Frick Air Compressor Overhaul Models:
GDSH Air Compressor Overhaul, RDB Air Compressor Overhaul, RWB II Air Compressor Overhaul, RWF Air Compressor Overhaul, SGC Air Compressor Overhaul, TDSH Air Compressor Overhaul
Frick GDSH Air Compressor Instalation Information: (From Frick Manual)
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. 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 must 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 RIGGING and HANDLING), 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 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.
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 two feet of vertical pipe run) so that the lines won’t move if disconnected from the compressor. See Allowable Flange Loads table.
Frick GDSH Air Compressor Rotor Repair
Frick GDSH Troubleshooting Air Compressor: (From Frick Manual)
Troubleshooting the RWF II Compressor SYMPTOM PROBABLE CAUSES and CORRECTIONS
EXCESSIVE NOISE and VIBRATION Main oil injection valve may be closed. Open valve. Main oil injection valve may be open too far. Adjust. Bearing damage or excessive wear. CONTACT Frick Factor or Frick service. Slide valve/slide stop out of calibration (over- or under compression) Coupling loose on shaft. Tighten coupling. Replace if damaged. If motor or compressor have been reinstalled, check that installation done according to 070.660-SM Refrigerant flood-back. Correct system problem.
SLIDE VALVE and/or SLIDE STOP WILL NOT MOVE 4-way hydraulic control valve failed. Repair or replace. Slide stop indicator rod stuck. Contact Frick Factor or Frick service for assistance. Check both S.V. and S.S. feedback devices for wiring and resistance. Compressor must be running with sufficient oil pressure. Unloaded piston stuck. Contact Frick Factor or Frick service for assistance. Slipper seals worn out or damaged. Contact Frick Factor or Frick service for assistance.
Troubleshooting The Demand Pump System SYMPTOM PROBABLE CAUSES and CORRECTIONS
PUMP WILL NOT PRODUCE ENOUGH OIL PRESSURE TO START COMPRESSOR Check pump rotation. Check that service valves are open. Filter cartridges may be blocked. Check PSID across filters. Strainer may be blocked. Clean. Oil pressure regulator set too low or stuck open. Readjust or repair. Pump worn out. Repair or replace.
OIL PRESSURE RAPIDLY DROPS OFF WHEN COMPRESSOR STARTS RESULTS IN COMPRESSOR DIFFERENTIAL ALARM Main oil injection throttling valve too wide open or oil pressure regulating valve improperly adjusted. Readjust both valves.
OIL PRESSURE FLUCTUATES Liquid injection overfeeding or refrigerant flood back from system. Make necessary adjustments or corrections
NOISE and VIBRATION Pump strainer blocked. Clean. Liquid refrigerant overfeed. 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. If leakage exceeds normal allowable rate of 7 drops per minute, replace seal.
OIL PRESSURE DROPS AS HEAD PRESSURE INCREASES Normal behavior. Set main oil injection and oil pressure for maximum head pressure condition.
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 valves fully.
Troubleshooting The Oil Separation System 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. Loss of suction superheat. Adjust evaporator feeds. Contaminated oil, damaged or not seated coalesce filter elements. Replace oil charge and coalesces. Coalesce return valve closed. Open return valve. Coalescing oil return line strainer blocked. Clean.
RAPID LOSS WITH NO OIL LEVEL IN THE COALESCER SECTION SIGHT GLASS On shutdown, compressor unit suction check valve did not close. Repair valve. Suction check valve bypass valve open too far to meter flow. Close valve. Coalesces loose or not seated properly. Correct or replace. On economized unit: economizer check valve not working. Repair or replace. Economizer check valve not in automatic position or manually opened. Place in auto position.
Troubleshooting The Hydraulic System SYMPTOM PROBABLE CAUSES and CORRECTIONS
SLIDE VALVE WILL NOT LOAD OR UNLOAD Solenoid coils may be burned out. Test and replace if necessary. Valve may be closed. Open hydraulic service valves. Solenoid spool may be stuck or centering spring broken. Replace. Check outputs 2 and 3 and fuses. Check LED on coil. If lit, there is power to the coil. Check coil. Solenoid may be actuated mechanically by inserting a piece of 3/16" rod against armature pin and pushing spool to opposite end. Push A side to confirm unload capability. If valve works, problem is electrical.
SLIDE VALVE WILL LOAD BUT WILL NOT UNLOAD A side solenoid coil may be burned out. Test and replace if necessary. Dirt inside solenoid valve preventing valve from operating both ways. Clean. Check LED on coil. If lit, valve is functioning mechanically. Problem is electrical. Solenoid may be actuated mechanically by inserting a piece of 3/16" rod against armature pin and pushing spool to opposite end. Push A side to confirm unload capability. If valve works, problem is electrical.
SLIDE VALVE WILL UNLOAD BUT WILL NOT LOAD A side solenoid coil may be burned out. Test and replace if necessary. Dirt inside solenoid valve preventing valve from operating both ways. Clean. Check LED on coil. If lit, valve is functioning mechanically. Problem is electrical. Solenoid may be actuated mechanically by inserting a piece of 3/16" rod against armature pin and pushing spool to opposite end. Push A side to confirm unload capability. If valve works, problem is electrical.
SLIDE STOP WILL NOT FUNCTION EITHER DIRECTION Solenoid coils may be burned out. Test and replace if necessary. Solenoid service valves may be closed. Open. Manually actuate solenoid. If slide stop will not move mechanical problems are indicated. Consult Frick factor or Frick service.