve should be installed if refrigerant isolation
valves are used for the oil cooler.
4. Frick recommends the installation of an angle valve in the
piping before the thermosyphon oil cooler to balance the
thermosyphon system. Frick also recommends the installation of sight glasses at the TSOC inlet and outlet to aid in
troubleshooting. The factory-mounted, plate-type thermosyphon oil cooler requires a refrigerant-side drain valve
to be provided and installed by the customer.
Other units, which do not use this special safety valve arrangement, will have factory mounted safety valves on the
shell side of the oil cooler which the installing contractor
should pipe into house safety systems designated suitable
for oil relief.
The component and piping arrangement shown below is intended only to illustrate the operating principles of thermosyphon oil cooling. Other component layouts may be better suited
to a specific installation. Refer to publication E70-900E for additional information on Thermosyphon Oil Cooling.
SYSTEM
CONDENSER
VAPOR
SAFETY
STATIC HEAD
VALVE
TO OVERCOME
CONDENSER
PRESSURE DROP
3
THERMOSYPHON
RECEIVER
LIQUID
LEVEL
OIL TEMP
CONTROL VALVE
8 Ft.
Min.
A
B
LIQUID OVERFLOW
DRAIN TO RECEIVER
C
COOL
HOT
2
OIL OUT
4
THERMOSYPHON
OIL COOLER
HOT OIL IN
TSOCA
TO SYSTEM
EVAPORATOR
SYSTEM
1
Refrigerant-side drain valve
required for plate-type
thermosyphon oil coolers.
RECEIVER
(Mounted below Thermosyphon
receiver level)
1. The thermosyphon oil cooler is supplied with the oil side piped to the compressor unit and stub ends supplied on the refrigerant side.
2. A three-way oil temperature control valve is required where condensing temperature is expected to go below 65OF.
3. A refrigerant-side safety valve is required in this location only when refrigerant isolation valves are installed between the cooler
and thermosyphon 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.
S70-101 IOM
Page 12
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
INSTALLATION
ECONOMIZER - HIGH STAGE (OPTIONAL)
The economizer option provides an increase in system capacity and efficiency by subcooling liquid from the condenser
through a heat exchanger or flash tank before it goes to the
evaporator. The subcooling is provided by flashing liquid in
the economizer cooler to an intermediate pressure level.The
intermediate pressure is provided by a port located part way
down the compression process on the screw compressor.
As the screw compressor unloads, the economizer port will
drop in pressure level, eventually being fully open to suction. Because of this, an output from the microprocessor is
generally used to turn off the supply of flashing liquid on a
shell and coil or DX economizer when the capacity falls below approximately 45%-60% capacity (85%-90% slide valve
position). This is done because the compressor will be more
efficient 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 shell and coil and DX economizers can be used at low
compressor capacities in cases where efficiency is not as
important as ensuring that the liquid supply is subcooled. In
such cases, the economizer liquid solenoid can be programmed to be left open whenever the compressor is running.
ticipated in the flash economizer vessel, it may be necessary to add an outlet pressure regulator to the flash vessel
outlet to avoid overpressurizing the economizer port, which
could result in motor overload. Example: A system feeding
liquid to the flash vessel in batches.
The recommended economizer systems are shown below.
Notice that in all systems there should be a strainer (STR)
and a check valve (VCK) between the economizer vessel
and the economizer port on the compressor. The strainer
prevents dirt from passing into the compressor and the check
valve prevents oil from flowing from the compressor unit to
the economizer vessel during shutdown.
Other than the isolation valve
needed for strainer cleaning, it is
essential that the strainer be the
last device in the economizer line before the compressor. Also, piston-type check valves are recommended
for installation in the economizer line, as opposed to
disc-type check valves. The latter are more prone to gaspulsation-induced failure. The isolation and check valves and strainer should be located as closely as possible to the compressor, preferably within a few feet.
Due to the tendency of the port pressure to fall with decreasing compressor capacity, a back-pressure regulator
valve (BPR) is generally required on a flash economizer
system (FIG. 3) in order to maintain some preset pressure
difference between the subcooled liquid in the flash vessel
and the evaporators. If the back-pressure regulator valve is
not used on a flash economizer, it is possible that no pressure difference will exist to drive liquid from the flash vessel
to the evaporators, since the flash vessel will be at suction
pressure. In cases where wide swings in pressure are an-
For refrigeration plants employing multiple compressors on
a common economizing vessel, regardless of economizer
type, each compressor must have a back-pressure regulating valve in order to balance the economizer load, or gas
flow, 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 flash vessel, there is no need for
the redundancy of a back-pressure regulating valve on the
vessel and each of the multiple compressors. Omit the BPR
valve on the flash economizer vessel and use one on each
compressor, as shown in FIG. 4.
FIG. 1 - SHELL and COIL ECONOMIZER SYSTEM
FIG. 3- FLASH ECONOMIZER SYSTEM
FIG. 2 - DIRECT EXPANSION ECONOMIZER SYSTEM
FIG. 4 -MULTIPLE COMPRESSOR ECONOMIZER SYSTEM
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
INSTALLATION
ELECTRICAL
NOTE: Before proceeding with electrical installation, read
the instructions in the section “Proper Installation of
Electronic Equipment in an Industrial Environment”.
RXB PLUS units are supplied with a SBC (single-board computer) microprocessor control system. Care must be taken
that the controls are not exposed to physical damage during handling, storage, and installation. The microprocessor
enclosure cover must be kept tightly closed to prevent entry
of moisture and foreign matter.
Customer-control power connections are made at the BOTTOM of
the microprocessor enclosure.
Consult local ordinances before installation. Current
transformer wiring should be kept separate. Extreme
care should be taken that metal filings or other foreign
material is not left in the microprocessor enclosure. Use
seal-tight conduit fittings to prevent moisture entry into
the microprocessor enclosure. This is the ONLY electrical enclosure that should be opened during installation
and it should be kept tightly closed whenever work is
not being performed in it.
S70-101 IOM
Page 13
1. The compressor motor starter of the specified HP and
voltage for the starting method specified (across-the-line,
autotransformer, wye-delta, or solid state).
NOTE: If starting methods other than across-the-line are
desired, a motor/compressor torque analysis must be
done to ensure that sufficient starting torque is available, particularly in booster applications. Contact FRICK
Company if assistance is required.
2. If specified, the starter package can be supplied as a
combination starter with circuit breaker disconnect. However, the motor overcurrent protection/disconnection device
can be supplied by others, usually as a part of an electrical
power distribution board.
3. A 2.0 KVA control power transformer (CPT), to supply
120 volt control power to the control system and separator
oil heaters, is included. If environmental conditions require
more than a 500 watt oil heater, an appropriately oversized
control transformer will be required.
4. One (1) normally open, compressor-motor-starter auxiliary contact and 1 normally open, oil-pump-motor-starter
auxiliary contact (opt.) should be supplied and wired as
shown on the starter package wiring diagram. In addition,
the compressor and oil pump motor starter (opt.) coils and
the CPT secondaries should be wired as shown on starter
package wiring diagram.
5. The compressor motor Current Transformer (CT) can be
installed on any one phase of the compressor leads. NOTE:
The CT must see all the current on any one phase; therefore in wye-delta applications, BOTH leads of any one
phase must pass through the CT.
6. Oil Pump Option: If the optional oil pump is specified, an
oil pump starter must be a component of the unit starter
package. The pump starter should be equipped with fuses
or, in the case where the compressor motor is a different
voltage from the oil pump motor, a circuit breaker disconnect suitable for separate power feed.
NOTE: Do not install a compressor HAND/OFF/AUTO
switch in the starter package as this would bypass the
compressor safety devices.
NOTE: Customer ground required, see Micro Panel Assembly Wiring Diagram.
MOTOR STARTER PACKAGE
Motor starter and interlock wiring requirements are shown
in the wiring diagram, above. All the equipment shown is
supplied by the installer unless a starter package is purchased from Frick . Starter packages should consist of:
NOTE: When compressor motor voltage is different from
oil pump motor voltage, supply a circuit breaker disconnect for separate feed in lieu of fuses.
S70-101 IOM
Page 14
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
INSTALLATION
CURRENT TRANSFORMER (CT) RATIOS
BATTERY BACKUP
The CT ratio for various motor sizes (with a 5 amp secondary) is given in the following table:
The battery backup prevents data loss during power interruption. It will maintain the adjustable setpoints stored in
RAM (Random Access Memory) for up to 1 year after power
loss. Expected battery life is 10 years. A trickle charge maintains the battery backup at peak charge when control voltage is present.
VOLTAGE
HP
200
230
380
460
575
2300
4160
20
25
30
40
50
60
75
100
125
150
200
250
100:5
100:5
200:5
200:5
200:5
300:5
300:5
400:5
500:5
500:5
800:5
800:5
100:5
100:5
100:5
200:5
200:5
200:5
300:5
300:5
400:5
500:5
600:5
800:5
100:5
100:5
100:5
100:5
100:5
200:5
200:5
200:5
300:5
300:5
400:5
500:5
100:5
100:5
100:5
100:5
100:5
100:5
200:5
200:5
200:5
300:5
300:5
400:5
100:5
100:5
100:5
100:5
100:5
100:5
100:5
200:5
200:5
200:5
300:5
300:5
100:5
100:5
50:5
50:5
MINIMUM 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
ANSI
VA
B-0.1
B-0.2
B-0.5
2.5
5
12.5
MAXIMUM DISTANCE FROM
FRICK PANEL
USING #
USING #
USING #
14 AWG
12 AWG
10 AWG
15 ft
35 ft
93 ft
25 ft
55 ft
148 ft
40 ft
88 ft
236 ft
In addition to the starter package interlocks shown on the
starter package diagram, the following optional interlocks
are on the typical RXB PLUS Screw Compressor unit with
the SBC Microprocessor Control System wiring diagram:
1. Remote LOAD, UNLOAD, and RUN interlocks in case the
customer desires to operate the unit from a remote control
device.
2. Alarm Horn output.
3. Control solenoid valve for the economizer option.
For customer control options, consult FRICK Company.
NOTE: The microprocessor will not operate without
EPROM chips installed. When EPROM chips are not installed, the microprocessor display will typically indicate two dark lines across both the upper and lower display screens.
To prevent power loss, the battery backup is shipped disabled. To enable the battery backup, a jumper pin located
near the top of the microprocessor circuit board (see illustration page 52) must be moved from OFF (pins 1-2) to ON
(pins 2-3).
NOTE: It is not necessary to disconnect the battery
backup during extended downtime.
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
OPERATION
S70-101 IOM
Page 15
OPERATION and START-UP INSTRUCTIONS
GENERAL INFORMATION
The Frick RXB PLUS Rotary Screw Compressor Unit is an
integrated system consisting of six major subsystems:
1. Microprocessor Control Panel
2. Compressor
3. Compressor Lubrication System
4. Compressor Oil Separation System
5. Compressor Hydraulic System
6. Compressor Oil Cooling System
The information in this section of the manual provides the
logical step-by-step instructions to properly start up and operate the RXB PLUS Rotary Screw Compressor Unit.
THE FOLLOWING SUBSECTIONS MUST BE READ AND
UNDERSTOOD BEFORE ATTEMPTING TO START OR
OPERATE THE UNIT.
MICROPROCESSOR CONTROL PANEL
The RXB PLUS compressor is controlled by a state-ofthe-art microprocessor control system. The microprocessor
continuously monitors the compressor unit’s condition and
operation. The microprocessor also directs instructions to
the various compressor unit subsystems.
sor auxiliary systems such as the oil pump and liquid injection solenoid. THE EMERGENCY STOP BUTTON IS FOR
EMERGENCY SHUTDOWN SITUATIONS ONLY and
MUST NOT BE USED TO ROUTINELY SHUT OFF THE
COMPRESSOR.
The microprocessor has a membrane switch keyboard.
Pressing the keyboard in the area outlined as a key will cause
that function to be recognized by the microprocessor. The
keyboard has 32 membrane-type keys.
The microprocessor continuously monitors the state of the
battery which maintains setpoints and various other data. If
the battery voltage is low, the message “LOW BATT” will
flash in the lower right hand corner of the bottom display
(see page 14 for description of battery backup).
In addition to the keyboard, there is an emergency stop button. Pushing the emergency stop will bypass the computer
and remove all power from the outputs. This will shut down
the compressor motor and all high voltage to the compres-
The microprocessor hardware contains an output watchdog circuit. If the microprocessor should fail, this circuit will
disable (turn off) all outputs.
S70-101 IOM
Page 16
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
OPERATION
Revised 2/95
KEYS AND KEY FUNCTIONS
NOTE: The microprocessor will automatically return to
the main operating display after 60 seconds of keyboard nonactivity.
The [CHANGE] key rotates the dual display screen through
six display modes. The [CHANGE] key is also used to change
the status of various setpoints.
The [STEP] key steps or moves a set of flashing brackets
through the variable setpoints on the Adjustable setpoints
display, the Auto-cycle display, the Security display and the
Setback display. The setpoint enclosed within the flashing
brackets may be changed or updated. The [STEP] key is
also used when the Annunciator display is selected to step
through the annunciator’s four information displays.
NOTE: The [ * ] key is used to step or move the flashing
brackets, described above, backwards.
The [ENTER] key is used to enter new setpoint limits.
The [CLEAR] key will reset an alarm or cutout indication on
the annunciator screen and will clear the microprocessor to
allow continued operation or restarting if all conditions have
returned to normal and no other control lockouts are in force.
The [NUMERIC KEYPAD] is used to introduce new setpoint
limits.
The [+/-] key is used to toggle between pounds per square
inch gauge (g) and inches of mercury (hg).
The [RUN], [STOP], and [REMOTE START] keys control
the starting and stopping of the compressor unit.
The [ALARM SILENCE] key will de-energize the alarm horn
output.
The [AUTO], [REMOTE], and [MANUAL] keys control the
operation of the compressor slide valve.
The [AUTO], [MANUAL 2.2], [MANUAL 3.5], and [MANUAL
5.0] keys control the operation of the compressor slide stop.
The [F1] function key will return the operator to the main
operating display. This function may be invoked at any time,
even during setpoint entry.
The [F2] function key will call up the Security display. NOTE:
Press the [F2] key, as prompted by the display, to return
to the previously selected display.
The [F3] function key will call up the Setback display. NOTE:
To exit the Setback display, press the [F1] key as
prompted by the display.
The [F4] function key will call up the Auto Cycle display.
NOTE: To exit the Auto Cycle display, press the [F1] key
as prompted by the display.
The microprocessor has two liquid crystal displays in an 8
line by 40 character format, for a total of 320 characters.
When power is first applied to the control panel, the unit will
be in the Operating display mode. To change to a different
display mode, press the [CHANGE] key. The display modes
in their order of rotation are:
*Display for illustrative purposes only.
1.
2.
3.
4.
5.
Operating displays
Setpoints displays
Annunciator displays
Shutdown Record displays
Freeze displays
[F1]
[F2]
[F3]
[F4]
Operating display
Security display
Setback display
Auto Cycle display
NOTE: On initial powering of the microprocessor, and
any time power has been removed from the microprocessor, only the Operating, Setpoints, Annunciator, and
Shutdown displays will display information. The Freeze
display will appear as a dark screen. The Freeze display
will only be present after a compressor unit cutout.
OPERATING DISPLAY *, Pages 1 and 2
OP.DISPLAY PAGE 1 Thu 03-01-89 15:33:36
Suction Disch
Oil
Compressor
14.3 hg 024 g
060 g
Man Mode
Running
-040OF 135OF 135OF
OP.DISPLAY PAGE 2 Thu 03-01-89 15:33:36
V Ratio S V Pos Pump
%FLA Sep 132OF
2.2
070%
on
096%
HTR off
Auto
Auto U
OPERATING DISPLAY, Page 1
The Operating display is continuously updated and provides
a variety of information in regard to the current status of the
compressor’s condition and performance.
The information furnished by the Operating display is as follows:
The DAY, DATE, and TIME are displayed at the top right of
the display.
NOTE: To set day, date, and time, see TO CHANGE THE
ADJUSTABLE SETPOINTS.
SUCTION - Suction Pressure and Temperature are measured at the compressor inlet and are, respectively, displayed
in pounds per square inch gauge (g) or inches of mercury
(hg) and degrees Fahrenheit.
DISCH - Discharge Pressure and Temperature are measured at the compressor outlet and are, respectively, displayed
in pounds per square inch gauge (g) and degrees Fahrenheit.
OIL - Oil Pressure and Temperature are measured prior to
entering the compressor and are, respectively, displayed in
pounds per square inch gauge (g) and degrees Fahrenheit.
ALARM/CUTOUT - An Alarm or Cutout message indicates
an Alarm or Cutout setpoint has been reached, or exceeded.
Rotate the display mode to the Annunciator display for details. In the event of a cutout, rotate to the Freeze display for
further details.
COMPRESSOR - The compressor displays the status of the
compressor unit. The mode of operation will be indicated as
either manual (Man Mode) when the [RUN] key has been
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
OPERATION
pressed, automatic (AUTO MODE) when Auto Cycle has
been activated, remote (RMT MODE) when the [REMOTE]
key has been pressed, or off (OFF MODE).
RECYCLE DELAY - A Recycle Delay message indicates
that the compressor has started and has shut down within
the time delay setpoint period. The Recycle Delay will prevent the compressor from starting until the delay time expires and is intended to prevent damage to the compressor
motor from successive restarts. During Recycle Delay, the
microprocessor will alternatively flash “RECYCLE DELAY”
and the remaining delay time in minutes.
NOTE: Consult Motor Manufacturer for the recommended duration of the Recycle Delay.
If the [RUN] key is pushed while
the unit is in Recycle Delay, the
compressor will start at the end of
the delay period.
S70-101 IOM
Page 17
SETPOINTS PAGE 1B
Dead Band--[/./#]
Prop. Band--[/ / %]
Cycle Time--[/ / sec]
LOW % FLA---[/ / / %]
SETPOINTS PAGE 2
MLC Stop LD-[095%]
CT Factor-[078]
MLC Force ULD[100%]
Aux1[Alarm] [NO] Hi Disch Cutout-[050 g ]
Aux2[Shutd] [NO] Hi Disch Alarm—[045 g ]
SETPOINTS PAGE 3 HIGH STAGE RXB NP-22
PB-[10%
DB-[1.0 #]
Oil Heater ----- [113F] Liq Inj Con ------- [122F]
Hi Disch Cut - [212F] Hi Disch Alarm - [194F]
OPERATING DISPLAY, Page 2
V RATIO - Volume Ratio is the ratio selected by the microprocessor to provide the highest efficiency at any given suction and discharge pressure condition. Immediately below
this, an information space has been provided to indicate
whether V ratio is in the automatic (AUTO) or the manual
(MAN) mode.
SV POS - Slide valve position is displayed as a percentage.
This percentage reflects the mechanical position of the slide
valve and does not reflect the percentage of full load operation. Immediately below this information, space has been
provided to indicate whether SV Pos is in the automatic
(AUTO), manual (MAN), or remote (RMT) mode. The microprocessor will control this function in the automatic mode.
To the right of the mode indicator, two other messages may
appear:
L - Indicates Slide Valve loading.
U - Indicates Slide Valve unloading.
SETPOINTS PAGE 4
Hi Oil Temp Cutout -- [167F] Alarm -- [158F]
Lo Oil Temp Cutout -- [49F] Alarm -- [58F]
Lo Oil Press. Cutout -- [005]
Alarm -- [010]
The information furnished by these displays is as follows:
SETPOINTS DISPLAY, Page 1A:
CAP CONTROL - The Capacity Control setpoint, reported
in pounds per square inch gauge (g) or inches of mercury
(hg), controls the loading and unloading of the compressor
when Capacity is in the automatic (AUTO) mode.
LO SUCT CUTOUT - The Low Suction Pressure Cutout,
reported in pounds per square inch gauge (g) or inches of
mercury (hg), will shut down the compressor if the suction
pressure drops to this limit or lower, for 90 seconds or longer.
PUMP (Optional) - Pump displays the current status of the
oil pump. The display will read ON or OFF whenever the
HAND-OFF-AUTO switch is selected to AUTO and the compressor is running.
LO SUCT ALARM - The Low Suction Pressure Alarm, reported in pounds per square inch gauge (g) or inches of
mercury (hg), will trigger a prealarm if the suction pressure
drops to this limit or lower.
% FLA - Percent Full-Load Amps displays the percentage
of the drive motor, full-load amperage rating that the motor
is currently using.
ID - The ID number is a programmable identification code used
in telecommunications to access a specific compressor.
SEP - Separator displays the oil separator temperature in
degrees Fahrenheit.
DATE - The Date displays the current date in the following
format: Month - Day - Year.
HTR - Heater displays the condition of the oil separator
heater(s), indicating ON or OFF.
DAY - Day will display the current day of the week.
FORCED UNLD - A Forced Unload message indicates that
the percentage of motor, full-load amps has exceeded the
maximum limit and the microprocessor is unloading the compressor until the percentage FLA falls back to normal limits.
TIME - The Time displays the current time in the following
format: Hours - Minutes - Seconds. The time is in 24:00:00
hour clock format.
SETPOINTS DISPLAY *
SETPOINTS PAGE 1A ID=[33] [03-01-89]
Cap. Control ----- [14.3 hg] Thu [15:33:36]
Lo Suct Cutout - [20.0 hg] Baud----[ 2400]
Lo Suct Alarm -- [18.0 hg] Recy.Delay-[30]
*Display for illustrative purposes only.
BAUD - Shows the baud rate of the RS422 communication
port. Both ports are configured as follows: word = 8 bit, parity = none or even, stop = 1 bit. The communications port is
programmable from 300 to 19200 baud.
RECY. DELAY - The Recycle Delay displays the current
recycle delay setpoint in minutes. NOTE: Consult the motor manufacturer for recommended setpoint.
S70-101 IOM
Page 18
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
OPERATION
SETPOINTS DISPLAY, Page 1B:
Dead Band - This is a + (plus) or - (minus) value above or
below the setpoint at which the compressor will neither load
nor unload. A dead band of 1 is the default value. It is adjustable between .5 lb to 5 lb in increments of .5. The [Step]
key is used to select this setpoint; then press the [Change]
key to toggle through the selections.
Proportional Band - This setpoint is used to determine the
amount of time the load/unload solenoid is energized, according to how far from the setpoint the actual control pressure is. The smaller the number, the longer a load/unload
signal will be sent; 10% is the default value. Selections are
2, 5, 10, 15, 20, or 25%. The [Step] key is used to select this
setpoint; then press the [Change] key to toggle through the
selections.
Cycle Time - Cycle time is the amount of time between the
beginning of each load/unload response. Ten seconds is
the default value. “Cycle Time” is adjustable between 5 and
30 seconds in 5 second intervals. The [Step] key is used to
select a setpoint; then press the [Change] key to toggle
through the selections.
Low % FLA - This setpoint is used to determine if the coupling has broken; 20% is the default value. It is adjustable
from 0 to 100% FLA. Use the [Step] key to select a setpoint;
then enter the desired setpoint and press the [Enter] key.
SETPOINTS DISPLAY, Page 2:
MLC STOP LD - The Motor Load Control Stop Load, reported as a percentage of the motor, full-load amps (FLA),
will prevent the compressor capacity control pistons from
loading when the setpoint is equaled or exceeded. NOTE:
Consult motor manufacturer for recommended setpoint.
MLC FORCE ULD - The motor Load Control Force Unload,
reported as a percentage of the motor, full-load amps (FLA),
will force the compressor to unload until the motor, full-load
amps (FLA) fall within 1% of the setpoint or lower. NOTE:
Consult motor manufacturer for recommended setpoint.
HI DISCH CUTOUT - The High Discharge Pressure Cutout,
reported in pounds per square inch gauge (g), will shut down
the compressor if the discharge pressure equals or exceeds
this setpoint.
HI DISCH ALARM - The High Discharge Pressure Alarm,
reported in pounds per square inch gauge (g) will trigger a
prealarm if the discharge pressure equals or exceeds this
setpoint.
CT FACTOR - The Current Transformer Factor records the
proper current transformer factor to match the compressor
motor FLA rating to the current transformer primary rating.
The CTF factor is programmable and its correct value is
determined by the following formula:
1024 x FLA (Full Load Amps *)
CTF =
10x CT (Current Transformer Primary Amps **)
* See motor nameplate.
** See CT located in starter panel.
EXAMPLE: FLA = 230 Amps
CT = 300 (300:5)
CTF =
1024 x 230
= 78 (Round to whole number)
10 x 300
AUX 1 and AUX 2 - May be configured for either an alarm or
shutdown and with either a normally closed (NC) or normally open (NO) contact.
TO CHANGE THE ADJUSTABLE SETPOINTS:
Adjustable Setpoints are stored in RAM (random access
memory) and are easily changed in the field.
Adjustable Setpoints are lost if
power is interrupted and the battery is not fully charged. To facilitate reentry, we suggest that a list of Adjustable
Setpoints be affixed to one end of the microprocessor
cabinet for reference.
NOTE:The following procedure also applies to the changing of the Security, Setback, and Auto Cycle display
setpoints.
1. Press the [CHANGE] key to rotate the display to the Adjustable Setpoints display.
2. Press the [STEP] key to move or step a set of flashing
brackets through the various setpoints. A setpoint is selected
for change or update when it is enclosed by the flashing
brackets.
NOTE: The DAY indicator, itself, will flash when selected
for change or update.
3. Having selected the setpoint to be changed, the [NUMERIC KEYPAD] may be used to enter the new setpoint.
NOTE: All digits must be entered, including zeros. For
example, (01.0).
NOTE: The DAY, AUX 1, and AUX 2 setpoints, once selected,
are changed or updated by pressing the [CHANGE] key.
NOTE: Certain setpoints may be reported in either pounds
per square inch gauge (g) or inches of mercury (hg). To
toggle between (g) and (hg), having selected the setpoint,
press the [+/-] key to toggle between (g) and (hg).
4. In the event that an incorrect setpoint is keyed in completely or partially, press the [CLEAR] key to restore the
original setpoint. Pressing the [CLEAR] key a second time
will eliminate the flashing brackets.
5. Having keyed the desired setpoint, press the [ENTER]
key. The new setpoint will be entered and the flashing brackets will move or step to the next setpoint.
NOTE: A setpoint entry outside the parameters of the
Adjustable Setpoint display will be refused and the original Adjustable setpoint will be restored.
NOTE: To clear any time values [STEP] to the desired
setpoint, press [CHANGE] and then press [CLEAR].
HOW TO DETERMINE
ADJUSTABLE SETPOINTS:
Adjustable Setpoints should reflect values compatible with
normal system operation. Too high a Low Suction Pressure
Alarm setpoint may cause nuisance prealarms. Similarly,
cutout setpoints should not fall within what are considered
normal plant operation. As a rule of thumb, set the Low Suction Pressure Alarm 5 PSIG lower than the lowest normal
suction pressure. The Low Suction Pressure Cutout should
be 5 to 10 PSIG lower than the Low Suction Pressure Alarm
setpoint.
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
OPERATION
The High Discharge Pressure Cutout should be set at 90%
of the setting of the lowest high side relief valve. The High
Discharge Pressure Alarm should be set 10 PSIG lower than
the Cutout.
The Capacity Control setpoint should be the equivalent of
the normal suction condition.
FIXED SETPOINTS:
Fixed setpoints define the limits of acceptable compressor
operation. Fixed Setpoints are factory determined, stored in
programmed memory (PROM), and will remain in memory if
power to the microprocessor is interrupted.
SETPOINTS DISPLAY, Page 3:
OIL HEATER - The Oil Heater setpoint, reported in degrees
Fahrenheit, turns on the oil separator heater(s) when the oil
temperature equals or falls below this setpoint whenever the
compressor is NOT running.
LIQ INJ CON - The Liquid Injection Control, reported in degrees Fahrenheit, will shut off the liquid refrigerant supply to
the compressor if the oil temperature equals or falls below
this setpoint.
HI DISCH CUT - The High Discharge Temperature Cutout, reported in degrees Fahrenheit, will shut down the compressor if
the discharge temperature equals or exceeds this setpoint.
HI DISCH ALARM - The High Discharge Temperature Alarm,
reported in degrees Fahrenheit, will trigger a prealarm if the
discharge temperature equals or exceeds this setpoint.
SETPOINTS DISPLAY, Fixed, Page 4:
HI OIL TEMP CUTOUT - The High Oil Temperature Cutout,
reported in degrees Fahrenheit, will shut down the compressor if the oil temperature equals or exceeds this setpoint.
HI OIL TEMP ALARM - The High Oil Temperature Alarm,
reported in degrees Fahrenheit, will trigger a prealarm if the
oil temperature equals or exceeds this setpoint.
LOW OIL TEMP CUTOUT - The Low Oil Temperature Cutout,
reported in degrees Fahrenheit, will shut down the compressor if the oil temperature equals or falls below this setpoint.
LOW OIL TEMP ALARM - The Low Oil Temperature Alarm,
reported in degrees Fahrenheit, will trigger a prealarm if the
oil temperature equals or falls below this setpoint.
LO OIL PRESS CUTOUT - The Low Oil Cutout will shut
down the compressor when the oil pressure equals or falls
below this setpoint.
LO OIL PRESS ALARM - The Low Oil Alarm will trigger a
prealarm when the oil pressure equals or falls below this
setpoint.
When a prealarm or cutout occurs, a flashing ALARM or
CUTOUT indicator will appear in the lower right hand corner
of the Operating display. To determine the fault, rotate to the
Annunciator display by pressing the [CHANGE] key.
The Annunciator display lists all key operative points on nine
sequential displays. These displays can be rotated from page
#1 thru page #9 by pressing the [STEP] key. When a prealarm
or cutout is triggered, the pertinent point will flash and the
time of the occurrence will be recorded to the right of the
alarm.
S70-101 IOM
Page 19
Revised 8/97
ANNUNCIATOR DISPLAY *
ANNUNCIATOR: PG-01 Thu 03-01-89 15:33:36
(Use STEP key to advance PAGE)
High Press. Cutout *********************
High Press. Alarm *********************
ANNUNCIATOR: PG-02 Thu 03-01-89 15:33:36
(Use STEP key to advance PAGE)
Low Press. Cutout *********************
Low Press. Alarm
*********************
ANNUNCIATOR: PG-03 Thu 03-01-89 15:33:36
(Use STEP key to advance PAGE)
Oil Press. Cutout
*********************
Oil Press. Alarm
*********************
ANNUNCIATOR: PG-04 Thu 03-01-89 15:33:36
(Use STEP key to advance PAGE)
Hi Oil Temp Cutout *********************
Hi Oil Temp Alarm *********************
ANNUNCIATOR: PG-05 Thu 03-01-89 15:33:36
(Use STEP key to advance PAGE)
Low Oil Temp Cutout *********************
Low Oil Temp Alarm *********************
ANNUNCIATOR: PG-06 Thu 03-01-89 15:33:36
(Use STEP key to advance PAGE)
Disch. Temp Cutout *********************
Disch. Temp Alarm *********************
ANNUNCIATOR: PG-07 Thu 03-01-89 15:33:36
(Use STEP key to advance PAGE)
Comp. Auxiliary
*********************
Pump Aux. Not Used *********************
ANNUNCIATOR: PG-08 Thu 03-01-89 15:33:36
(Use STEP key to advance PAGE)
Oil Level
*********************
Comp. Differential
*********************
ANNUNCIATOR: PG-09 Thu 03-01-89 15:33:36
(Use STEP key to advance PAGE)
Superheat Cutout
*********************
Superheat Alarm
*********************
ANNUNCIATOR: PG-10Thu 03-01-89 15:33:36
(Use STEP key to advance PAGE)
Aux. 1 (Alarm)
*********************
Aux. 2 (Shutdown) *********************
ANNUNCIATOR: PG-11 Thu 03-01-89 15:33:36
(Use STEP key to advance PAGE)
Low Motor Amps
*********************
Sensor Fault
*********************
*Displays for illustrative purposes only.
S70-101 IOM
Page 20
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
OPERATION
Compressor Differential Cutout - The differential cutout
has been lowered from 55 lb to 25 lb. Cutout will occur after
five minutes. To allow operation at low differential pressures,
the micro will take the following steps:
A. Force unload the compressor to 50% and display an "F
Unload" when the oil pressure is within 10 lb of the main oil
injection port pressure and the slide valve position is greater
than 50%.
B. Prohibit the compressor from loading and display a "Ld
Inhib" message when the differential is within 15 lb of the
main oil injection port pressure.
Oil Pressure Alarm and cutout - Prelube and Cycling Oil
Pump version when pump is not running. Alarm will occur if
oil pressure is 25 lb below discharge pressure or within 10
lb of suction pressure for 30 seconds. Cutout occurs if oil
pressure is 30 lb below discharge pressure or if oil pressure
is within 7 lb of suction pressure for 10 seconds and alarm
has already been set.
Full Lube and Cycling Oil Pump version when oil pump is
running. Alarm occurs if oil pressure is within 10 lb of discharge pressure for 30 seconds. Cutout occurs when oil
pressure is within 5 lb of discharge pressure for 10 seconds
and oil pressure alarm has been set.
Cycling Oil Pump Control - The oil pump will cut off when
differential pressure between suction and discharge pressure is 55 lb or greater. Upon pump termination the above
cutout logic (pump not running) is utilized. Pump cut-in occurs when the differential pressure between suction and discharge is 45 lb or less. Oil pressure alarm and cutout logic
(pump running) begins after a 30 second delay which allows the oil pump to build pressure.
Prealarms are self-clearing. At this time the alarm will stop
flashing, but the time of the first occurrence will still be recorded to the right of the alarm. Pressing the [CLEAR] key
while at the Annunciator display will clear all alarms and/or
cutouts.
In order to restore the Annunciator display and resume normal operation it will be necessary to go through the following steps:
1. Correct the conditions causing the alarm.
2. Press the [ALARM SILENCE] key. (This action may precede correcting the conditions causing the alarm).
3. To clear or reset the Annunciator pages, press the
[CLEAR] key. This will also clear the ALARM or CUTOUT
indicator from the Operating display.
4. Press [F1] to call up the Operating display. If the conditions causing the alarm have not been corrected or a new
fault has occurred, a new ALARM or CUTOUT message
will appear.
NOTE: Use of the Emergency Stop Button may trip one
or more alarm setpoints.
SHUTDOWN RECORD DISPLAY *
SHUTDOWN RECORD P1 Thu 03-01-89 15:33:36
Hi Oil Temp Cutout *********************
Hi Oil Temp Cutout *********************
Low Temp Cutout *********************
SHUTDOWN RECORD P2 Thu 03-01-89 15:33:36
Low Temp Cutout *********************
Disch. Temp Cutout *********************
Disch. Temp Cutout *********************
The Shutdown Record display keeps a record of the last six
shutdowns (cutouts). This information will help troubleshoot
persistent operational problems. The most recent cutout will
appear on the top line of page 1 of the display with the oldest appearing on the last or bottom line of page 2. When a
cutout occurs, all information is moved down one line and
the new cutout appears at the top of page 1. When the display is full, the oldest record is dropped off the display and
is not retained in memory. The information presented is echoed from the Annunciator display, providing the type of cutout, the day, the date, and the time. NOTE: This information will not be lost due to power failure.
FREEZE DISPLAY *
FREEZE DISPLAY P1 Thu 03-01-89 15:33:36
Suction Disch Oil CUTOUT Compressor
14.3 hg 120 g 060 g
OFF Mode
-040 F
135 F 135 F
FREEZE DISPLAY P2 Thu 03-01-89 15:33:36
V Ratio SV Pos
Pump
%FLA Sep 132OF
2.2
000%
off
000%
HTR off
Auto
Auto L
The Freeze display has the same appearance and contains
the same information as the Operating display. (For a description of the information presented by the Freeze display,
refer to the Operating display.) The Freeze display freezes
the information of the Operating display AT THE MOMENT
OF A COMPRESSOR CUTOUT. The information on the
Freeze display can help the operator to identify the cause of
a fault which occurred when no one was present. The Freeze
display will retain the information generated by a cutout until
a new cutout occurs or power is removed from the microprocessor.
Do not confuse the Freeze display
with the Operating display. In order to avoid confusion remember
that the displayed information on the Operating display
is constantly being updated and changed. The Freeze
display is fixed and FREEZE DISPLAY appears in the
upper left hand corner of the display.
NOTE: The Freeze display will appear as a blank screen
when power is initially furnished to the unit, and it will
return to a blank screen anytime power is removed from
the microprocessor.
SECURITY DISPLAY *
SECURITY DISPLAY
Press F2 To Exit
Setpoints Access ---- [Enabled ] Keyboard
Enter Access Code - [*****]
*Display for illustrative purposes only.
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
OPERATION
The [F2] function key will call up the Security display. The
Security display allows the operator to either enable or disable the microprocessor’s keyboard and, thereby, prevent
unauthorized tampering with the various adjustable setpoints.
When enabled, the microprocessor keyboard is fully operative and the security lockout is not in effect. When disabled,
the keyboard is rendered partially nonfunctional. All displays
will still be accessible through the keyboard. If any attempt
is made to enter new adjustable setpoints, however, the microprocessor will default to the Security display.
TO ENABLE THE KEYBOARD, press the [STEP] key so
that the brackets beside Enter Access Code flash; key the
proper five digit access code and press [ENTER]. The
Setpoints Access will toggle from disabled to enabled and
adjustable setpoint entry is now possible.
S70-101 IOM
Page 21
AUTO CYCLE DISPLAY *
AUTO CYCLE
F1 To Exit
Suct.Press.
=[03.5 g ]
Compressor Start Compressor Stop -Min. Cap. Control -Auto Cycle Active --
[20.0 g ]
[18.0 hg]
[050%]
[No ]
The Auto Cycle display is accessed by pressing [F4]. The
Auto Cycle display provides for independently adjustable
setpoints to turn the compressor on and off in response to
the suction pressure or as an adjustable setpoint to limit the
minimum slide valve position.
NOTE: To change the Auto Cycle setpoints, refer to “TO
CHANGE THE ADJUSTABLE SETPOINTS”
TO DISABLE THE KEYBOARD, press the [F2] function key
to call up the Security display; press the [STEP] key until
the brackets beside Enter Access Code flash; key the proper
five digit access code and press [ENTER]. Now press the
[STEP] key until the brackets beside Setpoints Access flash;
and press the [CHANGE] key to toggle from enabled to disabled.
SUCT.PRESS. - Constantly monitors and displays the suction pressure in pounds per square inch gauge (g) or inches
of mercury (hg).
TO CHANGE THE ACCESS CODE, press the [F2] function
key to call up the Security display; press the [STEP] key until
the brackets beside Enter Access Code flash; key the proper
five digit access code and press [ENTER]. Now, select the
Enter Access Code a second time by pressing the [STEP]
key until the brackets beside Setpoints Access flash; key in
the new five digit access code and press [ENTER].
COMPRESSOR STOP - Compressor Stop will shut down
the unit if the suction pressure drops to or below the displayed setpoint limit. NOTE: This limit must be set higher
than Low Suction Pressure Cutout and the Low Suction
Pressure Alarm setpoints.
NOTE: Power loss will not effect the Security display.
NOTE: IF NO ACCESS CODE WAS ENTERED AND THE
DISABLED COMMAND WAS SELECTED, THE ACCESS
CODE IS [00000].
LOST OR FORGOTTEN ACCESS CODE: Consult Frick
Company for assistance.
SETBACK DISPLAY *
SETBACK DISPLAY
Thu 03-01-89 15:33:36
Setback Setpoint-[05.0 g ] Active-[No ]
Mon Start Time-[- -:- -]
F1 To Exit
Stop Time-[- -:- -]
The [F3] function key will call up the Setback display. The
Setback feature enables automatic operation at two separate suction conditions on a preset time schedule. Having
entered the desired Setback setpoint, enter the start and
stop time or times and select Active: (Yes) or (No).
NOTE: To change the Setback setpoints, refer to “TO
CHANGE THE ADJUSTABLE SETPOINTS”
COMPRESSOR START - Compressor Start-up will bring
the compressor back on line when the suction pressure rises
to the displayed setpoint.
MIN. CAP. CONTROL - Minimum Capacity Control, shown
as a percentage, will limit the slide valve position to the displayed setpoint.
AUTO CYCLE ACTIVE - Indicates whether Auto Cycle is
active (YES) or not active (NO). Press the [CHANGE] key
while at this setpoint to change the status. Upon deactivation, the compressor will return to the previous mode of
operation.
ANALOG OFFSET DISPLAY*
ANALOG OFFSET:
Suc Disch Oil
Temp +0
+0
+0
Pres +0.0 +0
+0
Sep
+0
Filt Spare
+0.0
+0
Econ
+0
The Analog Offset Display is accessed by pressing [+/-]
key. All analog values can be offset + or - 3 to 9 units depending on which value is being adjusted. Use the [STEP]
key to step through the desired setpoint. Press the
[CHANGE] key to change the value of the offset by 1. The
actual analog value will be displayed on the top line of the
display. The “Econ” and channels 10, 12, and 13 are displayed but do not pertain to the program.
*Display for illustrative purposes only.
S70-101 IOM
Page 22
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
OPERATION
TEMPERATURE-PRESSURE CONTROL
PROGRAM (OPTION)
NOTE: The following displays are provided only when
the Temperature-Pressure Control Program option has
been ordered with the RXB Plus Rotary Screw Compressor Unit.
SETPOINTS DISPLAY, Page 1 *
SETPOINTS PAGE 1 Capacity Control=Press
C.C. CUTOUT ALARM PB DB
Press 25.3g
01.3g
05.3g
10 1.0
Temp +40.0F +32.0F +33.0F 10 0.5
CT
10
10
The Setpoints Display is accessed by pressing the
[CHANGE] key.
CONTROL - This setpoint is used to select either Pressure
Capacity Control or Temperature Capacity Control. NOTE:
There are only two setpoints, press for pressure capacity control and temp for temperature capacity control.
CC - The capacity control setpoint is for normal operation,
not setback.
CUTOUT -This setpoint will stop the compressor if the suction pressure drops below the pressure setpoint for 90 seconds or if the CC Temperature drops below the temperature
setpoint. There is no time delay on the temperature cutout.
ALARM - An alarm will be activated if the suction pressure
drops below the pressure setpoint or if the CC Temperature
drops below the temperature setpoint. There is no time delay for either.
NOTE: Lo Temp Cutout and Alarm are active when operating in temperature capacity control mode only.
These are failures based on the controlling temperature
input. They precede the auxiliary failures on the annunciator display.
PB - The Proportional Band (PB) is used to determine the
amount of time the load/unload solenoid is energized, according to how far away from the setpoint the actual control
pressure or temperature is. The smaller the number, the more
load/unload will be sent. A PB of 10% is default. It is adjustable to 2, 5, 10, 15, 20, or 25 percent.
DB - The Dead Band (DB) is a + (plus) or - (minus) value
above or below the setpoint which the compressor will neither load nor unload. It is adjustable between .5 and 5.0
psig or degrees, in increments of .5 units.
SETPOINTS DISPLAY, Page 3*
SETPOINTS PAGE 3
offset-act
Sup Heat-Alarm-10F-no
Sep Cond-Alarm-10F-no
ID=[02] [04-09-90]
Mon [01:00:18]
Baud-[19200]
Recycle--[30]
The new setpoints provided on this display allow monitoring
of compressor superheat and condensing in the separator.
The following setpoints apply to the monitoring of the superheat and condensing in the separator.
ALARM/(SHUTDOWN) - The Alarm/(shutdown) setpoints
select the conditions for an alarm or shutdown. If alarm is
selected, the alarm will occur after a 30 second delay. If
shutdown is selected, the shutdown will occur 60 seconds
after the alarm. NOTE: The Superheat Cutout and Alarm
follow the auxiliary failures on the annunciator display
of the TEMPERATURE-PRESSURE CONTROL PROGRAM option. The Sep Cond Alarm and Cutout are new
failure features and are currently the last two listed in
the Annunciator Display for the TEMPERATURE-PRESSURE CONTROL program option.
OFFSET - This setpoint is the degrees F above the saturation-point temperature where the alarm or shutdown will occur.
ACT - The function selects whether the alarm/shutdown is
activated or not.
SETPOINTS DISPLAY, Page 4*
SETPOINTS PAGE 4 Active When Running in
Temperature Cap. Cont.
Low Suction Press Stop Load ------------- [05.0g]
Low Suction Press Force Unload -------- [00.0g]
Low-suction-pressure and motor-load-control features were
added to the TEMPERATURE-PRESSURE CONTROL program and placed on this display. They are active only while
the compressor is operating in Temperature Capacity Control
Mode. The two new setpoints are Low Suction Press Stop
Load and Low Suction Press Force Unload. Both are entered
as a pressure in gauge or inches of mercury (HG). When suction pressure reaches the stop-load setpoint, loading of the
compressor is inhibited. When the suction reaches the forceunload setpoint, the compressor will unload until the suction
pressure is greater than the force-unload setpoint. Control
will then be released to allow normal operation.
SETPOINTS DISPLAY, Pages 5 and 6
CT - The Cycle Time (CT) setpoint is the amount of time
between the beginning of each load/unload response. It is
adjustable to 5, 10, 15, 20, 25, or 30 seconds.
Refer to “SETPOINTS DISPLAY” (FIXED PAGES 1 & 2) on
page 17 and “SETPOINTS DISPLAY, Fixed, Pages 1 and
2:” on page 19.
Use the [STEP] key to step to the desired setpoint, then
press the [CHANGE] key to change the CC, PB, DB, and
CT values. Enter the desired value for the remaining
setpoints and press [ENTER] when complete.
Use the [STEP] key to step to the desired setpoint, then
press the [CHANGE] key to change it. Press [ENTER] when
all desired setpoint changes have been made.
SETBACK DISPLAY *
SETPOINTS DISPLAY, Page 2
Refer to “SETPOINTS DISPLAY” (SETPOINTS PAGE 2) on
page 17 and “SETPOINTS DISPLAY, Page 2:” on page 18.
* Display for illustrative purposes only.
SETBACK DISPLAY:
Press Setpt-[25.3g]
Active-[No ]
F1 to Exit
Mon 04-09-90 01:00:51
Temp Setpt[+50.0F]
Mon Start Time-[- -:- -]
Stop Time-[- -:- -]
The Setback Display is accessed by pressing the [F3] key.
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
OPERATION
S70-101 IOM
Page 23
TEMPERATURE-PRESSURE CONTROL
PROGRAM (OPTION) (continued)
MIN SV - Minimum Slide Valve Position, shown as a percentage, will limit the slide valve position to the displayed
setpoint.
PRESS SETPOINT - The capacity-control setpoint is used
when in the Setback mode and Pressure is selected as the
capacity control desired.
ACTIVE - Indicates whether Auto Cycle is active or not. Press
the [CHANGE] key while at this setpoint to change the status. Upon deactivation, the compressor will return to the
previous mode of operation.
TEMP SETPOINT - The capacity-control setpoint is used
when in the Setback mode and Temperature is selected as
the capacity control desired.
NOTE: To change the Setback setpoints, refer to “TO
CHANGE THE ADJUSTABLE SETPOINTS”.
ANALOG OFFSET DISPLAY*
ANALOG OFFSET:
Suc Disch Oil
Temp +0
+0
0
Pres -1.0
+0 +0
Sep Filt Spare Econ
+0
+0.0
+0
-3
The Analog Offset Display is accessed by pressing [+/-] key.
All analog values can be offset + or - 3 to 10 units depending on which value is being adjusted. Use the [STEP] key to
step to the desired setpoint. Press the [CHANGE] key to
change the value of the offset by 1. The actual analog value
will be displayed on the top line of the display. The “Filt” and
“Econ” and channels are displayed but do not pertain to the
standard program.
AUTO CYCLE PRESS CONTROL DISPLAY *
AUTO CYCLE
Start[40.0 g ] Timer[01 min]
C.C.Press
Stop [25.0 g ] Timer[01 min]
=[35.5 g ]
Min SV-[50%] Active-[No ]
* for Temp Menu, F1 to Exit
The Auto Cycle Pressure Control Display is accessed by
pressing the [F4] key.
The Auto Cycle display provides for independently adjustable setpoints to turn the compressor on and off in response
to the suction pressure or as an adjustable setpoint to limit
the minimum slide valve position. The compressor can be
started and stopped by the following pressure setpoints even
if the capacity control is selected to temperature.
START - The suction pressure must be greater than or equal
to the “START” setpoint in order to start the compressor.
This setpoint works in conjunction with the “TIMER” setpoint
located to the right of it on the display.
(Start) TIMER - This is a time delay used to start the compressor. The timer only accumulates time whenever the pressure rises to or above the “START” setpoint and will reset if
the pressure drops below the “START” setpoint.
STOP - The suction pressure must be less than or equal to
the displayed “STOP” setpoint limit in order to stop the compressor. This setpoint works in conjunction with the “TIMER”
setpoint located to the right of it on the display. NOTE: This
limit must be set higher than Low Suction Pressure Cutout and the Low Suction Pressure Alarm setpoints.
(Stop) TIMER - The (stop) TIMER is a time delay used to
stop the compressor. The timer only accumulates time whenever the pressure drops to or below the “STOP”setpoint and
will reset if the pressure rises above the “STOP” setpoint.
AUTO CYCLE TEMP CONTROL DISPLAY *
AUTO CYCLE
Start[+50.0 F] Timer[01 min]
C.C. Temp
Stop [=20.0 F] Timer[01 min]
=[+44.3 F]
Min SV-[50%] Active-[Yes]
* for Press Menu, F1 to Exit
The Auto Cycle Temperature Control Display is accessed
by pressing [F4] and then the [ * ] keys.
The Auto Cycle display provides for independently adjustable setpoints to turn the compressor on and off in response
to the suction temperature or as an adjustable setpoint to
limit the minimum slide valve position. The compressor can
be started and stopped by the following temperature setpoints,
even if the capacity control is selected to pressure.
START - The CC (capacity control) Temperature must be
greater than or equal to the “START” setpoint in order to
start the compressor. This setpoint works in conjunction with
the “TIMER” setpoint located to the right of it on the display.
(Start) TIMER - This is a time delay used to start the compressor. The timer only accumulates time whenever the CC
Temperature rises to or above the “START” setpoint and
will reset if the CC Temperature drops below the “START”
setpoint.
STOP - The CC Temperature must be less than or equal to
the “STOP” setpoint in order to stop the compressor. This
setpoint works in conjunction with the “TIMER” setpoint located to the right of it on the display.
(Stop) TIMER - The (stop) TIMER is a time delay used to
stop the compressor. The timer only accumulates time whenever the CC Temperature drops to or below the “STOP”
setpoint and will reset if the CC Temperature rises above
the “STOP” setpoint.
MIN SV - Minimum Slide Valve Position, shown as a percentage, will limit the slide valve position to the displayed
setpoint.
ACTIVE - It indicates whether Auto Cycle is active or not.
Press the [CHANGE] key while at this setpoint to change
the status. Upon deactivation, the compressor will return to
the previous mode of operation.
TELECOMMUNICATIONS COMMANDS
ADDED OR CHANGED:
Command:
#01DS will send the Adjustable Setpoints pages 1 and 2.
#01D3 will send the Adjustable Setpoint page 3.
#01DC will send both Auto Cycle Displays.
#01D+ will send the Analog Offset Display.
*Display for illustrative purposes only.
S70-101 IOM
Page 24
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
OPERATION
LEAD-LAG OPTION
The lead-lag compressor sequencing option provides the
controls for operating two RXB compressors in one system.
AUTO CYCLE DISPLAY *
AUTO CYCLE
F1 To Exit
Suct Press
=[35.5 g ]
Start[40.0 g ]
Stop [25.0 g ]
Min SV-[50%]
Active-[No ]
Timer[01 min]
Timer[01 min]
Lead [Yes]
The software includes user adjustable setpoints on the Auto
Cycle setpoints screen (F4 on Main Menu) for the following:
START - The suction pressure must be greater than or equal
to the “START” setpoint in order to start the compressor.
This setpoint works in conjunction with the “Timer” setpoint
located to the right of it on the Auto Cycle setpoints screen.
(Start) TIMER - This is a time delay used to start the compressor. The timer only accumulates time whenever the pressure rises to or above the “START” setpoint and will reset if
the pressure drops below the “START” setpoint.
STOP - The suction pressure must be less than or equal to
the “STOP” setpoint in order to stop the compressor. This
setpoint works in conjunction with the “Timer” setpoint located to the right of it on the Auto Cycle setpoints screen.
(Stop) TIMER - This is a time delay used to stop the compressor. The timer only accumulates time whenever the pressure drops to or below the “STOP” setpoint and will reset if
the pressure rises above the “STOP” setpoint.
MIN SV -This setpoint is the minimum slide valve position
and is shown as a percentage. It will limit the slide valve
position to the displayed setpoint.
LEAD - This setpoint assigns the compressor as the lead or
the lag unit. Press the [CHANGE] key while at this setpoint
to change the status.
ACTIVE - This setpoint indicates whether the Auto Cycle
Mode is active or not. Press the [CHANGE] key while at this
setpoint to change the status.
OPERATION
For operation of the LEAD-LAG sequence, both units must
be in Auto Cycle compressor mode - one compressor micro
selected as the LEAD compressor, the other compressor
selected as the LAG compressor - and the slide valves must
be in Auto mode.
With NO Compressor Running
The lead will start when its “START” setpoint is reached for
the amount of time selected for the “TIME” setpoint.
If the load falls:
The lead compressor will stop when its “STOP” setpoint is
reached for the amount of time selected for the “TIME” setpoint.
With TWO Compressors Running
If the load rises:
The lead and lag compressor will load independently.
If the load falls:
The lag compressor will unload to its “MIN SV” setpoint.
Then the lead compressor will unload to its “MIN SV” setpoint. The lag compressor will stop when the suction pressure drops below the “STOP” setpoint for the amount of time
selected for the “TIME” setpoint.
NOTE: Be careful not to select both compressors as lead
compressors or as lag compressors as improper operation will result.
NOTE: One compressor will operate as a normal auto
cycle compressor when any one of the following occurs:
a. Power is removed from one of the two compressors,
b. Either of the compressors is NOT selected to “AUTO”, or
c. If communication is lost between the compressors for any
reason.
COMMUNICATIONS TROUBLESHOOTING
Troubleshooting the communications:
Go to the SETPOINTS DISPLAY FIXED Page 2 by using
the [CHANGE] key and the [ * ] key. The display will appear
as:
SETPOINTS DISPLAY *
FIXED
PAGE 2
Comm. Activity-[ ]
Hi Oil Temp Cutout -- [167F]
Alarm -- [158F]
Lo Oil Temp Cutout --- [49F]
Alarm --- [58F]
Lo Oil Press. Cutout --- [005]
Alarm --- [010]
If the microprocessor is receiving information in the communications port from the other compressor, a “1” will flash
between the brackets. During normal operation a “1” will
flash every 5 seconds.
At the same time information is displayed on the lower right
hand corner of the Auto Cycle display concerning the leadlag information:
AUTO CYCLE DISPLAY *
AUTO CYCLE
F1 to Exit
Suct Press
=[35.5 g ]
Start[20.0 g] Timer[01 min]
Stop-[25.0 g] Timer[01 min]
Min SV-[50%] Lead-[Yes]
Active-[Yes]
0101
With ONE Compressor Running
If the load rises:
The lag compressor will start when its “START” setpoint is
reached for the amount of time selected for the “TIME” setpoint and the lead compressor is running at 100% slide valve
or running with the motor load inhibit.
This information is either “0” or “1” and represents what is
being sent from the other compressor. Consult Frick Company if additional information is required.
*Display for illustrative purposes only.
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
OPERATION
which is forwarded to the output modules. The instruction
triggers a solid state output device capable of handling control voltage and the instruction is executed. In some cases,
such as load and unload instructions, the computer displays
the instruction on the Operating display with an L (load) or
U (unload) symbol at the same time as the appropriate output is energized.
LEAD-LAG OPTION (continued)
TYPICAL LEAD-LAG WIRING
OPTIONAL
WIRING FOR LEAD-LAG SEQUENCING
DE-9P
+RX
SBC
RS422
DE-9P
4
GRN
4
+RX
-RX
5
BLK
5
-RX
+TX
8
RED
8
+TX
-TX
9
BLK
9
-TX
COM
3
3
COM
PORT 1
UNIT "A"
S70-101 IOM
Page 25
WHT
(NOT USED)
SBC
RS422
PORT 1
If the microprocessor receives information that indicates an
abnormal operating condition has been reached or is
present, it will generate one or more of the following instructions:
UNIT "B"
BLK
1. If a subsystem on the compressor unit, such as the oil
heater(s) or liquid injection, can correct the problem, the
microprocessor will energize or de-energize this system.
USE BELDEN #8777 OR EQUAL (3 TWISTED PAIRS)
COLOR CODING SHOWN IS BELDEN #8777
RS 422 WIRING SHALL BE SEPARATE
FROM ALL OTHER WIRING
CONNECTORS-#DE-9P MALE
WITH DBCH-9 HOOD (2 THUS)
JUMPER PIN 1 TO 6 AND 2 TO 7
ON BOTH CONNECTORS
WIRED AT FRICK IF BOTH UNITS
ARE ON THE SAME SKID
NOTE: WHEN USING THE RS422 PORTS FOR
LEAD-LAG, THEY CANNOT BE USED FOR
2. If a prealarm setpoint has been reached the microprocessor will trigger the prealarm and display this information on the Operating display and the Annunciator display.
3. If a cutout setpoint has been reached, the microprocessor will shut down the compressor. The microprocessor will
indicate CUTOUT on the Operating display and the information present on the Operating display at the moment of
cutout will be stored and can be retrieved by rotating displays to the Freeze display. Additional information will be
available through the Annunciator and Shutdown Record
displays.
ANY OTHER COMMUNICATIONS
HOW THE MICROPROCESSOR WORKS
- SUMMARY The Frick microprocessor has 4 major components and a
variety of sensors. The major components are the SBC
(single board computer), two display screens, and the keyboard.
The SBC can be considered the brain of the microprocessor control console. The SBC contains the logic center which
provides the rules by which the microprocessor will operate, the integrated circuit chips which store the burned-in
memory of how the compressor unit is to behave, an analog
input to convert VDC from the various sensors into computer binary language, and RAM (random access memory)
integrated circuit chips to store information which can be
readily changed by the microprocessor or, as in the case of
adjustable setpoints, by the operator. The SBC collects information, processes the information, and delivers instructions to the displays and to the output modules.
The SBC gathers information from several sources on the
compressor unit. Pressure transducers sense changes in
pressure and return a variable DC voltage of 1 to 5 VDC to
the SBC. The signals are converted into binary code which
the microprocessor understands. The microprocessor scans
the incoming data many times per second and compares
the information it receives with the instructions programmed
in the PROM chips, information stored in the RAM chips,
and instructions it has received from the console keyboard.
As operating conditions change, the microprocessor also
forwards the information it is receiving to the display screen.
When an operating condition or conditions develop which
the microprocessor program identifies as requiring a specific action, the microprocessor generates an instruction
A typical example of how the microprocessor responds can
be illustrated by the responses generated by the microprocessor as oil temperature increases. Assume that the ambient temperature and compressor unit temperature are 45OF
and you have just pressed the [RUN] key to start the compressor unit:
AT 45OF.
The microprocessor receives information that the oil
temperature is below 49OF, the Low Oil Temperature Cutout
setpoint, and and shuts down the unit. The microprocessor
will prevent the compressor package from running. The
microprocessor also instructs the oil heater(s) output to energize the oil heater(s).
AT 50OF.
When the oil temperature reached 50OF the microprocessor
would allow the Low Oil Temperature Cutout to be cleared
and the compressor unit could now be started. (Assume
that the [RUN] key has been pressed and that the compressor has now started.) The Low Oil Temperature Alarm
would still be engaged and cannot be cleared until oil temperature exceeds 58OF. The oil heater(s) shut off on compressor start.
AT 113OF
The microprocessor instructs the liquid injection solenoid
output to deenergize the liquid-injection solenoid.
AT 122OF
The microprocessor instructs the liquid injection solenoid
output to energize.
AT 110OF TO 150OF.
Normal operating range. The microprocessor continues
monitoring oil temperature and reporting this information on
the Operating display.
S70-101 IOM
Page 26
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
OPERATION
AT 158O F.
The microprocessor triggers the High Oil Temperature Alarm
and displays the alarm on the Operating display and the
Annunciator display.
AT 167O F.
The microprocessor instructs the compressor motor to shut
down and displays a CUTOUT indication on the Operating
display. It stores the operating conditions at the moment of
MULTIPLE COMPRESSOR SEQUENCING
FOR RXB COMPRESSOR UNITS WITH
MICROPROCESSOR CONTROLS
cutout in the Freeze display. Information regarding the cutout will also be retained by the Annunciator and the Shutdown Record displays.
NOTE: If the operator makes an error by attempting to
start the compressor under conditions outside safe
normal operating conditions, the microprocessor will
prevent start-up and advise the operator of the fault.
SUGGESTED PROGRAMMABLE
CONTROLLER PROGRAM TO DECODE
MICROPROCESSOR OUTPUT DATA CODES
A - The standard microprocessor panel includes:
1. Remote Run Input
2. Remote Load Input
3. Remote Unload Input
The remote run input is only recognized when the remote
run mode has been selected by pressing the [REMOTE
START] key on the front panel of the microprocessor.
The remote load and unload inputs can only be recognized
when the [REMOTE] key in the slide valve column on the
front panel of the microprocessor has been pressed.
B - If master sequencing between multiple compressors in
parallel on a common suction is desired. This output data
will permit the compressor microprocessor to be interfaced
with a master sequence controller. See electrical diagram
for details.
C - A master sequence controller must be installed to provide the signals to remote start and stop the compressors
and remote load and unload the compressors based on the
common suction pressure or other parameter and the compressor status based on the optional microprocessor output data feedback. The customer may supply his own master sequencer panel (usually a programmable controller) or
Frick, can supply this sequencer if desired (contact Frick
Company for pricing).
OUTPUT NO.
16
15
14
13
TERMINAL NO.
31
32
33
34
BIT
3
BIT
2
HEX
BIT BIT CODES
1
0
MNEMONIC
MEANING
OUTPUT DATA CODE
Compressor Off
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
0
0
0
1
1
1
1
0
0
0
0
1
1
0
0
1
1
0
0
1
1
0
1
0
1
0
1
0
1
0
1
2
3
4
5
6
7
8
9
A
Running with MLC Inhibit
1
0
1
1
B
Lockout on Recycle Delay
1
1
0
0
C
Cutout
1
1
0
1
D
Undefined
1
1
1
0
E
Undefined
1
1
1
1
F
Running
Slide
Valve
Position
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
OPERATION
S70-101 IOM
Page 27
MICROPROCESSOR OUTPUT DATA CODE
NEUTRAL
HOT
A 3.5 KOHM, 10 watt resistor (RES) must
be field installed, as shown below, when
the 120 VAC outputs of the RXB PLUS are
driving 120 VAC solid state input devices
such as programmable controllers.
PROGRAMMABLE CONTROL
48
OUTPUT
16
47
46
OUTPUT
15
45
44
OUTPUT
14
43
RES
31
42
OUTPUT
13
The Frick RXB PLUS Microprocessor comes with an onboard telecommunication interface. The telecommunication
feature permits interfacing the microprocessor with a modem, remote data communications terminal, or master computer via RS-422 protocol. In the case of a modem, telephone lines are used for the actual transmission of data,
permitting communication from a remote location.
The components necessary to utilize the telecommunication feature will vary with the application. Information
concerning these items may be obtained from Frick Company, Waynesboro, Pa.
41
All commands must be in ASCII (CAPS) to be recognized.
A compressor with an ID code of [00] is considered disabled. ID Codes from [01] thru [99] are valid and are recognized by the microprocessor.
The following is a complete list of available command types:
COMMAND CODE and DESCRIPTION
Returns compressor status information.
Compressor start command.
Compressor stop command.
Compressor capacity control command.
Compressor display screens command.
Return Pressures information.
Return Temperatures information.
Return full-load amps information.
Enter change setpoints mode.
The following is a detailed description of each command:
RETURN COMPRESSOR STATUS INFORMATION: #01I
#
01
I
Start of command sequence.
Compressor ID code.
Return Status information command.
RETURNED ANSWER, ie: 090RRRN340
Character
Description
Positionof returned data
1,2,3 Capacity control position.
4
Remote, Auto, Manual (Cap control)
5
Delay-recycle, Running, Off.
6
Rem, Man, Off, Auto (Compressor mode)
7
Cutout, Alarm, Normal.
8,9,10 Suction in PSIA.
(Carriage return, line feed.)
PROGRAMMABLE CONTROL
DATA CODE BIT 1
RES
PROGRAMMABLE CONTROL
DATA CODE BIT 0
34
COMPRESSOR START COMMAND:
#
01
R
01
#01R01
Start command sequence.
Compressor ID code.
Start compressor command.
ID code repeated for verification
NOTE: The compressor must be in the remote
start mode for this command to be executed.
Returned answer: A01
Character
Position
1
2,3
COMMUNICATIONS PROTOCOL
SPECIFICATIONS:
=
=
=
=
=
=
=
=
=
RES
33
MICROPROCESSOR TELECOMMUNICATION
I
R
S
V
D
P
T
A
C
PROGRAMMABLE CONTROL
DATA CODE BIT 2
32
5
DATA CODE BIT 3
RES
Description
of returned data
Acknowledgement of command sent.
ID code of compressor.
(Carriage return, line feed.)
COMPRESSOR STOP COMMAND:
#
01
S
01
#01S01
Start command sequence.
Compressor ID code.
Stop compressor command.
ID code repeated for verification
NOTE: The compressor must be in the remote
start mode for this command to be executed.
RETURNED ANSWER: A01
Character
Position
1
2,3
Description
of returned data
Acknowledgement of command sent.
ID code of compressor.
(Carriage return, line feed.)
COMPRESSOR SLIDE VALVE
CONTROL COMMANDS:
#01VLXX
#01VUXX
#01VS
#
01
V
L
U
Start command sequence.
Compressor ID code.
Compressor control command.
Load slide valve command.
Unload slide valve command.
XX = 00
Turns selected output off.
XX = 01 to 15 Turns selected output on for XX seconds.
XX = 99
Turns selected output on.
S
Return slide valve position value.
If the command was #01VL00, then the load slide valve
output on compressor #1 would be turned off. If the command
was #01VL05, then the load slide valve output on compressor #1 would be turned on for 5 seconds, and would then
automatically turn off. NOTE: the slide valve must be in the
remote mode for this command to be executed.
RETURNED ANSWER (for L or U commands): A01
Character
Position
1
2,3
Description
of returned data
Acknowledgement of command sent.
ID code of compressor.
(Carriage return, line feed.)
RETURNED ANSWER (for S command), ie: 090
1,2,3 Slide valve position.
S70-101 IOM
Page 28
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
OPERATION
CHANGE SETPOINTS COMMAND: #01C
COMPRESSOR DISPLAY SCREENS COMMAND: #01DXNN
#
01
C
xxx
xx
y
# Start command sequence.
01 Compressor ID code.
D Compressor control command.
X
X
X
X
X
X
X
X
X
X
=
=
=
=
=
=
=
=
=
=
O Operating display (Page 1 & 2).
S Setpoints display (Page 1 & 2).
X Setpoints display (Page 3 & 4).
R Shutdown record display (Page 1 & 2).
F Freeze display (Page 1 & 2).
C Autocycle display.
P Security display.
B Setback display.
+ Analog offset display.
ANN Annunciator display page “NN”.
Start command sequence.
Compressor ID code.
Change setpoint command.
New setpoint.
New setpoint.
g or h for gauge or inches.
The following is the complete list of the
setpoints that may be changed while in the
change setpoints command:
NOTE: “NN” parameter is used to access the
annunciator display pages.
If the command was #01DA10, then the microprocessor
would dump the annunciator display page number ten.
01xxxy
02xxxy
03xxxy
04xxx
05xxx
06xxx
07xxx
08xx
09xxx
01
Capacity Control Setpoint.
Change Low Pressure Cutout Setpoint.
Change Low Pressure Alarm Setpoint.
Change High Pressure Cutout Setpoint.
Change High Pressure Alarm Setpoint.
Change MLC Stop Load Setpoint.
Change MLC Force Unload Setpoint.
Change Recycle Delay Setpoint.
Change CTF Setpoint.
Compressor ID code.
RETURN FULL LOAD AMPS COMMAND: #01A
RETURNED ANSWER:
#
01
A
Start command sequence.
Compressor ID code.
Return full load amps command.
Axxxx The new setpoint which was sent,
followed by a carriage return, line feed.
If the command was #01A, then the microprocessor
would dump the full-load amps value.
RETURNED ANSWER:
XXX = 3 characters followed by a carriage return, line feed.
RETURN TEMPERATURES COMMAND:
#
01
T
X
X
X
X
X
#01TX
Start command sequence.
Compressor ID code.
Return temperature command.
=
=
=
=
=
S
D
O
P
A
Return
Return
Return
Return
Return
suction temperature.
discharge temperature.
oil temperature.
separator temperature.
all temperatures as a string of data.
If the command was #01TS, then the microprocessor
would dump the suction temperature.
RETURNED ANSWER:
XXXX = 4 characters followed by a carriage
return, line feed if suction temperature is
requested. The first character is “+” or “-”
followed by 3 digits.
If the command was sent #01C01300g01, the
capacity control setpoint would be changed to
30.0g and the returned answer is A300g
followed by a carriage return, line feed.
If the command sent was #01C0711001, the MLC
force unload setpoint would be changed to 110%
and the returned answer is A110 followed by
a carriage return, line feed.
If the command sent was #01C0520002, the
returned answer is “BAD” followed by the ID
number and a carriage return, line feed.
RETURN PRESSURES COMMAND:
#
01
P
X
X
X
X
X
#01PX
Start command sequence.
Compressor ID code.
Return pressures command.
=
=
=
=
=
S
D
O
F
A
Return suction pressure (PSIA).
Return discharge pressure (g/hg).
Return oil pressure (g).
Return filter differential pressure.
Return all pressures.
If the command was #01PS, then the microprocessor
would dump the suction pressure.
RETURNED ANSWER:
XXX = 3 characters followed by a carriage
return, line feed for all other temperatures.
If using the “A” command, then the returned
data would be:
XXXXXXXXXXXXX = 13 characters followed by a
carriage return, line feed.
The first 4 characters are
Suction Temp, the next 3 are
Discharge Temp, the next 3 are
Oil, and the last 3 are Separator.
XXX = 3 characters followed by a carriage
return, line feed.
If using the “A” command, then the returned
data would be:
XXXXXXXXXXXX = 12 characters followed by a
carriage return, line feed.
g or h : must be lower case - exception to “All commands
must be caps” statement at beginning of section.
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
OPERATION
READ FAILURES COMMAND: #01F
READ INPUT/OUTPUT COMMAND
#01X
#
Start command sequence.
01 Compressor ID Code.
X
Read Input/Output(s) command.
S70-101 IOM
Page 29
#
01
F
Start command sequence.
Compressor ID Code.
Read Failures command.
Returned Answer:
Returned Answer:
A00000000000000000000000002
A10000011000000000100000001
Character
Position
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26,27
Description
Acknowledge of command sent.
Oil Level Input 1
Remote Run Input 2
Remote Load Input 3
Remote Unload Input 4
Compressor Aux Input 5
Oil Pump Aux 6
Aux 1 Input 7
Aux 2 Input 8
Compressor Run Output 1
Slide Valve Load Output 2
Slide Valve Unload Output 3
Slide Stop Increase Output 4
Slide Stop Decrease Output 5
Liquid Injection Output 6
High Vi Liquid Injection
Output 7
Economizer Output 8
Alarm Output 9
Oil Heater Output 10
Oil Pump Start Output 11
Spare Output 12
Programmable Control Data
Bit 0 Output 13
Programmable Control Data
Bit 1 Output 14
Programmable Control Data
Bit 2 Output 15
Programmable Control Data
Bit 3 Output 16
Compressor ID Code
Example:
If the answer returned was
A10000011000000000100000001,
the inputs/outputs on compressor #1
which are energized are:
Oil level input 1
Aux 1 Input 7
Aux 2 Input 8
Oil Heater Output 10
Character
Position
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25,26
Description
Acknowledge of command sent.
High Press Cutout
High Press Alarm
Low Press Cutout
Low Press Alarm
Oil Press Cutout
Oil Press Alarm
Hi Oil Temp Cutout
Hi Oil Temp Alarm
Lo Oil Temp Cutout
Lo Oil Temp Alarm
Disch Temp Cutout
Disch Temp Alarm
Comp Auxiliary
Pump Auxiliary
Oil Level
Comp Differential
Dirty Filter
Spare
Aux 1 Alarm or Cutout
Aux 2 Alarm or Cutout
Spare
Spare
Spare
Compressor ID Code
Example:
If the answer returned was
A00000100000000000000000002,
compressor #2 has an Oil Press Alarm.
S70-101 IOM
Page 30
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
OPERATION
RXB COMPRESSOR
The Frick RXB rotary screw compressor utilizes mating,
asymmetrical-profile helical rotors to provide a continuous
pulse-free flow of refrigerant vapor and is designed for both
high pressure and low pressure applications. The compressor incorporates the following features:
3. Serves to remove the heat of compression from the gas,
keeping discharge temperatures low and minimizing refrigerant or oil breakdown.
4. Fills gas leakage paths between or around the rotors with
oil, thus greatly reducing gas leakage and maintaining good
compressor performance even at high compression ratios.
1. High-capacity roller bearings to carry radial loads at both
the inlet and outlet ends of the compressor.
5. Provides oil pressure for development of balance load on
the balance pistons to reduce bearing loading and increase
bearing life.
2. Heavy-duty, four-point, angular-contact ball bearings to
carry axial loads are mounted at the discharge end of compressor.
FULL-LUBE OIL SYSTEM
3. Moveable slide valve to provide infinite step capacity control from 100 to 25% of full load.
4. VOLUMIZER® adjusts to the most efficient of three volume ratios (2.2, 3.5 or 5.0) depending upon system requirements.
5. A hydraulic unloader cylinder to operate the slide stop
and slide valve.
6. Compressor housing suitable for 350 PSI pressure. Dualcompressor casing design for very low airborne noise transmission.
7. Most bearing and control oil vented to closed thread in
the compressor instead of suction port to avoid performance
penalties from superheating suction gas.
8. Shaft seal design to maintain operating pressure on seal
well below discharge pressure for increased seal life.
9. Oil injected into the rotors to maintain good volumetric
and adiabatic efficiency even at very high compression ratios.
IT IS MANDATORY THAT THE COUPLING CENTER BE REMOVED
AND THE DIRECTION OF MOTOR
ROTATION BE CONFIRMED BEFORE RUNNING THE
COMPRESSOR. Proper rotation of the compressor shaft
is clockwise looking at the end of the compressor shaft.
FAILURE TO FOLLOW THIS STEP COULD RESULT IN
BACKWARD COMPRESSOR ROTATION WHICH CAN
CAUSE COMPRESSOR FAILURE OR EXPLOSION OF
THE SUCTION HOUSING.
COMPRESSOR LUBRICATION SYSTEM
The RXB compressor is designed specifically for operation
without an oil pump for high stage service. Boosters and
some low-differential-pressure applications will require the
full-lube pump option.
The lubrication system on an RXB screw compressor unit
performs several functions:
1. Lubricates the rotor contact area, allowing the male rotor
to drive the female rotor on a cushioning film of oil.
2. Provides lubrication of the bearings and shaft seal.
RXB PLUS booster compressors and high-stage compressors, that operate with very low differential pressures across
the compressor suction and compressor discharge, require
a full-time oil pump to produce the oil flow and pressures
required. Oil is pumped from the oil separator through the
oil filter to the main oil injection feed and the compressor.
An oil pressure regulating valve downstream of the pump is
used to regulate oil pressure at the compressor by returning
excess oil to the separator.
Oil pressure on RXB PLUS compressors with full-time oil
pumps should be adjusted to provide 20 – 25 PSI (high stage)
or 30 – 35 PSI (booster) pounds of oil pressure at the highest normal head pressure or intermediate pressure expected
with the compressor fully loaded. The compressor will require maximum oil flow under these conditions.
COMPRESSOR OIL SEPARATION SYSTEM
The RXB PLUS is an oil flooded screw compressor. Most
of the oil discharged by the compressor separates from the
gas flow in the oil charge reservoir. Some oil, however, is
discharged as a mist, which does not separate readily from
the gas flow and is carried past the oil-charge reservoir. One
or more coalescer filter elements then coalesce the oil mist
into droplets; the droplets of oil fall to the bottom of the
coalescer section of the oil separator. The return of this oil
to the compressor is controlled by a needle valve on both
high-stage and booster applications.
NOTE: Open needle the valve only enough to keep the
coalescer end of the separator free of oil.
The sight glass located near the bottom of the coalescer
section 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
compressor operation has developed. Refer to Maintenance
for information on how to correct the problem.
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
OPERATION
COMPRESSOR HYDRAULIC SYSTEM
S70-101 IOM
Page 31
FUNCTIONAL CHECK OF THE COMPRESSOR
VOLUME RATIO CONTROL (Vi) OPERATION
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).
1. Remove the slide valve potentiometer cover located on
the outlet end of the compressor and secured by 4 cap
screws.
CAPACITY CONTROL
2. Push the Slide Stop Manual 2.2 Vi key on the micro keypad.
COMPRESSOR LOADING: If the capacity control valve is
mounted on the base, the compressor loads when MSV solenoid coil SV1 is energized. If the capacity control valve is
mounted on the compressor, the compressor loads when
MSV solenoid coil SV2 is energized. Oil flows from the solenoid valve through the needle valve (NV2) to compressor
port 2, where it enters the load side of the slide valve piston.
This equalizes the force on the slide valve piston and discharge pressure on the slide valve area loads the compressor.
COMPRESSOR UNLOADING: If the capacity control valve
is mounted on the base, the compressor unloads when MSV
solenoid SV2 is energized. If the capacity control valve is
mounted on the compressor, the compressor unloads when
MSV solenoid coil SV2 is energized. Oil is allowed to flow
from compressor port 2 through the needle valve to the MSV
solenoid. This allows discharge pressure on the slide valve
piston to unload the slide valve as the piston moves outward.
ADJUSTMENT (Capacity Control): A needle valve (NV2)
is provided to adjust slide valve travel time, preventing excessive slide valve “hunting”. NV2 should be adjusted to
restrict oil flow to compressor port so that slide valve travel
time from full load to full unload, or vice versa is a minimum
of 30 seconds.
3. Push Manual Load on the Slide Valve Control and hold in
the depressed position until the compressor is fully loaded.
4. Remove the Capacity Position Potentiometer which is
secured by 2 bolts. This will expose the indicator rod which
protrudes from the indicator rod guide.
5. In the 2.2 Vi position, the rod should extend from the
guide the amount shown in the Indicator Rod Extension
table.
6. With the slide valve fully loaded, depress the manual 3.5
Vi key. Movement of the indicator rod should occur as the
Vi is changed so that the rod extension corresponds to the
table.
7. Reassemble the parts if the functional check is satisfactory.
If the indicator rod does not move to the proper position as
the table indicates, then the compressor is not changing Vi
in either manual or optional automatic operation. This would
result in higher compressor motor horsepower consumption and possibly high oil temperature. The problem would
be caused by a malfunction of either solenoid valve 3SOL
or 4SOL, or the solenoid coil. Replace as required.
INDICATOR ROD EXTENSION (in.)
NOTE: A change in operating conditions may require
readjustment of Slide Valve travel time (NV).
VOLUMIZER®II Vi CONTROL
Solenoid valves 3 and 4 control the Vi Ratio. Oil is internally
ported to move the Movable Slide Stop.
Vi
SOL-3 (TOP)
SOL-4 (BOTTOM)
2.2
3.5
5.0
Energized
De-energized
De-energized
Energized
Energized
De-energized
CAPACITY CONTROL VALVE MOUNTED ON BASE
Vi
POSITION
RXB
12, 15, & 19
RXB
24, 30, 39, & 50
2.2
3.5
5.0
.412 / .454
.297 / .339
.235 / .277
.434 / .474
.319 / .359
.258 / .298
CAPACITY CONTROL VALVE ON COMPRESSOR
S70-101 IOM
Page 32
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
OPERATION
COMPRESSOR OIL COOLING SYSTEMS
SINGLE-PORT LIQUID INJECTION
The RXB PLUS unit can be equipped with one of several
systems for controlling the compressor oil temperature. They
are single or dual-port liquid injection, thermosyphon or
water-cooled oil coolers. Each system is automatically controlled, independent of compressor loading or unloading. Oil
cooling systems maintain oil temperature within the following ranges:
The single-port liquid injection system is designed to permit
liquid refrigerant injection into one port on the compressor
at any given moment and operate as outlined.
LIQUID INJECTION
OIL COOLING
EXTERNAL*
OIL COOLING
R-717 110 - 130OF.
R-22 130 - 150OF.
110 - 130OF
110 - 130OF
* Thermosyphon oil cooling (TSOC) or Water-cooled oil cooling (WCOC).
Solenoid valve SV7 is energized by the microprocessor when
the temperature element (TE3), installed in the piping after
the oil filter, exceeds the LICO setpoint. High pressure liquid refrigerant is then supplied to the temperature control
valve TCV1. The temperature control valve is equalized to
a constant back pressure by the differential pressure control valve PDCV (see LIQUID INJECTION ADJUSTMENT
PROCEDURE). The differential pressure control valve uses
discharge gas to maintain downstream pressure. The gas
downstream of the differential pressure control valve is bled
off to the compressor suction to ensure steady and constant operation of the valve.
BOOSTER APPLICATION - Discharge gas from the highstage compressor is required to assist the differential pressure control valve (PDCV) in providing the temperature control valve (TCV) with a constant back pressure.
A solenoid valve SV6 is installed before the differential pressure control valve (PDCV) to prevent migration of high pressure gas during shut down.
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
OPERATION
DUAL-PORT LIQUID INJECTION
The dual-port liquid injection system is designed to obtain
the most efficient compressor performance at high and low
compression ratios by permitting injection of liquid refrigerant into one of two ports on the compressor.
The dual-port system contains all the components of the
single-port system with the addition of a double-acting solenoid valve SV9 and operates as outlined.
Solenoid valve SV7 is energized by the microprocessor when
the temperature element (TE3), installed in the oil piping
after the oil filter, exceeds the LICO setpoint. Liquid refrigerant is then passed through the temperature control valve
TCV1 to the double-acting solenoid valve SV9. Depending
on the compressor’s operating volume ratio Vi, the microprocessor will select the flow of the liquid refrigerant to either
compressor port 3 or port 4.
When the compressor operates at 3.5 or 2.2, Vi compressor
port 3 (low Vi) supplies the liquid cooling. At 5.0 Vi, port 4
(high Vi) supplies the liquid cooling.
The temperature control valve TCV1 is equalized to a constant back pressure by the differential pressure control valve
PDCV.
Both the differential pressure control valve PDCV and the
double-acting solenoid valve SV9 use discharge gas to
maintain downstream pressure. The gas downstream of both
valves is bled off to the compressor suction to ensure steady
and constant operation of the valves.
S70-101 IOM
Page 33
LIQUID INJECTION
ADJUSTMENT PROCEDURE
1. Close vent valve (V4).
2. Open service valve (V5) until approximately 80 PSIG is
registered at the Pressure Indicator (PI).
3. Open vent valve (V4) until 75 PSIG is registered at the
Pressure Indicator (PI).
4. Monitor the oil temperature of the compressor. If the oil
temperature rises above 130OF (R-717) or 150OF (R-22),
open vent valve (V4) a very small amount. This will reduce
pressure on the equalizer and allow more refrigerant to flow
to the compressor. If the oil temperature drops below 110OF
(R-717) or 130OF (R-22), close vent valve (V4) a very small
amount. This will increase pressure on the equalizer. The
ideal condition is to maintain an oil temperature as stable
as possible. An incorrectly tuned liquid injection system will
cause extreme swings in the discharge temperature and
the oil temperature.
The vent valve (V4) MUST be open
at least 1/4 turn during normal operation. A higher initial pressure
(step 2) may be required.
S70-101 IOM
Page 34
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
OPERATION
PRESTART CHECKLIST
All check points in the following list must be completed before placing the compressor unit in operation. Only when the checklist
is completed will the unit be ready for initial start-up.
CHECKPOINT
Ammonia Units: Only refrigerant grade Ammonia as specified by International Institute of Ammonia Refrigeration
(IIAR) Bulletin # 110, Section 3.3 should be used with FRICK equipment.
Unit pressure test. Close suction and discharge service valves, and isolation valve to low pressure transducer.
Introduce pressure to unit and check for leaks. CAUTION: Do NOT exceed 80% of relief valve and/or 100% of
the vessel’s design working pressure.
Charge unit with proper amount and grade of oil. Oil level should be between the two
sight glasses on the oil separator.
Evacuate unit and system to 29.88" Hg. vacuum (1000 microns) to ensure that the system
is free of moisture and noncondensable gases. Additional information regarding
evacuation is detailed in the following publications:
AMMONIA - International Institute Of Ammonia Refrigeration (IIAR) Bulletin # 110, Section 5.4.
HALOCARBONS - Refrigeration Service Engineering Society (RSES) Service Application Manual,
Section 83, Forms 610-57 and 630-46.
Confirm that all field wiring is complete.
With coupling center removed, check for proper compressor motor rotation. COMPRESSOR
ROTATION IS CLOCKWISE WHEN FACING COMPRESSOR SHAFT. Check for proper alignment. OPEN
compressor motor disconnect. Replace coupling center.
If applicable, check Full-Time Oil Pump for correct rotation. OPEN oil pump motor disconnect.
Confirm that motor overload and CT is properly sized.
With ALL motor disconnects OPEN, turn control power ON and check ALL voltages.
Check that oil heater circuit is on. CAUTION: The oil heater should be on 24 hours
before initial start-up is attempted.
Confirm that the Emergency Stop Button is not depressed. Disengage by gently twisting to the left.
Confirm Microprocessor function. Rotate through displays.
Rotate to the ADJUSTABLE setpoints display (2 pages) and enter setpoints including DAY, DATE, and TIME.
Return to the Operating display, then rotate back to the ADJUSTABLE setpoints display to confirm that the
proper setpoints have registered. Press [F1] to return to the Operating display.
Rotate to the ANNUNCIATOR display. Confirm that all setpoints are normal and that no
alarm or cutout indications are present. Press [F1] to return to the Operating display.
Open all oil circuit service valves to allow normal oil flow.
If applicable, start the oil pump by turning the oil pump switch to HAND. Confirm oil
pressure buildup pump rotation. Separator oil level may drop as oil filter(s) and oil
cooler fills up. Add oil as required. Allow oil pump to operate 10 minutes to flush the
lubricating circuit. Shut down oil pump. Place the oil pump switch in the AUTO mode.
Open discharge and suction service valves.
Open the oil return needle valve located at the bottom of the coalescer section of the oil separator.
Open all hydraulic control valves for the slide valve (compressor loading and unloading)
and the slide stop (volumizer).
Open all required oil cooling valves. LIQUID INJECTION: service valves should be fully
open with the exception of the bleed valve which should be opened 1/4 turn. WATER-COOLED
OIL COOLER: confirm adequate water supply is present and adjust water-regulating valve to midrange.
Close economizer service valves, if applicable. The economizer can be put into service
once normal operation is established.
Confirm that the entire refrigeration system is ready for compressor operation and that
sufficient load is available for compressor start-up.
Close compressor motor main disconnect.
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
OPERATION
INITIAL START-UP PROCEDURE
Having performed the checkpoints on the prestart check list,
the compressor unit is ready for start-up. It is important that
an adequate refrigerant load be available to load test the
unit at normal operating conditions. The following points
should be kept in mind during initial start-up.
1. On start-up, the unit should be operated at as high a load
as possible for 3 hours. During this period, adjust liquid injection oil cooling if applicable. If the unit has water- cooled oil
cooling, adjust the water control valve to the cooler. No adjustment is required for thermosyphon oil cooling.
2. The compressor slide valve potentiometer should be calibrated.
3. After three hours, stop the unit and open the motor’s main
disconnect. Check hot alignment and adjust as necessary.
4. Pull and clean the suction strainer after 24 hours of operation. Repeat every 24 hours until the system is clean.
NORMAL START-UP PROCEDURE
1. Confirm that system conditions permit starting the compressor.
2. Press the [RUN] key.
3. Allow the compressor to start up and stabilize. At start-up
the slide stop (volumizer) and the slide valve (capacity control) are in the AUTO mode.
RESTARTING COMPRESSOR UNIT AFTER
CONTROL POWER INTERRUPTION
(PLANT POWER FAILURE)
1. Check ADJUSTABLE setpoints.
2. Follow normal start-up procedure.
S70-101 IOM
Page 35
S70-101 IOM
Page 36
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
MAINTENANCE
MAINTENANCE
3. Open suction, discharge, and liquid injection service valves
and remove tags.
This section provides instructions for normal maintenance,
a recommended maintenance program, troubleshooting and
correction guides, typical wiring diagrams, and typical P and I
diagrams.
4. Compressor unit is ready for prestart checks. Refer to
PRESTART CHECKLIST.
THIS SECTION MUST BE READ
AND UNDERSTOOD BEFORE ATTEMPTING TO PERFORM ANY
MAINTENANCE OR SERVICE TO THE UNIT.
CLOSE ALL COMPRESSOR PACKAGE ISOLATION VALVES PRIOR
TO SERVICING THE UNIT. FAILURE
TO DO SO MAY RESULT IN SERIOUS INJURY.
GENERAL INSTRUCTIONS FOR REPLACING
COMPRESSOR UNIT COMPONENTS
When replacing or repairing components which are exposed
to refrigerant, proceed as follows:
1. Push [STOP] key to shutdown the unit.
2. Open disconnect switches for the compressor motor starter
and the oil pump motor starter (if applicable).
3. Close discharge service valve.
NORMAL MAINTENANCE OPERATIONS
When performing maintenance
you must take several precautions
to ensure your safety:
1. If the unit is running, push [STOP] key to shut down the
unit.
2. Disconnect power from unit before performing any maintenance.
3. Wear proper safety equipment when the compressor unit
is opened to the atmosphere.
4. Ensure adequate ventilation.
5. Take necessary safety precautions required for the refrigerant being used.
COMPRESSOR SHUTDOWN and START-UP
4. SLOWLY vent the component to low-side system pressure using suction check valve bypass. Then close suction
service valve and suction bypass valve. NOTE: Recover or
transfer all refrigerant vapor, in accordance with local
ordinances, before opening to atmosphere. The component MUST be equalized to atmospheric pressure before opening.
Oil-entrained refrigerant may vaporize, causing a pressure increase. Repeat venting and recovery procedure, if necessary.
5. Make replacement or repair.
6. Isolate the low pressure transducer, PE-4, to prevent damage during pressurization and leak test.
7. Pressurize the unit and leak test.
8. Evacuate the unit to 29.88" Hg (1000 microns).
For seasonal or prolonged shutdown, the following procedure should be used:
9. Open suction and discharge service valves, and the low
pressure transducer. Readjust suction bypass valve.
1. Push [STOP] key to shutdown the unit.
10. Close disconnect switches for the compressor motor
starter and the oil pump motor starter, if applicable.
2. Open the disconnect switch for the compressor motor
starter and oil pump motor starter (if applicable).
3. Turn off power.
4. Close suction, discharge, suction check valve bypass, and
liquid injection service valves. Attach CLOSED TAGS.
5. Shut off cooling water supply valve to the oil cooler, if
applicable. Attach CLOSED TAG.
6. Protect the oil cooler from ambient temperatures below
freezing or remove the water heads.
NOTE: The unit should be inspected weekly during shutdown. Check for leaks or abnormal pressure. Manually
rotate the compressor. Consult motor manufacturer for
recommendations.
To start up after a seasonal or prolonged shutdown, the
following procedure should be used:
1. Perform routine maintenance. Change oil and replace filters. Check strainers.
2. Any water necessary for the operation of the system that
may have been drained or shut off should be restored or
turned on. If the oil cooler heads were removed, reinstall
and remove tags.
11. The unit is ready to put into operation.
SUCTION CHECK VALVE BYPASS
A 1/4" angle valve (HV-1 on P & I diagram) is installed between the compressor and suction flange that can be used
as a suction valve bypass. This feature has several uses
including reducing starting torque, improving oil quality, and
relieving the refrigerant to low side for servicing.
In most cases, the valve should be left open approximately 1/4
to 1/2 turn at all times. If the compressor back-spins or too
much oil foaming is experienced while venting, partially close
valve to slow speed of equalization. If system is on AUTO
CYCLE and short cycling occurs, the valve must be closed.
To relieve refrigerant to low side, close separator discharge
service valve. Slowly open bypass valve (if closed) and wait
for pressure to equalize. Close bypass and suction service
valves before evacuating the unit.
OIL FILTER - SINGLE
To change the filter cartridge proceed as follows:
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
MAINTENANCE
1. If a single oil filter is installed, push [STOP] key to shutdown the unit. Open disconnect switches for the compressor and (if applicable) oil pump motor starters.
2. Close discharge service valve. SLOWLY vent the separator to low-side system pressure using the suction check valve
bypass. Close suction valve and suction check valve bypass. NOTE: Recover or transfer all refrigerant vapor, in
accordance with local ordinances, before opening to atmosphere. The oil filter cartridge MUST be equalized to
atmospheric pressure before opening.
Oil-entrained refrigerant may vaporize, causing a pressure increase. Repeat venting and recovery procedure, if necessary.
3. Remove the plug from the bottom of the filter canister and
drain the oil. Remove the canister cover and discard the
gasket. Remove the screws securing the filter assembly. Pull
the filter assembly from the canister and discard the gasket
and the element.
4. Flush the canister with clean Frick refrigeration oil; wipe
dry with a clean, lint-free cloth; and replace the plug.
5. Install a new element and tighten the nut on the end plate
to 10 ft-lb torque. Then, while holding the nut with a wrench,
apply a second nut to act as a lock nut. Replace the gasket
and reinstall the filter assembly into canister, securing with
screws tightened to 7 ft-lb torque. Fill the canister with new
Frick refrigeration oil. Replace the gasket and reinstall the
canister cover. Torque cover bolts first to finger tight, then
65 ft-lb, then 130 ft-lb.
6. Isolate the low pressure transducer, PE-4, to prevent damage during pressurization and leak test.
7. Pressurize and leak test. Evacuate the unit to 29.88" hg
(1000 microns).
8. Open suction and discharge the service valves, and the
low pressure transducer. Readjust suction check valve bypass. Close disconnect switches for the compressor and (if
applicable) the oil pump motor starters. Start the unit.
OIL FILTER(s) - DUAL
RXB compressor units are furnished with one main oil filter.
A second filter is installed as optional
equipment to minimize down time and
reduce refrigerant loss.
1. If dual oil filters are furnished, open the inlet and then the
outlet service valves of the standby filter.
S70-101 IOM
Page 37
OIL RETURN STRAINER
The unit must be shut down and equalized to atmospheric
pressure. NOTE: Recover or transfer all refrigerant vapor in accordance with local ordinances before opening to atmosphere.
1. Remove the large plug from the bottom of the strainer,
remove the element from the strainer.
2. Wash the element in solvent and blow it clean with air.
3. Replace the element and the large plug.
4. Open the valves closed in Step 1 and check for leakage.
OIL PUMP STRAINER (Optional)
To clean the full-lube oil pump strainer, the unit must be
shut down. The procedure is as follows:
1. Shut down the unit and open the disconnect switches for
the compressor and (if applicable) the oil pump motor starters. Isolate and equalize unit to atmospheric pressure (See
General Instructions for Replacing Compressor Unit Components).
2. Close the inlet service valve.
3. Open the drain valve located in the strainer cover and
drain the oil into a container.
4. Remove the capscrews securing the strainer cover,
strainer cover gasket, and element. Retain the gasket.
5. Wash the element in solvent and blow it clean with air.
6. Wipe the strainer body cavity clean with a lint-free clean
cloth.
7. Replace the cleaned element and gasket, then reattach
the cover using the retained capscrews.
8. Close the drain valve and open the strainer inlet service
valve.
9. Check for leakage.
10. Open suction and discharge valves and readjust suction check valve bypass (if required). Close the disconnect
switches for the compressor and (if applicable) the oil pump
motor starters.
11. Start the unit.
LIQUID INJECTION STRAINER
To clean the liquid injection strainer, the unit must be shut
down. The procedure is as follows:
Open outlet and inlet service valves SLOWLY to prevent
a sudden pressure drop which could cause an oil filter
differential cutout.
1. Shut down unit and open the disconnect switches for the
compressor and (if applicable) oil pump motor starters. Isolate and equalize unit to atmospheric pressure (See General Instructions for Replacing Compressor Unit Components).
2. Close the outlet and then the inlet service valves of the
filter being serviced. Open the bleed valve on the filter canister and SLOWLY purge to atmospheric pressure.
2. Close the liquid supply service valve located before the
liquid solenoid.
3. Follow instructions 3, 4, and 5 under “OIL FILTER SINGLE”
3. Immediately screw in the manual solenoid valve stem
to relieve liquid refrigerant pressure trapped between
the solenoid and the service valve.
4. Place the unit back into service.
S70-101 IOM
Page 38
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
MAINTENANCE
4. Close the service valve located between the compressor
and the liquid injection, thermal expansion valve.
proved in writing by Frick engineering or warranty claim
may be denied.
5. Carefully loosen the capscrews securing the strainer cover
to the strainer. Allow pressure to relieve slowly.
Shut down the unit when changing oil. At the same time, all
oil filter cartridges must be changed and all oil strainer elements removed and cleaned. The procedure is as follows:
6. When all entrapped refrigerant has been relieved, carefully remove the loosened capscrews (as liquid refrigerant
is sometimes caught in the strainer), strainer cover, and
strainer basket.
7. Wash the strainer basket and cover in solvent and blow
them clean with air.
8. Reassemble the strainer.
9. Open the service valve between the compressor and the
liquid injection thermal expansion valve and check for leakage.
10. Screw out the manual solenoid valve stem.
11. Carefully open the liquid supply service valve.
1. Push [STOP] key to shut down the unit.
2. Open the disconnect switch for the compressor motor
starter and (if applicable) oil pump motor starter.
3. Close the discharge, and liquid injection (if applicable)
service valves.
4. SLOWLY vent the separator to low-side system pressure
using the suction check valve bypass. Close suction valve
and suction check valve bypass. NOTE: Recover or transfer all refrigerant vapor in accordance with local ordinances before opening to atmosphere. The separator
MUST be equalized to atmospheric pressure.
Oil-entrained refrigerant may vaporize, causing a separator pressure increase. Repeat venting and
recovery procedure if necessary.
12. Leak test.
13. Open suction and discharge valves and readjust suction
check valve bypass (if required). Close the disconnect
switches for the compressor and (if applicable) oil pump
motor starters.
14. Start the unit.
COALESCER FILTER ELEMENT
When changing the coalescer filter element, it is recommended that the oil and oil filter(s) be changed. Applicable
strainer elements should be removed and cleaned.
5. Open the drain valve(s) located on the underside of the
separator and drain the oil.
6. Drain the oil filter, strainers, and oil cooler, if applicable.
7. Remove and install new oil filter cartridge(s). Inspect check
valve in the bottom of the filter housing to ensure that the
parts are in good condition.
1. Refer to CHANGING OIL, Steps 1 thru 8.
8. Remove, clean, and reinstall strainer elements in strainers.
2. Remove the coalescer head and gasket. Discard the gasket.
9. Evacuate the unit to 29.88" Hg (1000 microns).
3. Remove and retain the nut securing the coalescer filter
retainer.
10. Open the suction service valve and pressurize the unit
to system suction pressure. Close the suction valve and leak
test.
4. Remove the retainer, coalescer filter element, and 2
O-rings. Discard the filter element.
5. Install the new coalescer filter element.
Seat the element in center of locating tabs on separator bulkhead.
6. Replace the coalescer filter retainer and nut. DO NOT
OVERTIGHTEN THE NUT. Torque values for nut are: 15 ftlb for models 12 and 15; 17 ft-lb for 19 and 24; and 21 ft-lb
for 30–50. Install jam nut.
7. Install a new head gasket and replace the coalescer head.
8. Tighten the head bolts. NOTE: WHEN THE COMPRESSOR UNIT IS REPRESSURIZED, RETIGHTEN THE HEAD
BOLTS TO PREVENT THEM FROM LOOSENING.
9. Refer to CHANGING OIL, Steps 9 thru 14.
CHANGING OIL
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.
Use of oils other than Frick Oil in
Frick compressors must be ap-
11. Add oil by attaching suitable pressure-type hose to the
oil-charging valve located on top of the separator. Using a
pressure-type oil pump and recommended Frick oil, open
the charging valve and fill separator until oil level is midway
in the top sight glass. The following table gives approximate
oil charge quantities.
TABLE BASIC OIL CHARGE
RXB MODEL
BASIC CHARGE*(Gal.)
12 & 15
19 & 24
30 & 39
50
10
14
17
21
* Add oil volume for external oil cooler, according to cooler
size selected: 6 x 5 TSOC - 4 gal.; 6 x 5 WCOC - 5 gal.; 8 x
5 TSOC - 6-1/2 gal.; and 8 x 5 WCOC - 8 gal.
12. Open the suction, discharge, and liquid injection service
valves. Readjust suction check valve bypass.
13. Close the disconnect switch for the compressor motor
starter and (if applicable) oil pump motor starter.
14. Start the unit.
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
MAINTENANCE
RECOMMENDED MAINTENANCE PROGRAM
In order to obtain maximum compressor unit performance
and ensure reliable operation, a regular maintenance program should be followed.
S70-101 IOM
Page 39
4. Vibration readings can be influenced by other equipment
operating in the vicinity or connected to the same piping as
the unit.
OIL QUALITY and ANALYSIS
The compressor unit should be checked daily for leaks, abnormal vibration, noise, and proper operation. A daily log
should also be maintained. There should be a continued
monitoring of oil quality and oil analysis testing. In addition,
an analysis of the unit’s vibration should be made periodically.
High quality refrigeration oil is necessary to ensure compressor longevity and reliability. Oil quality will rapidly deteriorate in refrigeration systems containing moisture and air or
other contaminants. In order to ensure the quality of the
refrigeration oil in the compressor unit, follow these
recommendations:
VIBRATION ANALYSIS
1. Only use Frick refrigeration oil as recommended by Frick
Company for your application.
Periodic vibration analysis can be useful in detecting bearing wear and other mechanical failures. If vibration analysis
is used as a part of your preventive maintenance program,
take the following guidelines into consideration:
2. Participate in a regular, periodic, oil analysis program to
help maintain oil and system integrity.
1. Always take the vibration reading from exactly the same
places and at exactly the same percentage of load.
2. Use vibration readings taken from the new unit at start-up
as the base line reference.
3. Evaluate vibration readings carefully as the instrument
range and function used can vary. Findings can be easily
misinterpreted.
MOTOR BEARINGS
Follow the motor manufacturer’s maintenance recommendations.
Lubricate the motor bearings properly before start-up. Maintain subsequent lubrication as recommended by the motor manufacturer.
LUBRICATION SCHEDULE / INSTRUCTIONS
SYNC. FRAME
RPM SERIES
3600
1800
1200
SERVICE CYCLE* - BALL BEARING**
8 HR/DAY OPERATION
24 HR/DAY OPERATION
150 DAYS (1200 HRS)
50 DAYS (1200 HRS)
360
390 DAYS (3120 HRS)
130 DAYS (3120 HRS)
400-440
270 DAYS (2160 HRS)
90 DAYS (2160 HRS)
5000-5800
210 DAYS (1680 HRS)
70 DAYS (1680 HRS)
360-440
390 DAYS (3120 HRS)
130 DAYS (3120 HRS)
5000-5800
270 DAYS (2160 HRS)
90 DAYS (2160 HRS)
360-5800
* LUBRICATION SCHEDULE FOR SEVERE SERVICE (VIBRATION, SHOCK AND/OR
ENVIRONMENTAL EXTREME) = 1/3 OF THE ABOVE INTERVALS.
• LUBRICATE BEARINGS WITH POWER IN
THE OFF CONDITION.
• CLEAR AND CLEAN THE GREASE FITTINGS
AND SURROUNDING AREA.
• REMOVE THE PIPE PLUG FROM THE
VENTING PORT OPPOSITE THE GREASE
FITTING.
• USING A LOW PRESSURE GREASE GUN
APPLY 2 OZS. (60 GRAMS) OF GREASE
AT EACH FITTING. DO NOT OVER GREASE.
• WITH THE VENT PORTS OPEN, OPERATE
THE MOTOR FOR A MINIMUM OF
15 MINUTES AND UNTIL ANY GREASE FLOW
HAS CEASED AT THE VENTING PORTS.
• REMOVE POWER.
• REPLACE THE VENT PIPE PLUGS.
• REPLACE ANY AND ALL GUARDS AND
COVERS THAT MAY HAVE BEEN REMOVED
TO ACCESS THE MOTOR.
** LUBRICATION SCHEDULE FOR ROLLER BEARINGS = 1/3 OF THE ABOVE INTERVALS.
THE FACTORY INSTALLED, RECOMMENDED LUBRICANT IS LISTED ON THE MOTOR DATA PLATE. THE FOLLOWING PRODUCTS ARE DEEMED
SUITABLE LUBRICANTS UNDER NORMAL SERVICE CONDITIONS BUT MAY NOT BE CHEMICALLY COMPATIBLE OR INTERCHANGEABLE ONE
TO THE OTHER OR CORRECT FOR ALL AMBIENT OR SERVICE CONDITIONS. FOLLOW ALL MANUFACTURER'S GUIDELINES WHEN
INTRODUCING ALTERNATES - WHEN DOUBT EXISTS, PURGE THE BEARINGS AS DESCRIBED IN THE INSTRUCTION MANUAL.
CHEVRON OIL CO. - SRI#2
EXXON CORP. - POLYREX
SHELL OIL CO. - DOLIUM R
EXXON CORP. - UNIREX#2
MOBIL OIL CO. - MOBILUX#2
OPERATING LOG: The use of an operating log, as shown on the inside back cover, permits thorough analysis of the operation
of a refrigeration system by those responsible for its maintenance and servicing. Continual recording of gauge pressures, temperatures, and other pertinent information enables the observer and serviceman to be constantly familiar with the operation of
the system and to recognize immediately any deviations from normal operating conditions. It is recommended that readings be
taken at least every four hours.
S70-101 IOM
Page 40
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
MAINTENANCE
MAINTENANCE SCHEDULE
This schedule should be followed to ensure trouble-free operation of the compressor unit.
CHANGE OIL
As directed by oil analysis
OIL ANALYSIS
Then every 6 months
CHANGE FILTERS
CLEAN OIL
STRAINERS
CLEAN LIQUID
STRAINERS
CHANGE COALESCERS
CHECK AND CLEAN
SUCTION SCREEN
CHECK ALIGNMENT
CHECK COUPLING
VIBRATION ANALYSIS
REPLACE SEAL
Every 6 months, more frequently if levels increase
When leak rate exceeds 7 - 8 drops per minute
95000
90000
85000
80000
75000
70000
65000
60000
55000
50000
45000
40000
35000
30000
25000
20000
15000
10000
8000
5000
1000
MAINTENANCE
200
HOURS OPERATION (MAXIMUM)
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
MAINTENANCE
TROUBLESHOOTING GUIDE
3. Excessively high suction superheat.
Successful problem solving requires an organized approach
to define the problem, identify the cause, and make the
proper correction.
4. Excessively high discharge pressure.
ABNORMAL OPERATION
ANALYSIS and CORRECTION
S70-101 IOM
Page 41
5. Inadequate refrigerant charge or low receiver level.
6. Excessively high or low-temperature coolant to the oil
cooler.
7. Liquid return from the system (carryover).
Four logical steps are required to analyze an operational
problem effectively and make the necessary corrections:
1. Define the problem and its limits.
8. Refrigerant underfeed or overfeed to the evaporators.
9. Blocked tubes in the water-cooled oil cooler from high
mineral content of the water.
2. Identify all possible causes.
10. Insufficient evaporator or condenser sizing.
3. Test each cause until the source of the problem is found.
11. Incorrect refrigerant line sizing.
4. Make the necessary corrections.
12. Improper system piping.
The first step in effective problem solving is to define the
limits of the problem. If, for example, the compressor periodically experiences high oil temperatures, do not rely on
this observation alone to help identify the problem. On the
basis of this information, the apparent corrective measure
would appear to be a readjustment of the liquid injection
system. Lowering the equalizing pressure on the thermal
expansion valve would increase the refrigerant feed and the
oil temperature should drop.
If the high oil temperature was the result of high suction
superheat, however, and not just a matter of improper liquid
injection adjustment, increasing the liquid feed could lead
to other problems. Under low load conditions the liquid injection system may have a tendency to overfeed. The high
suction superheat condition, moreover, may only be temporary. When system conditions return to normal, the unit’s liquid injection will overfeed and oil temperature will drop. In
solving the wrong problem, a new problem was created.
The following list of abnormal system conditions can cause
abnormal operation of the RXB compressor unit:
1. Insufficient or excessive refrigeration load.
2. Excessively high suction pressure.
13. Problems in electrical service to the compressor unit.
14. Air and moisture present in the system.
Make a list of all deviations from normal plant operation and
normal compressor unit operation. Delete any items which
do not relate to the symptom and separately list those items
that might relate to the symptom. Use the list as a guide to
further investigate the problem.
The second step in problem solving is to decide which items
on the list are possible causes and which items are additional symptoms. High discharge temperature and high oil
temperature readings may both be symptoms of a problem
and not casually related. High suction superheat or a low
receiver level, however, could cause both symptoms.
The third step is to identify the most likely cause and take
action to correct the problem. If the symptoms are not relieved, move to the next item on the list and repeat the procedure until you have identified the cause of the problem.
Once the cause has been identified and confirmed, make
the necessary corrections.
S70-101 IOM
Page 42
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
MAINTENANCE
TROUBLESHOOTING
THE RXB PLUS MICROPROCESSOR
This section contains information on troubleshooting and
making corrections to the microprocessor and control circuits of the RXB PLUS unit. The section is composed of
four parts: a general information section, a troubleshooting
guide, a repair procedure guide, and a section with illustrative schematics and data.
GENERAL INFORMATION
THE COMPONENTS WITHIN THE
MICROPROCESSOR CONSOLE
CAN BE INADVERTENTLY DAMAGED BY STATIC ELECTRICITY OR MISHANDLING.
ONLY QUALIFIED TECHNICIANS SHOULD DIRECTLY
HANDLE THESE COMPONENTS.
1. DO NOT REMOVE the microprocessor console cover or
attempt to make corrections to the microprocessor power
supply without shutting off the control power. Accidental
shorts can irreparably damage the SBC (single board computer) or the display screen.
The control system of the RXB PLUS compressor consists
of a 120 volt AC (high voltage) side and a DC (low voltage)
side. The 120 volt side actuates solenoids, relays, alarms,
and other electromechanical functions. The DC side operates the computer and its various sensors. The microprocessor console contains the SBC (single board computer) and
one display screen.
When working within the microprocessor console, 120 VOLTS CAN
CAUSE INJURY OR DEATH.
To troubleshoot the low-voltage side of the RXB PLUS control circuits, it is necessary to have the following tools:
1. Accurate digital multimeter.*
2. Small wire stripper.
3. Small screwdriver.
4. Small snip nose pliers.
5. 15 watt soldering iron (no larger).
6. .032,60/40 rosin core solder.
7. IC chip extraction and insertion tools.*
8. Grounding strap.*
9. Static free grounded work surface.
* Available from Frick. Order kit no. 111Q0451862
2. DO NOT HANDLE the SBC or the display screen board
when their cables are disconnected without first attaching a
ground strap to prevent static electrcial discharge from your
body.
Most problems encountered with the microprocessor and
control circuits will be the result of a wiring fault, blown fuse,
or failure of a peripheral control such as a solenoid coil or a
pressure transducer. Faults in the computer, while possible,
are unlikely. If a fault develops in the computer, the probability is that all functions will cease and the display screen
will go blank.
TROUBLESHOOTING FRICK SBC MICROPROCESSOR SYSTEM
(REFER TO WIRING DIAGRAMS)
SYMPTOM
DISPLAY IS INOPERATIVE
PROBABLE CAUSES and CORRECTIONS
Check the 10 amp fuse (2FU) which controls all voltage going to the microprocessor.
Shut off power to the microprocessor and confirm that all cable and wire connections
are made.
COMPRESSOR AUXILIARY
SHUTDOWN
Output 1 controls the Compressor Start Relay (2CR). If the compressor does not start
and the LED for Output 1 is on, check the fuse FU1 (1.5 amp). If the problem persists,
check the interposing relay (2CR).
The Compressor Starter Auxiliary Contacts turn on Input 5 when they are closed.
These contacts are located on the Compressor Starter.
OIL HEATERS DO NOT
OPERATE
The oil heaters should operate only when the compressor is NOT running and the oil in the
separator sump is cold.
If the oil heaters do not work, check fuse 1FU (10 amp). If the fuse is not blown, check between
Wires 25 and 2. If 120VAC is not found, check between wires 26 and 2. If 120VAC is found
between wires 26 and 2, the Oil Heater Relay is defective. Next, check the voltage between
Wires 11 and 2. If 120 VAC is present, the Oil Heater Relay is defective.
If you do not read 120VAC between Wires 9 and 2 when the LED for output 10 is on, check the
fuse (FU10).
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
MAINTENANCE
S70-101 IOM
Page 43
TROUBLESHOOTING FRICK SBC MICROPROCESSOR SYSTEM (Continued)
SYMPTOM
SLIDE VALVE DOES NOT LOAD
and/or UNLOAD
PROBABLE CAUSES and CORRECTIONS
Verify that the Slide Valve is in the AUTO mode and that capacity control is calling for loading
or unloading (AUTO L or AUTO U will appear on the Operating display).
Output 2 controls the Slide Valve Load Solenoid. If 120VAC is found across Wires 17 and 2, the
Slide Valve Load Solenoid should be energized. If not, the solenoid is defective. If 120VAC is not
found when the LED for Output 2 is on, check the fuse (FU2).
Output 3 controls the Slide Valve Unload Solenoid. If 120VAC is found across Wires 16 and 2, the
Slide Valve Unload Solenoid should be energized. If not, the solenoid is defective. If 120VAC is
not found across Wires 16 and 2 when the LED for Output 3 is on, check the fuse (FU3).
NOTE: Verify that the proper setpoint has been programmed into C.C. (Capacity Control) on
the Adjustable Setpoints display.
SLIDE STOP DOES NOT
INCREASE and/or DECREASE
Output 4 controls the Slide Stop 3.5 Vi Solenoid. If 120VAC is found across Wires 15 and 2, the
Slide Stop 3.5 Vi Solenoid should be energized. If not, the solenoid is defective. If 120VAC is not
found across Wires 15 and 2 when the LED for Output 4 is on, check the fuse (FU4).
Outputs 4 and 5 control the Slide Stop 2.2 Vi Solenoid. If 120VAC is found across Wires 14 and 2,
the Slide Stop 2.2 Vi Solenoid should be energized. If not, the solenoid is defective. If 120VAC is
not found across Wires 14 and 2 when the LED for Output 5 is on, check the fuse (FU5).
LIQUID INJECTION SOLENOID
DOES NOT ENERGIZE (LICO
ONLY)
Verify that the Liquid Injection TXV is modulating properly and not feeding excessive liquid to
the compressor. When oil temperature drops too low, the microprocessor SHOULD de-energize
this solenoid.
Output 6 controls the Liquid Injection Solenoid. If 120VAC is found across Wires 13 and 2, the
Liquid Injection Solenoid should be energized. If not, the solenoid is defective. If 120VAC is not
found when the LED for Output 6 is on, check the fuse (FU6).
HI Vi LIQUID INJECTION PORT
Output 7 controls the Hi Vi Liquid Injection Port solenoid. If 120VAC is found across Wires 12 and
2, the Hi Vi Liquid Injection Port Solenoid should be energized. If not, the solenoid is defective.
If 120VAC is not found when the LED for output 7 is on, check the fuse (FU7).
NOTE: This output should only be on when the Vi is at 5.0.
ECONOMIZER (OPTIONAL)
SOLENOID DOES NOT
ENERGIZE
Output 8 controls the Economizer Solenoid Valve. If 120VAC is found across Wires 11 and 2,
the Economizer Solenoid should be energized. If not, the solenoid is defective. If 120VAC is not
found when the LED for Output 8 is on, check the fuse (FU8).
NOTE: The economizer output should only lbe on when the slide valve is at or above the
90% position.
ALARM CIRCUIT DOES NOT
ENERGIZE
Output 9 controls the Alarm Circuit. The Alarm should turn on only when there is a prealarm or
shutdown. If the Alarm does not sound when these conditions are found, check for 120VAC
across Wires 10 and 2. If 120VAC is not found, check the fuse (FU9).
CONTROL PANEL DOES NOT
RESPOND TO REMOTE
CONTROL SIGNALS
Inputs 2 through 4 can be used to operate the compressor from a remote location.
NOTE: Check the Operating display to verify that the compressor and the Slide Valve
are in the REMOTE MODE.
If 120VAC is found (across Wires 21 and 2, 22 and 2, and 23 and 2) and the input does not turn
on, consult Frick Company.
MOTOR LOAD CONTROL
(FORCED UNLOAD) OCCURS
AT HIGH MOTOR AMPS
The current transducer is used to convert the AC motor amps to a DC voltage signal for the
microprocessor. If the %FLA reading from the Operating display is incorrect, consult Frick Co.
PRESSURES ON THE
OPERATING DISPLAY
DO NOT APPEAR CORRECT
TEST 1 - Shut down the compressor and allow pressures to equalize. Discharge pressure
and oil pressure should have the same reading.
TEST 2 - If either oil pressure or discharge pressure read different pressures, one or both
transducers are at fault. Valve off the suction transducer from the unit and open the vent
valve on transducer manifold to atmosphere. If the suction transducer reads atmospheric
pressure, then the suction transducer is correct.
NOTE: A 1% tolerance is allowed for all transducers.
COMPRESSOR DOES NOT
AUTOMATICALLY
LOAD OR UNLOAD
Verify that the [AUTO] key has been pressed and AUTO appears under SV Pos on the
Operating display #4.
If the problem persists, see the Troubleshooting section SLIDE VALVE DOES NOT LOAD
and/or UNLOAD.
S70-101 IOM
Page 44
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
MAINTENANCE
TROUBLESHOOTING FRICK SBC MICROPROCESSOR SYSTEM (Continued)
SYMPTOM
PROBABLE CAUSES and CORRECTIONS
DISPLAY SCREENS DISPLAY
SCRAMBLED PATTERN OR
LIST ALPHABET
A loose or improper connection between the displays and the SBC is indicated. Remove fuse
(2FU, 10 amp) for 15 seconds, then restore to reset the displays.
OIL PUMP DOES NOT START
(Optional)
Verify that the Oil Pump HAND-OFF-AUTO switch (1SS) is in the AUTO position and
that the Emergency Stop Button is not depressed.
Output 11 controls the Oil Pump Starter Relay (3CR) when in the AUTO mode. If HAND is
selected on 1SS, Output 11 will not have any effect on the operation of the oil pump starter.
If AUTO has been selected and the oil pump does not start, check for 120VAC
between Wires 39 and 2. If 120VAC is not found when the LED for Output 11 is on,
check the fuse (FU11). If the problem persists, check the control relay (3CR).
The Oil Pump Starter Auxiliary Contact switches voltage to Input 6 (Wires 28
and 2) when the auxiliary contacts are closed and the AUTO mode is selected on
1SS. If the Input does not turn on and voltage is present at Input 6, consult
Frick Company.
OIL PUMP IS RUNNING BUT
COMPRESSOR DOES
NOT START (Optional)
The (HAND-OFF-AUTO) Oil Pump Selector Switch (1SS) controls oil pump operation
and must be in the AUTO position before the compressor can be started.
Verify that the Slide Valve has unloaded to 5% or less. If the Slide Valve has
not unloaded, troubleshoot the hydraulic system. The compressor will not start
until the Slide Valve is unloaded.
Output 1 controls the motor starter. Check between terminals 38 and 2 for 120VAC.
If 120VAC is not found when the LED for Output 1 is on, check the fuse (FU1).
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
MAINTENANCE
EPROM MEMORY I/C CHIP REPLACEMENT
Microprocessor EPROM memory I/C chips are located inside the microprocessor console on the SBC board. A special tool is required to remove these chips to lessen the
chance of damaging them (See Troubleshooting The
Microprocessor). The procedure to replace EPROM memory
chips is outlined below:
1. Shut off control power.
2. Remove the microprocessor console cover.
3. Using a chip extraction tool, remove the old EPROM chips
from the SBC board. Pay particular attention to the orientation of the notch on the end of the chip; then install new chip
with the notch in the same position. NOTE: The chip labeled 4 must be inserted into socket U4 and the chip
labeled 5 must be inserted into socket U5.
S70-101 IOM
Page 45
OUTPUT FUSE REPLACEMENT
1. Shut off control power.
2. Remove the microprocessor console cover.
3. Identify the faulty fuse.
4. Use a voltmeter to verify that no voltage is present on
either side of the fuse.
5. Remove the faulty fuse using a fuse puller or screwdriver.
6. Install a new plug-type fuse.
PRESSURE TRANSDUCERS - TESTING
Pressure transducers are located below the microprocessor console.
Test Procedure
SBC BOARD REPLACEMENT
The procedure to replace SBC boards is outlined below:
1. Shut off control power.
2. Remove the old board from the machine and the new
board from its packing and place both on an antistatic surface.
3. Remove the program chip(s) from the defective board and
install them in the replacement board.
Pay particular attention to the orientation of the notch(es) on the
end of the chip(s). Install the
chip(s) on the replacement board in exactly the same
position as they were on the defective board.
4. IMPORTANT: Before installing the new board, determine
if there are gray/yellow wires from P15 (see page 14 for location) on the old board. If they are present, the display is
the old style and the new board can be installed without
modification.
5. If the gray/yellow wires are not present on the old SBC,
the machine is equipped with a new style display. Resistor
R6 must be removed from the new board by cutting the wire
leads on either side of the resistor.
6. Then install the modified replacement board in the panel.
MICROPROCESSOR DISPLAY
REPLACEMENT
The procedure to replace the microprocessor display is outlined below:
1. Shut off control power.
2. Remove the defective display(s).
3. Install the new display(s).
4. If present, remove the grey/yellow wires from P15 (on the
SBC, see page 14 for location) to the display(s) as they are
no longer needed.
5. If resistor R6 is present on the SBC, cut off the wire leads
on both sides (see page 14 for location) and remove it. This
resistor is no longer needed.
1. Shut down the compressor and allow pressures to equalize.
PRESSURE TRANSDUCER CONVERSION DATA
0-100 Transducer
0-300 Transducer
1.388V** 1.788V**
1.046V**
1.346V**
PROBE
Range - PSIG*
Range - PSIG*
VOLT.
Low
High
Low
High
1.0
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2.0
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3.0
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
4.0
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
5.0
29.92"
29.92"
29.92"
24.83"
19.74"
14.65"
9.57"
4.48"
0.30
2.80
5.30
7.80
10.30
12.80
15.30
17.80
20.30
22.80
25.30
27.80
30.30
32.80
35.30
37.80
40.30
42.80
45.30
47.80
50.30
52.80
55.30
57.80
60.30
62.80
65.30
67.80
70.30
72.80
75.30
77.80
80.30
19.74"
14.65"
9.57"
4.48"
0.30
2.80
5.30
7.80
10.30
12.80
15.30
17.80
20.30
22.80
25.30
27.80
30.30
32.80
35.30
37.80
40.30
42.80
45.30
47.80
50.30
52.80
55.30
57.80
60.30
62.80
65.30
67.80
70.30
72.80
75.30
77.80
80.30
82.80
85.30
87.80
90.30
29.92"
29.92"
22.30"
7.00"
4.10
11.60
19.10
26.60
34.10
41.60
49.10
56.60
64.10
71.60
79.10
86.60
94.10
101.60
109.10
116.60
124.10
131.60
139.10
146.60
154.10
161.60
169.10
176.60
184.10
191.60
199.10
206.60
214.10
221.60
229.10
236.60
244.10
251.60
259.10
266.60
274.10
* Below 0 PSIG measured in inches of mercury.
** At zero psig.
7.00"
4.10
11.60
19.10
26.60
34.10
41.60
49.10
56.60
64.10
71.60
79.10
86.60
94.10
101.60
109.10
116.60
124.10
131.60
139.10
146.60
154.10
161.60
169.10
176.60
184.10
191.60
199.10
206.60
214.10
221.60
229.10
236.60
244.10
251.60
259.10
266.60
274.10
281.60
289.10
296.60
S70-101 IOM
Page 46
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
MAINTENANCE
2. Isolate suction transducer PE-4 from the unit and open it
to atmosphere using valves provided at the transducer
manifold.Close the applicable transducer isolation valve.
NOTE: To change the discharge pressure transducer
(PE-3), it will be necessary to depressurize the entire
compressor package. Follow "General Instructions For
Replacing Compressor Unit Components" (p. 36) before
going to step 3.
3. Measure the voltage of PE-4 on connector P4 (terminals
WHT and BLK) on the SBC with a digital voltmeter.
4. The voltage reading should be 1.48 VDC to 1.72 VDC at
standard atmospheric pressure (14.7 PSIA or 0 PSIG). When
checking transducers at higher elevations, an allowance in
the readings must be made by subtracting approximately
0.02 VDC per 1000 feet of elevation above sea level. Therefore, if PE-4 is measured at 5000 feet elevation under relatively normal weather conditions, the output voltage should
differ by 0.10 VDC to read between 1.38 VDC and 1.62 VDC.
5. Subtract 1 from the voltage.
PRESSURE TRANSDUCERS REPLACEMENT
1. Shut off control power.
2. Close the applicable transducer isolation valve. NOTE: To
change the discharge pressure transducers, it will be
necessary to depressurize the entire compressor package. Follow "General Instructions For Replacing Compressor Unit Components" (p. 36) before going to step
3.
3. Open the microprocessor console door.
4. Use the chart to identify transducer terminals of the SBC.
TRANSDUCER
P&I
CONNECTION
Oil Pressure
Discharge Pressure
Suction Pressure
PE-1
PE-3
PE-4
6. Multiply by 25.
7. This result is the absolute suction pressure (PSIA). The
Operating display will indicate PSIG (14.7 PSIA = 0.0 PSIG).
5. Disconnect transducer leads by loosening the terminal
screws for the transducer to be changed.
8. Measure the voltage of PE-1 on connector P4 (terminals
WHT and BLK) on the SBC.
6. Tape a 3 ft. length of pull wire to the leads of the transducer to be removed.
9. The voltage reading should be between 1.1 VDC and 1.29
VDC at standard atmospheric pressure. PE-1 and PE-3 have
a span of 300 PSI as compared to PE-4 with a span of 100
PSI. Therefore, atmospheric pressure changes have a lesser
effect which is 0.0067 VDC per 1000 feet of elevation and
0.00067 VDC per 0.1 inch Hg barometric deviation.
7. Pull the transducer leads through the conduit until pull
wire extends out of the conduit hole in the transducer manifold. Separate the transducer leads from the pull wire.
10. Measure the voltage of PE-3 on connector P4 (terminals WHT and BLK) on the SBC.
11. Measure the voltage of PE-1 on connector P4 (terminals WHT and BLK) on the SBC.
8. Unscrew the transducer using a wrench on the metal hex
at the base of the transducer. DO NOT ATTEMPT TO LOOSEN
OR TIGHTEN TRANSDUCERS BY THEIR TOP CASING.
9. Install new transducer and tape leads to the pull wire.
10. Pull new transducer leads into the microprocessor console and reconnect them to the terminal strip.
12. These two voltages should be within .04 VDC of one
another.
11. Close the microprocessor console door.
13. Test complete.
12. Reopen the transducer isolation valve.
13. Turn on control power.
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
MAINTENANCE
SLIDE VALVE POSITION POTENTIOMETER
REPLACEMENT AND ADJUSTMENT
The slide valve potentiometer is located under a cover on
the right side of the compressor (facing shaft) at the inlet
end.
1. Shut off control power.
2. Remove the potentiometer cover and gasket.
3. Remove the potentiometer and mounting bracket.
4. Install new potentiometer and bracket.
S70-101 IOM
Page 47
BARE COMPRESSOR MOUNTING
The following procedure is required only when a bare compressor is replaced in the field.
1. Thoroughly clean the compressor feet and mounting pads
of burrs and other foreign matter to ensure firm seating of
the compressor.
2. Clean the discharge flange surfaces on the compressor
and separator.
3. Install a gasket on the compressor discharge connection
of the separator.
4. Set the compressor on its base and tighten the discharge
flange bolts. The feet of the compressor should lift off
the mounting base. If the compressor feet do not raise
off the mounting base install a thicker discharge gasket
and reinstall the discharge flange bolts. Check the clearance between the feet and the base with a feeler gauge.
Shim the compressor feet (gauge reading plus .002").
5. Tighten compressor hold down bolts.
6. Complete compressor/motor coupling alignment (see INSTALLATION section).
7. Complete tubing, piping and wiring per the P & I and wiring diagrams.
5. ADJUSTMENT must be made with the slide valve fully
unloaded and the compressor running. The Operating display at this time should indicate a slide valve position of 0%.
If the display is greater than 0%, adjust potentiometer POT
#4 on the SBC until 0% is indicated. If 0% is not attainable,
get as close as possible and then proceed to the next step.
The adjustments of POT #4 and POT #3 are interactive and
POT #3 may require adjustment to allow POT #4 to come
into range.
Completely load the slide valve at 2.2 Vi. The display at this
time should indicate 100%. If the display is less than 100%,
adjust potentiometer POT #3 on the SBC until 100% is indicated.
Repeat this sequence until the slide valve indicates 0% fully
unloaded and 100% fully loaded.
TEMPERATURE and/or PRESSURE
ADJUSTMENT
All temperature and pressure sensors are factory set, calibration is not required.
NOTE: Refer to page 22 for description on microprocessor offset adjustment for temperature and/or pressure.
S70-101 IOM
Page 48
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
MAINTENANCE
TROUBLESHOOTING THE RWB II PLUS COMPRESSOR
SYMPTOM
PROBABLE CAUSES and CORRECTIONS
EXCESSIVE NOISE and VIBRATION
Bearing damage or excessive wear. CONTACT Frick Factor or Frick Co.
Coupling loose on shaft. Tighten coupling. Replace if damaged.
Misalignment between motor and compressor. Realign motor and compressor.
Refrigerant flood-back. Correct system problem.
TROUBLESHOOTING THE OIL SEPARATOR
SYMPTOM
PROBABLE CAUSES and CORRECTIONS
GRADUAL OIL LOSS WITH AN OIL
LEVEL IN THE COALESCER
SECTION SIGHT GLASS
Maintaining too high an oil level. Lower level.
Refrigerant carryover or liquid injection overfeeding. Correct operation.
Contaminated oil, damaged or not seated coalescer filter elements. Replace
oil charge and coalescers.
Oil return valve closed. Open return valve.
Return oil strainer blocked. Clean strainer.
RAPID LOSS WITH NO OIL LEVEL
IN THE COALESCER SECTION
SIGHT GLASS
Compressor unit suction check valve did not close on shutdown. Repair valve.
Bypass open around check valve (if field installed). Close bypass.
Economizer check valve (if applicable) failed.
Coalescer not seated. Reseal.
TROUBLESHOOTING THE HYDRAULIC SYSTEM
SYMPTOM
SLIDE VALVE WILL NOT LOAD OR
UNLOAD
PROBABLE CAUSES and CORRECTIONS
Solenoid coil may be burned out. Replace.
Hydraulic service valve may be closed. Open valve.
Solenoid spool may be stuck or centering spring broken. Free spool or replace spring.
Solenoid may be mechanically actuated by inserting a piece of 3/16" rod against armature pin
and pushing spool to opposite end. If valve is mounted on compressor, push "A" side to
confirm unload capability. If valve is mounted on base, push "B" side to confirm unload capability. If valve works, problem is electrical.
SLIDE VALVE WILL LOAD BUT
WILL NOT UNLOAD
Solenoid coil may be burned out ("A" side if mounted on compressor, "B" side if mounted on
base). Replace coil.
Dirt inside solenoid valve preventing valve from operating both ways. Clean valve.
Solenoid may be mechanically actuated by inserting a piece of 3/16" rod against armature pin
and pushing spool to opposite end. If valve is mounted on compressor, push "A" side to
confirm unload capability. If valve is mounted on base, push "B" side to confirm unload capability. If valve works, problem is electrical.
SLIDE VALVE WILL UNLOAD BUT
WILL NOT LOAD
Solenoid coil may be burned out ("B" side if mounted on compressor, "A" side if mounted on
base). Replace coil.
Dirt inside solenoid valve preventing valve from operating both ways. Clean valve.
Solenoid may be mechanically actuated by inserting a piece of 3/16" rod against armature
pin and pushing spool to opposite end. If valve works, problem is electrical.
SLIDE STOP WILL NOT FUNCTION
EITHER DIRECTION
Solenoid coil may be burned out. Replace.
Check solenoid coils (see Vi Control table, page 31).
SLIDE VALVE WILL NOT MOVE
Slipper seals worn out or damaged.
Unloader spindle or slide valve jammed.
Internal check valve bad. Clean, repair, or replace.
Check needle valve adjustment.
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
MAINTENANCE
S70-101 IOM
Page 49
TROUBLESHOOTING THE OIL PUMP SYSTEM
SYMPTOM
PUMP WILL NOT PRODUCE
ENOUGH OIL PRESSURE
TO START COMPRESSOR
PROBABLE CAUSES and CORRECTIONS
Filter cartridge may be blocked. Check PSID across filter. Replace filter.
Strainer may be blocked. Clean.
Oil pressure regulator set too low or stuck open. Readjust or repair.
Low oil level. Add oil.
Excessive refrigerant in oil. Equalize separator to a lower pressure.
OIL PRESSURE RAPIDLY DROPS
OFF WHEN COMPRESSOR STARTS
Oil pressure regulating valve improperly adjusted. Readjust valve. Check manual system.
Regulator defective. Replace.
Excessive refrigerant in oil. Check heaters.
OIL PRESSURE FLUCTUATES
Liquid injection overfeeding or refrigerant carryover. Make necessary adjustments
or corrections.
Dirty oil filter. Replace
Low oil level. Add oil.
NOISE and VIBRATION
Pump strainer blocked. Clean.
Liquid injection overfeeding. Adjust liquid injection.
Pump worn out. Repair or replace.
GREASE LEAKS FROM VENT PORT
IN THE SIDE OF THE PUMP BODY
Normal leakage which will cease after initial operation. Black oil leaking
from this vent indicates oil seal wear or failure. Replace seal.
MAIN FILTER PSID IS TOO HIGH
Filters clogged with dirt. Replace.
Oil is too cold. Allow oil to warm up and check again.
Service valve on filter outlet is partially closed. Open valve fully.
TROUBLESHOOTING THE LIQUID INJECTION OIL COOLING SYSTEM
SYMPTOM
HIGH OIL TEMPERATURE
PROBABLE CAUSES and CORRECTIONS
Insufficient liquid supply. Check receiver level. Check strainer.
Equalizer pressure too high. Lower pressure.
Suction superheat too high. Correct system problem.
Thermal valve power head lost charge. Replace.
Liquid strainer blocked. Clean.
Liquid supply line not sized properly. Install larger line.
Operating conditions significantlydifferent from design.
LOW OIL TEMPERATURE
Equalizing pressure too low. Raise.
Suction superheat too low or refrigerant flood-back on compressor. Correct
system problem.
Low load conditions. Valve oversized, increase load or use smaller thermovalve.
Operating conditions significantlydifferent from design.
OIL TEMPERATURE FLUCTUATES
System conditions rapidly fluctuate causing liquid injection system to overrespond.
Stabilize system operation.
S70-101 IOM
Page 50
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
MAINTENANCE
THERMAL EXPANSION VALVES
JORDAN TEMPERATURE REGULATOR VALVE
(For low differential pressure applications)
In situations where system load conditions increase or decrease over extended periods of time and the liquid injection thermal expansion valve is not adequate for the new
conditions, an improvement in valve performance may be
achieved by increasing or decreasing discharge tube size.
NOTE: DO NOT ATTEMPT TO ADJUST SUPERHEAT ADJUSTMENT STEM ON BOTTOM OF VALVE IN AN EFFORT
TO CHANGE THE VALVE’S PERFORMANCE. THIS ADJUSTMENT IS PRESET AT THE FACTORY. ONLY ADJUST
1/4" BLEED VALVE ON EQUALIZING LINE.
TYPE D THERMAL EXPANSION VALVE (1-15 TONS)
R-717
TYPE H THERMAL EXPANSION VALVE (2-1/2 TO 16
TONS) R-22
TYPE A THERMAL EXPANSION VALVE (20-100 TONS)
R-717
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
MAINTENANCE
TYPE M THERMAL EXPANSION VALVE (12 TO 34 TONS)
R-22
S70-101 IOM
Page 51
R-22 TX VALVE SIZES
TX VALVE MODE
HVE
HVE
HVE
HVE
-
2-/1/2
5-1/2
11
16
FPT CONNECTION
1/2
1/2
1/2
1/2
MVE - 12
MVE - 21
MVE - 34
1
1
1
VVE - 52
VVE - 70
VVE - 100
1
1
1
JORDAN TEMPERATURE REGULATOR
VALVE
TYPE V THERMAL EXPANSION VALVE (52 TO 100 TONS)
R-22
R-717 TX VALVE SIZES
TX VALVE MODE
PORT SIZE
DISCHARGE TUBE SIZE
DAE
DAE
DAE
DAE
DAE
-
1
2
5
10
15
1/16
1/16
7/64
3/16
3/16
1/32
1/16
5/64
7/64
5/32
AAE
AAE
AAE
AAE
AAE
-
20
30
50
75
100
5/16
5/16
3/8
3/8
7/16
1/8
5/32
3/16
NONE
NONE
To increase or decrease the discharge temperature/oil temperature, adjust the knurled nut located on the actuator stem
of the Jordan Temperature regulator valve. The temperature is allowed to increase as the nut is turned higher on the
stem and decreases as the nut is turned lower.
S70-101 IOM
Page 52
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
MAINTENANCE
MICRO COMPONENT PLACEMENT DIAGRAM
FRONT PANEL (REAR VIEW)
CONTRAST POT
26 COND
DISPLAY
1
GREEN WIRE
12 COND
CSA ONLY
OFF
POWER
SUPPLY
F1
115
GND
NEU
230
3
ON
BATTERY
BAT
U4
P13
F2
P11
P12
FRICK REV D
RXB/RDB
1
P9
ANALOG
EXPANSION
DIGITAL INPUT
MODULES
POT POT
3 4
C.T.
TERM
AVERTISSEMENT
CET EQUIPMENT
RENFERME PLUSIEURS
CIRCUITS SOUS TENSION.
VOIR LE SCHEMA
PORT
1
P10
P15
U5
WARNING
MORE THAN ONE
LIVE CIRCUIT
SEE DIAGRAM
DIGITAL OUTPUT
MODULES
FUSES FU1-FU16
SPAN ZERO
ANALOG TERMS
DIG I/O TERMS
P5
1
P4
16 17
P3
34 35
P2
48
P1
ANALOG
WIRING
WIREWAY-AC WIRING ONLY
1A FU
1FU
TYPE BAF 15 AMP
250 VOLTS
C.T. & SBC POWER
SUPPLY WIRING
SP FU
(IF REQ'D)
1A
TOROID
2A
*
2A
25
26
TR
CR
CR
CR
CR
3CR
2CR
1CR
27
1CR1
SPARE
GND
LUG
CUSTOMER'S
GROUND WIRE
GND
LUG
TO DOOR & STUD GREEN
ON FRONT PANEL
THIS STUD NOT REQ'D
IF GROUNDING WASHER &
STUD ON SIDE ARE USED
SPARE
2FU
TYPE FNM 10 AMP
250 VOLTS
ANALOG
DRAIN WIRES
SPARE
SPARE
40 TERMINALS
PANEL
STUD
TERMINAL SCREW
TIGHTENING TORQUE
#22-#8 AWG
20 LB.IN (2.3Nm)
L2 L1
GROUNDING WASHER
COPPER CONDUCTORS ONLY
CUSTOMER'S 120 VAC
POWER CONNECTION
INDICATES DEVICES SUPPLIED ONLY WHEN OPTIONAL OR REQUIRED
* INDICATES SUPPLIED ONLY WHEN OIL PUMP IS REQUIRED
RXBELD5
3
COMPUTER
COMMUNICATIONS
PORT: AC-422
8
8
8
9
9
9
4
4
4
5
5
5
RXB PLUS TELECOMMUNICATIONS
COMPUTER TO MICROPROCESSOR WIRING DIAGRAM
COMPRESSOR #1
COMPRESSOR #2
PORT #1
PORT #1
DATA BIT 3
DATA BIT 2
DATA BIT 1
DATA BIT 0
SPARE
OIL PUMP SEL SW
OIL HEATER RELAY
ALARM
POWER
ECONOMIZER (IF REQ’D)
HI VI LIQ INJ (IF REQ’D)
LIQUID INJECTION (IF REQ’D)
SLIDE STOP DECREASE
SLIDE STOP INCREASE
SLIDE VALVE UNLOAD
COMPRESSOR START RELAY
POWER
SLIDE VALVE LOAD
AUX 2
AUX 1
OIL PUMP SEL SW
COMPRESSOR AUX
REMOTE UNLOAD
REMOTE LOAD
REMOTE RUN
NEUTRAL
OIL LEVEL SWITCH
RED
WHT
BLK
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
MAINTENANCE
S70-101 IOM
Page 53
SBC WIRING DIAGRAM
1
1
S70-101 IOM
Page 54
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
MAINTENANCE
MICRO PANEL ASSEMBLY WIRING DIAGRAM
HOT
HOT
01
02
03
1
CUSTOMER SUPPLIED 120 VAC CONTROL TRANSFORMER POWER SOURCE IS REQUIRED
NEUTRAL
ALL POWER SOURCES SHALL BE GROUNDED ON ONE SIDE
-ISOLATED AND SEPARATED FROM OTHER INDUCTIVE LOADS SUCH AS LIGHTING CIRCUITS
-OR FROM FRICK SUPPLIED OR SPECIFIED STARTER, USE MINIMUM #12 AWG FOR FEED
NEUTRAL
IF SEPARATE FEED FOR HEATER CIRCUIT IS DESIRED,
REMOVE JUMPERS 1 TO 1A & 2 TO 2A & CONNECT
A SEPARATE 120 VAC SOURCE TO 1A & 2A
FOR (2) 115V-1 KW HTR'S,MOVE
WIRE TO 1A FU & NUMBER 25A
1 FU
1CR
15
1A
04
1CR
15
05
06
2A
26
SEPARATOR OIL HEATER(S)
5 KW HTR'S
1 KW HTR'S OPTIONAL
27
ALL HEATER WIRING
TO BE #14 AWG
#14 RED
ALL NEUTRAL (EXP: 2 & 2A)
WIRING TO BE WHITE
EXCEPT WHERE NOTED
*
07
08
10
TIE NEUTRAL TO GROUND
AT SOURCE
2
HEATER
25A
ADD 1A FU FOR 115V-1KW HTR
ALL NEUTRALS ENTERING
THIS ENCLOSURE SHALL
BE TIED TOGETHER AT
SOURCE, NOT IN THIS
ENCLOSURE
GROUND BAR IN MICRO
HEATER
25
1A FU
EARTH BUSBAR AT
POWER SOURCE
2 FU
OIL PUMP
OFF
AUTO
HAND
EMERGENCY
STOP
6
5
39
(XOO)
SBC TERMINALS
FOR DIGITAL I/O
FU16
09
10
48
16
11
46
15
47
31
PROGRAMMABLE CONTROL
DATA CODE BIT 3
45
32
PROGRAMMABLE CONTROL
DATA CODE BIT 2
43
33
PROGRAMMABLE CONTROL
DATA CODE BIT 1
34
PROGRAMMABLE CONTROL
DATA CODE BIT 0
FU15
FU14
12
44
14
FU13
13
42
13
41
FU12
14
40
12
39
15
38
11
36
10
B
(OOX)
39
3 *
CR
OIL PUMP START/RUN
63
35
9
1
CR
OIL HEATER
3, 4
33
10
31
11
29
12
HI VI LIQ INJ (IF REQ'D)
27
13
LIQUID INJECTION (IF REQ'D)
25
14
23
15
37
35
TO LN. 30
FU10
16
SPARE
7
*
FU11
FU9
17
34
9
ALARM (PRE & CUTOUT)
RELAY &/OR LAMP OPTIONAL
FU8
18
32
8
ECONOMIZER (IF REQ'D)
FU7
19
30
7
FU6
20
28
6
FU5
21
26
5
DECREASE TO 2.2 Vi
FU4
22
24
4
DECREASE TO 3.5 Vi
FU3
23
22
3
24
20
2
25
18
1
COIL
21
16
FU2
COIL
19
17
FU1
17
38
2
CR
SEE
NOTE C
SLIDE VALVE UNLOAD
SHOWN W/SOL ON COMPR
COIL W/SOL ON BASE
SLIDE VALVE LOAD
SHOWN W/SOL ON COMPR
COIL W/SOL ON BASE
COMPR. START/RUN
60
26
27
29
16
8
15
AUX 2 (SEE NOTE B)
30
14
7
13
AUX 1 (SEE NOTE B)
B
(OOX) 28
12
6
11
OIL PUMP AUX
20
10
5
9
28
29
*
FROM LN.15
*
OIL PUMP AUX
30
19
COMPR. AUX
31
COMPRESSOR AUX
COMPR. RUN TIME METER
32
LIQUID INJECTION
PRESSURE REGULATOR
(ONLY ON BOOSTERS
WITH LIQ INJ)
33
34
REMOTE UNLOAD
35
8
4
7
REMOTE UNLOAD
22
6
3
5
REMOTE LOAD
23
4
2
3
REMOTE START/RUN/STOP
24
2
1
1
OIL LEVEL
(NOT REQUIRED WITH
FULL-LUBE OIL PUMP)
21
REMOTE LOAD
36
REMOTE START/RUN/STOP
37
1 LSL
38
(N.O. HELD CLOSED)
39
5
2
RXBELD1
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
MAINTENANCE
S70-101 IOM
Page 55
MICRO PANEL ASSEMBLY WIRING DIAGRAM
RXBELD2
5
2
NOTE A:
IF COMPR. MOTOR STARTER IS A FRICK SUPPLIED STARTER
OR CONFORMS TO FRICK STARTER SPECS, WIRE AS SHOWN
ON LINE 60 ONLY. JUMP TERM 6 TO 36.
IF 2CR IS USED AS A ISOLATED CONTACT, WIRE AS SHOWN
BETWEEN THE HOT & NEUTRAL LINES ON LINE 60.
IF 2CR IS USED AS A ISOLATED CONTACT, WIRE AS SHOWN
BETWEEN THE HOT & NEUTRAL LINES ON LINE 60.
SAME NOTES APPLY TO OIL PUMP STARTER CIRCUIT
ON LINE 63.
40
41
42
43
44
NOTE B:
FOR OPTIONAL ALARMS & SHUTDOWNS:
(HIGH LEVEL SHUTDOWN ETC.)
WHEN REFERENCING MICRO POWER TO OPERATE COMPR.
MOTOR STARTER (PARAGRAPH 1-NOTE A), REMOVE JUMPER
36 TO 42 & INSERT ISOLATED CONTACT(S). JUMP 42 TO
EITHER 29 OR 30 (AUX 1 OR AUX 2). PROGRAM AUX TO
SHUTDOWN-NORMALLY CLOSED.
45
46
47
WHEN USING 2CR AS A ISOLATED CONTACT (PARAGRAPH 2,
NOTE A), REMOVE JUMPER 36 TO 42 & INSERT ISOLATED
CONTACT(S). A SEPARATE ISOLATED CONTACT SHOULD BE
INSERTED BETWEEN 5 & 29 OR 30. PROGRAM AUX AS
ABOVE. SEE 1-PSH WIRING BELOW FOR EXAMPLE.
AUX 1 & AUX 2 CAN BE PROGRAMMED TO ALARM OR
SHUTDOWN, NOR. OPEN OR NOR. CLOSED.
48
49
50
NOTE C:
A SURGE SUPPRESSOR OR MOV TO BE INSTALLED ACROSS
ALL INDUCTIVE LOADS IN CONTROL CENTER.
51
52
SURGE SUPPRESSOR
SUPPRESSOR SPECIFICATIONS:
RC NETWORK CONSISTING OF A .1 MFD CAPACITOR, 600
VDC IN SERIES WITH A 47 OHM RESISTOR.
USE ELECTROCUBE #RG2031-3-6 OR EQUAL.
53
54
VARISTOR
METAL OXIDE VARISTOR (MOV) SPECIFICATIONS:
GE #V130LA10A OR EQUAL
55
1 PSH WIRING FOR GAUGEBOARD OPTION
1-PSH
PROGRAM
HPCO
AUX 1 AS
NOR. CLOSED
5
30
SHUTDOWN
56
57
58
36
HOT
59
JUMP TO 6
IF REQ'D
SEE NOTE A
60
(Y)
JUMPER
SEE NOTE B
36
WIRING IF ISOLATED
2CR CONTACT IS USED
SEE NOTE A
(Y) 2CR (Y)
42
COMPR MOTOR STARTER
IF STARTER CONTAINS MULTIPLE
CONTACTORS, RELAYS, & TIMERS,
ADD SUPRESSORS OR VARISTORS
AT EACH COIL (SEE NOTE C)
18
61
HOT
62
JUMP TO 6
IF REQ'D
SEE NOTE A
63
(Y) 3CR (Y)
37
WIRING IF ISOLATED
3CR CONTACT IS USED
SEE NOTE A
42
NEU
NEU
OIL PUMP STARTER
SUPRESSOR OR VARISTOR
INSTALLED AT OIL
PUMP STARTER COIL
(SEE NOTE C)
8
64
TERMINALS IN CONTROL CENTER
65
66
NO THREE PHASE WIRING SHALL ENTER OR LEAVE MICRO PANEL
NO SINGLE PHASE OVER 300 VOLTS SHALL ENTER OR LEAVE
MICRO PANEL
* INDICATES FURNISHED OR REQUIRED WITH OIL PUMP ONLY
67
FOR PROPER INSTALLATION OF ELECTRONIC EQUIPMENT,
SEE FRICK PUBLICATION S90-400 SB/ SERVICE MANUAL.
ALL CONTROL CENTER WIRING TO BE #16 AWG
STRANDED WIRE UNLESS SPECIFIED OTHERWISE.
FOR RXB PACKAGE/MICROPROSSOR TEST PROCEDURE,
SEE MMIB NO. 4.11.10.8
INDICATES DEVICES SUPPLIED ONLY
WHEN OPTIONAL OR REQUIRED
WIRING BY OTHERS- ALL WIRING ENTERING CONTROL
CENTER (INCLUDING GROUND & NEUTRAL) TO BE #14
AWG STRANDED WIRES UNLESS SPECIFIED OTHERWISE.
68
69
70
5
2
FOR INSTALLATION OF MICROPROCESSOR BOARD
AND EPROMS, SEE MMIB NO. 4.11.10.11
FOR HIGH POT TEST PROCEDURE, SEE MMIB NO. 4.11.10.7
SEE 640D0024 FOR STANDARD CONTROL CENTER ASSEMBLY
S70-101 IOM
Page 56
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
MAINTENANCE
MICRO PANEL ASSEMBLY WIRING DIAGRAM
01
5
2
C.T. MOUNTED IN STARTER OR
MOTOR JUNCT. BOX (BY OTHERS)
02
03
MOTOR
AMPS
04
R
4
0-5 AMP AC
SECONDARY
3
ONE PHASE
OF MOTOR
CHANNEL 12
0-5 AMP AC
MOTOR AMPS
R
SEE IOM MANUAL
FOR C.T. WIRE SIZING
05
06
SLIDE VALVE
POSITION
POTENTIOMETER
07
3
2
1
RED
WHITE
BLACK
R
(CHANNEL 11)
SLIDE VALVE
W
B
CABLE #11
08
09
+
10
S
_
(CHANNEL 10)
1-5 VDC
ECON PRESS
11
+
12
PE-4
13
S
_
RED
WHITE
BLACK
+
(CHANNEL 9)
1-5 VDC
SUCT PRESS
S
_
CABLE #9
DO NOT GROUND PE DRAIN AT PANELCABLE
TYPICAL
14
+
15
PE-3
16
S
_
RED
WHITE
BLACK
+
(CHANNEL 8)
1-5 VDC
DISCH PRESS
S
_
CABLE #8
17
+
18
PE-2
19
S
_
RED
WHITE
BLACK
+
(CHANNEL 7)
1-5 VDC
FILTER PRESS
(IF OPTIONAL OR REQ'D)
S
_
CABLE #7
20
+
21
PE-1
22
S
_
RED
WHITE
BLACK
+
(CHANNEL 6)
1-5 VDC
OIL PRESS
S
_
CABLE #6
23
24
#20 AWG TWISTED PAIR
2000 FT. MAX. DISTANCE
25
TE-5
26
27
BLACK
CABLE #5
COLOR MAY VARY
TYPICAL
29
BLACK
BLACK
WHITE
28
TE-4
WHITE
CABLE #4
BLACK
+
(CHANNEL 5)
SPARE TEMP
REMOTE TEMPERATURE
CAPACITY CONTROL (OPTIONAL)
WIRING BY OTHERS
SEE NOTE 2A
_
+
(CHANNEL 4)
SEP TEMP
_
30
WHITE
31
TE-3
32
BLACK
CABLE #3
BLACK
+
(CHANNEL 3)
OIL TEMP
_
33
WHITE
34
TE-2
35
BLACK
CABLE #2
BLACK
+
(CHANNEL 2)
DISCH TEMP
_
36
WHITE
37
TE-1
38
5
39
BLACK
CABLE #1
BLACK
+
(CHANNEL 1)
SUCT TEMP
_
2
RXBELD3
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
MAINTENANCE
S70-101 IOM
Page 57
Revised 1/97
MICRO PANEL ASSEMBLY WIRING DIAGRAM
5
2
40
41
42
43
44
45
46
TEMPERATURE SENSOR WIRING TO BE #8760
BELDEN CABLE OR EQUAL. GROUND DRAIN WIRE
AT PANEL GROUND ONLY. INSULATE AT PROBE END
47
48
49
NOTE 2A:
SPECIFICATIONS FOR TEMP. CAPACITY CONTROL
50
-SETPOINT RANGE: -50
OF. TO 100OF.
-TEMP PROBE SIZE- .188 DIA x 4" LONG
304 S.S. WITH (2) 24" LEADS
51
-MOUNTING IN WELL IS DESIRABLE
USE HEAT TRANSFER COMPOUND
52
-WIRE AS SHOWN IN SEPARATE CONDUIT
FROM ALL OTHER WIRING
USE BELDEN #8761 CABLE OR EQUAL
53
TEMP PROBE-FRICK P/N - 111Q0280982
54
WELL FOR ABOVE, 3/4"MPT WELL CONNECTION,
1/2" FPT FOR CONNECTION BOX- P/N - 990A0014H01
55
HEAT TRANSFER COMPOUND-P/N - 111Q0831807
56
OPTIONAL
WIRING FOR LEAD-LAG SEQUENCING
57
58
3
59
SBC
RS422
PORT 1
UNIT "A"
60
61
4
5
8
9
3
GRN
BLK
RED
BLK
4
5
8
SBC
RS422
PORT 1
UNIT "B"
9
62
64
USE BELDEN #8777 OR EQUAL (3 TWISTED PAIRS)
COLOR CODING SHOWN IS BELDEN #8777
RS 422 WIRING SHALL BE SEPARATE
FROM ALL OTHER WIRING
65
WIRED AT FRICK IF BOTH UNITS
ARE ON THE SAME SKID
63
NOTE: WHEN USING THE RS422 PORTS FOR
LEAD-LAG, THEY CANNOT BE USED FOR
ANY OTHER COMMUNICATIONS
66
67
68
69
70
FRONT PANEL
71
DISPLAY
P1
1
26 COND RIBBON CABLE
1
P11
72
SBC
GREEN WIRE
STUD
P13
115
STUD
1 P10
230
74
12 COND RIBBON CABLE
SW1
KEY 1
PAD
73
SET SW1 TO CORRECT VOLTAGE
75
WRAP WIRES THROUGH TOROID TWO (2)
TIMES, ALL IN THE SAME DIRECTION
76
5
NO CONNECTION ON 230
FOR GROUNDED CIRCUITS
115 GND NEU 230
GREEN
REV D SBC ONLY
TOROID
FERRITE
RING
2
77
78
RXBELD4
S70-101 IOM
Page 58
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
MAINTENANCE
P & I DIAGRAM, Models 12, 15, & 19 w/Full-Lube Oil Pump
LEGEND (Covers P & I diagrams pages 58 – 60) See page 59 for additional notes
AC
C
CC
DTA
DTCO
F
HPA
HPCO
HTA
HTCO
HTR
HV
LICO
LLCO
LPA
LPCO
LSL
LTA
AUTO CYCLE
COMPRESSOR
CAPACITY CONTROL
HIGH DISCHARGE TEMPERATURE ALARM
HIGH DISCHARGE TEMPERATURE CUTOUT
FILTER
HIGH DISCHARGE PRESSURE ALARM
HIGH DISCHARGE PRESSURE CUTOUT
HIGH OIL TEMPERATURE ALARM
HIGH OIL TEMPERATURE CUTOUT
HEATER
HAND VALVE
LIQUID INJECTION REFRIGERANT CUTOUT
LOW OIL SEPARATOR LEVEL CUTOUT
LOW SUCTION PRESSURE ALARM
LOW SUCTION PRESSURE CUTOUT
LEVEL SWITCH
LOW OIL TEMPERATURE ALARM
LTCO
M
MLC
NV
OF
OHTR
OPA
OPCO
P
PE
PM
PSV
SG
STR
SV
TE
TW
V
LOW OIL TEMPERATURE CUTOUT
MOTOR
MOTOR LOAD CONTROLLER
NEEDLE VALVE
OIL FILTER
OIL HEATER TEMPERATURE SWITCH
LOW OIL PRESSURE ALARM
LOW OIL PRESSURE CUTOUT
PUMP
PRESSURE INDICATOR
PUMP MOTOR
HIGH PRESSURE SAFETY VALVE
SIGHT GLASS
STRAINER
SOLENOID VALVE
TEMPERATURE ELEMENT
THERMOWELL
VESSEL
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
MAINTENANCE
S70-101 IOM
Page 59
P & I DIAGRAM, Models 24, 30, 39, & 50 w/Full-Lube Oil Pump
SUCTION GAS TO
THE COMPRESSOR
AC
LPA
LPCO
OC
PE
4
19
HV
1
SHIPPED LOOSE
HPA
HPCO
16
TE
1
7
PE
3
11
12
SV
3
3
17
1
NV
C-1
M-1
4
1 MLC
2 MLC
8
5
2
10
6
SV
4
20
15
TE
2
OIL CHARGE
DISCHARGE GAS
FROM THE UNIT
DTA
DTCO
PSV
1
LSL
1
STOP/CHECK VALVE
NOTE: THIS VALVE
INCLUDES INTERNAL
CHECK VALVE
V-1
HTR
1
SG
LLCO
TE
4
SG
TE
3
HTA
HTCO
LICO
LTA
LTCO
OHTR
PIPING
WITH NO
OIL PUMP
P-1
PM-1
FROM OIL
RELIEF VALVE
ON OIL COOLER
(OPTIONAL)
F-1
PE
1
OPA
OPCO
CYCLING
OIL PUMP
OPTION
ORIFICE TO
RESTRICT OIL
FLOW AT
START-UP
NV
TO OIL COOLER
OR FILTER
FROM OIL
COOLER OR
SEPARATOR
STR
RXBPI50
CONNECTION DESCRIPTION
1 MAIN OIL SUPPLY
2 SLIDE VALVE POSITION
3 LOW Vi LIQUID INJECTION
4 HIGH Vi LIQUID INJECTION
5 ECONOMIZER
7 SUCTION PRESSURE
8 CLOSED THREAD
10 DISCHARGE PRESSURE
11 LIQUID INJECTION BLEED LINE
12 COALESCER BLEED LINE
15 VENT UNLOADING
16 THERMO WELL
18 OIL INJECTION
19 SUCTION PRESSURE
20 SEAL WEEPAGE
NOTES
PRESSURE TRANSDUCER INDICATE:
PE1 OIL PRESSURE (MAINIFOLD)
PE3 DISCHARGE PRESSURE
PE4 SUCTION PRESSURE
TEMPERATURE PROBES INDICATE:
TE1 SUCTION GAS TEMPERATURE
TE2 DISCHARGE GAS TEMPERATURE
TE3 LUBE OIL TEMPERATURE
TE4 SEPARATOR OIL TEMPERATURE
SOLENOID VALVE FUNCTION:
SV1 ENERGIZE UNLOAD SLIDE VALVE
SV2 ENERGIZE LOAD SLIDE VALVE
SV3 ENERGIZE INCREASE VOLUME RATIO
SV4 ENERGIZE DECREASE VOLUME RATIO
S70-101 IOM
Page 60
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
MAINTENANCE
P & I DIAGRAM, All Models
WATER-COOLED OIL COOLER
THERMOSYPHON OIL COOLER
1" AMOT VALVE (REMOVE TEMP.
ELEMENT BEFORE WELDING, REINSTALL
ELEMENT W/SENSING BULB IN "A" PORT)
TO OIL
SEPARATOR
TO OIL FILTER
FROM OIL
SEPARATOR
FROM OIL
SEPARATOR
WATER REGULATING VALVE
B
OIL
RELIEF
VALVE
(OPTIONAL)
A
TO OIL
SEPARATOR
WCOC
C
OIL
RELIEF
VALVE
(OPTIONAL)
3
TSOC
RXBWCOC
RXBTSOC
3
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
PROPER INSTALLATION OF ELECTRONIC EQUIPMENT
S70-101 IOM
Page 61
PROPER INSTALLATION OF ELECTRONIC EQUIPMENT
IN AN INDUSTRIAL ENVIRONMENT
In today’s refrigeration plants, electronic controls have found
their way into almost every aspect of refrigeration control.
Electronic controls have brought to the industry more precise control, improved energy savings and operator conveniences. Electronic control devices have revolutionized the
way refrigeration plants operate today.
The earlier relay systems were virtually immune to radio frequency interference (RFI), electromagnetic interference
(EMI), and ground loop currents. Therefore installation and
wiring were of little consequence and the wiring job consisted of hooking up the point-to-point wiring and sizing the
wire properly. In an electronic system, improper installation
will cause problems that outweigh the benefits of electronic
control. Electronic equipment is susceptible to RFI, EMI,
and ground loop currents which can cause equipment shutdowns, processor memory and program loss, erratic behavior, and false readings. Manufacturers of industrial electronic equipment take into consideration the effects of RFI,
EMI, and ground loop currents and incorporate protection of
the electronics in their designs. These manufacturers require that certain installation precautions be taken to protect the electronics from these effects. All electronic equipment must be viewed as sensitive instrumentation and therefore requires careful attention to installation procedures.
These procedures are well known to instrument engineers,
but are usually not followed by general electricians.
VOLTAGE SOURCE
Selecting the voltage source is extremely important for
proper operation of electronic equipment in an industrial environment. Standard procedure for electronic instrumentation is to provide a “clean” separate source voltage in order
to prevent EMI, from other equipment in the plant, from interfering with the operation of the electronic equipment. Connecting electronic equipment to a breaker panel (also known
as lighting panels and fuse panels) subjects the electronic
equipment to noise generated by other devices connected
to the breaker panel. This noise is known as electromagnetic interference (EMI). EMI flows on the wires that are
common to a circuit. EMI cannot travel easily through transformers and therefore can be isolated from selected circuits.
Use a control transformer to isolate the electronic control panel from other equipment in the plant that generate EMI. (Figure 1)
GROUND
CONTROL
TRANSFORMER
ISOLATED
CIRCUIT
There are a few basics, that if followed, will result in a troublefree installation. The National Electric Code (NEC) is a guideline for safe wiring practices, but it does not deal with procedures used for electronic control installation. Use the following procedures for electronic equipment installation.
These procedures do not override any rules by the NEC,
but are to be used in conjunction with the NEC code.
ELECTRONIC CONTROL
CORRECT
WIRE SIZING
Size supply wires one size larger than required for amperage draw to reduce instantaneous voltage dips
caused by large loads such as heaters and contactors
and solenoids. These sudden dips in voltage can cause
the processor, whether it be a microprocessor, a computer,
or a PLC to malfunction momentarily or cause a complete
reset of the control system. If the wire is loaded to its maximum capacity, the voltage dips are much larger, and the
potential of a malfunction is very high. If the wire is sized
one size larger than required, the voltage dips are smaller
than in a fully loaded supply wire, and the potential for malfunction is much lower. The NEC code book calls for specific wire sizes to be used based on current draw. An example of this would be to use #14 gauge wire for circuits up
to 15 amp or #12 gauge wire for circuits of up to 20 amp.
Therefore, when connecting the power feed circuit to an electronic industrial control, use #12 gauge wire for a maximum
current draw of 15 amp and #10 wire for a maximum current
draw of 20 amp. Use this rule of thumb to minimize voltage
dips at the electronic control.
ART1T
GROUND
CONTROL
TRANSFORMER
NONISOLATED
CIRCUIT
ELECTRONIC
CONTROL
INCORRECT
Figure 1
ART1B
S70-101 IOM
Page 62
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
PROPER INSTALLATION OF ELECTRONIC EQUIPMENT
GROUNDING
Grounding is the most important factor for successful operation and is also the most overlooked. The NEC states
that control equipment may be grounded by using the rigid
conduit as a conductor. This worked for the earlier relay
systems, but it is not acceptable for electronic control equipment. Conduit is made of steel and is a poor conductor relative to a copper wire. Electronic equipment reacts to very
small currents and must have a good ground in order to
operate properly; therefore, copper grounds are required
for proper operation. Note: aluminum may be used for the
large three-phase ground wire.
The ground wire must be sized the same size as the
supply wires or one size smaller as a minimum. The
three phase power brought into the plant must also have
a ground wire, making a total of four wires. In many installations that are having electronic control problems, this essential wire is usually missing. A good ground circuit must
be continuous from the plant source transformer to the electronic control panel for proper operation. (Figure 2) Driving
a ground stake at the electronic control will cause additional
problems since other equipment in the plant on the same
circuits will ground themselves to the ground stake causing
large ground flow at the electronic equipment.
3-PHASE
BUS
PLANT SUPPLY
TRANSFORMER
ALUMINUM
OR COPPER
COPPER
ELECTRONIC
CONTROL
Never run any wires through an electronic control panel
that do not relate to the function of the panel. Electronic control panels should never be used as a junction box. These wires may be carrying large transients that
will interfere with the operation of the control. An extreme
example of this would be to run the 480 volts from a motor
starter through the control panel to the motor.
When running conduit to an electronic control panel, take
notice of the access holes (knockouts) provided by the manufacturer. These holes are strategically placed so that the
field wiring does not interfere with the electronics in the panel.
Never allow field wiring to come in close proximity with
the controller boards since this will almost always cause
problems.
Do not drill a control panel to locate conduit connections. You are probably not entering the panel where the
manufacturer would like you to since most manufacturers
recommend or provide prepunched conduit connections.
Drilling can cause metal chips to land in the electronics and
create a short circuit. If you must drill the panel, take the
following precautions: First cover the electronics with plastic and tape it to the board with masking or electrical tape.
Second, place masking tape or duct tape on the inside of
the panel where you are going to drill. The tape will catch
most of the chips. Then clean all of the remaining chips from
the panel before removing the protective plastic. It would
be a good idea to call the manufacturer before drilling the
panel to be sure you are entering the panel at the right place.
When routing conduit to the top of an electronic control panel,
condensation must be taken into consideration. Water can
condense in the conduit and run into the panel causing catastrophic failure. Route the conduit to the sides or bottom
of the panel and use a conduit drain. If the conduit must
be routed to the top of the panel, use a sealable conduit
fitting which is poured with a sealer after the wires have
been pulled, terminated and the control functions have been
checked. A conduit entering the top of the enclosure must
have an “O” ring-type fitting between the conduit and
the enclosure so that if water gets on top of the enclosure
it cannot run in between the conduit and the enclosure. This
is extremely important in outdoor applications.
ART2
Figure 2
480 VOLT
3-PHASE
BUS
WIRING PRACTICES
GROUND BUS
Do not mix wires of different voltages in conduit. An
example of this would be the installation of a screw compressor package. The motor voltage is 480 volts and the
panel control power is 120 volts. The 480 volt circuit must
be run from the motor starter to the motor in its own
conduit. The 120 volt circuit must be run from the motor starter control transformer to the control panel in its
own separate conduit. If the two circuits are run in the
same conduit, transients on the 480 volt circuit will be inducted into the 120 volt circuit causing functional problems
with the electronic control. Dividers must be used in wire
way systems (conduit trays) to separate unlike voltages. The
same rule applies for 120 volt wires and 220 volt wires. Also,
never run low voltage wires in the same conduit with
120 volt wires. (Figure 3)
MOTOR
STARTER
PANEL
MOTOR
SEPARATE
CONDUIT
ART3
Figure 3
480 V
120 V
ELECTRONIC
CONTROL
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
PROPER INSTALLATION OF ELECTRONIC EQUIPMENT
Never add relays, starters, timers, transformers, etc. inside an electronic control panel without first contacting
the manufacturer. Contact arcing and EMI emitted from
these devices can interfere with the electronics. Relays and
timers are routinely added to electronic control panels by
the manufacturer, but the manufacturer knows the acceptable device types and proper placement in the panel that
will keep interference to a minimum. If you need to add these
devices contact the manufacturer for the proper device types
and placement.
PLANT SUPPLY
TRANSFORMER
3-PHASE
BUS
GROUND BUS
Never run refrigerant tubing inside an electronic control panel. If the refrigerant is ammonia, a leak will totally
destroy the electronics.
If the electronic control panel has a starter built into the
same panel, be sure to run the higher voltage wires
where indicated by the manufacturer. EMI from the wires
can interfere with the electronics if run too close to the circuitry.
S70-101 IOM
Page 63
ELECTRONIC
CONTROL
ELECTRONIC
CONTROL
ELECTRONIC
CONTROL
CORRECT
ART4T
PLANT SUPPLY
TRANSFORMER
Never daisy-chain or parallel-connect power or ground
wires to electronic control panels. Each electronic control panel must have its own supply wires back to the power
source. Multiple electronic control panels on the same power
wires create current surges in the supply wires which can
cause controller malfunctions. Daisy-chaining ground wires
allows ground loop currents to flow between electronic control panels which also causes malfunctions. (Figure 4)
It is very important to read the installation instructions thoroughly before beginning the project. Make sure you have
drawings and instructions with your equipment. If not, call
the manufacturer and have them send you the proper instructions. Every manufacturer of electronic equipment
should have a knowledgeable staff, willing to answer your
questions or fax additional information. Following correct wiring procedures will ensure proper installation of your electronic equipment.
3-PHASE
BUS
GROUND BUS
ELECTRONIC
CONTROL
ART4B
ELECTRONIC
CONTROL
INCORRECT
Figure 4
ELECTRONIC
CONTROL
S70-101 IOM
Page 64
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
MAINTENANCE
RECOMMENDED SPARE PARTS (Current Design)
DESCRIPTION
Fuse - 10 AMP
Shaft Seal Assy. Kit
Shaft Seal Assy. Kit
Oil Heater, 500 Watt, 110 Volt
Oil Heater, 500 Watt, 240 Volt
Oil Filter Cartridge
Oil Filter Gasket, End Cover
Oil Filter Gasket, Clamping Plate
Cap. Control Sol. Valve & Coil (120/110 Volt)
Coil Only for C.C. Sol. Valve (120/110 Volt)
Cap. Control Sol. Valve & Coil (240/220 Volt)
Coil Only for C.C. Sol. Valve (240/220 Volt)
Slide Valve Potentiometer
Slide Valve Potentiometer Bracket
Vi Control Sol. Valve Less Coil
Coil Only for Vi Solenoid
Microprocessor Cover and Keypad
Gasket for 640D0012H01
Display
Output Module
Input Module
SBC Board
2 PDT Relay (IDEC Type)
Base for 333Q0000194
3 PDT Relay (IDEC Type)
Base for 333Q0000206
Fuse - 5 AMP
Cable Assy. - 26 Conductor, SBC to Display
Cable Assy. - 12 Conductor, SBC to Keypad
Suppressor
Fuse 2 AMP (For F-1 & F-2)
Temperature Probe (TE-1–4)
Pressure Transducer 0–100 PSIA (PE-4)
Pressure Transducer 0–300 PSIA (PE-1–3)
Float Switch
Emergency Stop Button
Contact Block for 111Q0280832 Above
Fuse - 15 AMP
Battery Backup Kit
Coalescing Filter Element
Separator Head Gasket
Microprocessor Service Tool Kit
Includes: CMOS Extractor Tool
CMOS Insertion Tool
Digital Multimeter
Wrist Grounding Strap
Antistatic Pad
QTY
MODELS
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
5
1
1
3
2
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
ALL
12 – 19
24 – 50
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
12 & 15
19 & 24
30 & 39
50
12 & 15
19 & 24
30 – 50
ALL
ITEM
NUMBER
111Q0280687
111Q0043229
111Q0043231
913A0047H01
913A0047H03
531A0028H01
959A0082H01
959A0053H01
951A0056H02
951A0056H03
951A0056H41
951A0056H42
534B0293H01
534C0625H01
951A0056H39
951A0056H40
640D0012H01
649D0979H01
333Q0000068
111Q0281061
333Q0000116
333Q0000548
333Q0000194
333Q0000195
333Q0000206
333Q0000207
333Q0000117
111Q0280930
640B0019H01
111Q0280958
333Q0000573
111Q0280818
333Q0000426
333Q0000427
913A0086H01
111Q0280832
111Q0280833
111Q0281053
640A0020G01
531B0065H04
531B0065H06
531B0065H05
531B0065H03
959A0090H03
959A0090H02
959A0090H01
111Q0451862
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
OPERATING LOG SHEET
S70-101 IOM
Page 65
S70-101 IOM
Page 66
RXB PLUS ROTARY SCREW COMPRESSOR UNITS
York Refrigeration
100 CV Avenue, P.O. Box 997 Waynesboro, Pennsylvania USA 17268-0997
Phone: 717-762-2121 • Fax: 717-762-8624
Printed in U.S.A.
Subject To Change Without Notice