Home

RWF II - Johnson Controls Inc.

1. SC 4 INLET OIL DRAIN SC 7 SEAL WEAPAGE 3 4 14 17 117 NPTF 1 2 14 1 2 14 3 8 18 3 8 18 1 8 27 174 117 NPTF SUCTION PORT 172 1172 NPTF SD 1 COALESCER ee 14 CLASS 300 FLANGE 1 11 NPTF SP 1 HIGH 1 2 14 NPTF PRESSURE z 10 117 NPTF olL P 17 117 NPTF SB 3 z 2 SQ FLANGE DISCHARGE z 3 4 14 NPTF BEARINGS 3 SQ FLANGE 3 4 14 NPTF 3 4 14 NPTF Too oot SL 2 HIGH ViLIQUID ST 1 THERMOWELL SUCTION SS NEE PRESSURE INJECTION T 5 SB 2 H FB INLET BEARINGS AND BALANCE PISTON Es In 47 E b MM DISCHARGE PORT 10 CLASS 300 FLANGE Frick RWF ROTARY SCREW COMPRESSOR UNITS 070 610 IOM NOV 14 MAINTENANCE Page 47 COMPRESSOR PORT LOCATIONS RWF 676 SM 1 MAIN OIL INJ
2. 51 2 HIGH Vi LIQUID INJECTION SC 6 DISCHARGE PRESSURE 5005 SL 1 LOW Vi LIQUID INJECTION EY o SM 1 MAIN OIL sa o INJECTION al Qo J Koo 4121 ln i SC 13 SC 8 CLOSED THREAD DRAIN OIL DRAIN CYCLINDER a E E i OIL DRAIN E SC 9 INLET HOUSING SC 7 SEAL WEAPAGE RWF II ROTARY SCREW COMPRESSOR UNITS Pick MAINTENANCE BY JOHNSON CONTROLS COMPRESSOR PORT LOCATIONS RWF II 480 546 SD 1 COALESCER BLEED ono oncom SC 14 LIQUID INJECTION BLEED 3 4 16 UNF 2B 070 610 IOM NOV 14 Page 45 PORT THREAD SIZE O RING 980A0012K62 9 16 18 UNF 2B 980A0012K60 1 6 12 UN 2B 980A0012K69 9 16 18 UNF 2B 980A0012K60 Fe 9 16 18 UNF 2B 980A0012K60 9 16 18 UNF 2B 980 0012 60 1146 12 UN 2B 980 0012 66 1 6 12 UN 2B 980A0012K69 1 12 UN 2B
3. SC 5 INLET PRESSURE SB 3 COMPRESSOR OIL SUPPLY 980A0012K69 1 12 UN 2B 980A0012K71 SC 5 INLET PRESSURE 7 SL 2 HIGH Vi LIQUID INJECTION SC 6 DISCHARGE PRESSURE SL 1 LOW Vi LIQUID INJECTION SE 1 ELECTRICAL CONNECTOR 480 ONLY SM 1 MAIN OIL SV 1 VAPOR INJECTION INJECTION SC 13 OIL DRAIN CYCLINDER SC 9 INLET HOUSING OIL DRAIN SC 7 SEAL WEAPAGE 070 610 IOM NOV 14 RWF ROTARY SCREW COMPRESSOR UNITS Frick Page 46 MAINTENANCE BY JOHNSON CONTROLS COMPRESSOR PORT LOCATIONS RWF 496 SM 1 MAIN OIL SC 3 INJECTION MOVEABLE SL 1 LOW Vi LIQUID INJECTION SLIDE M SV 1 VAPOR 41 STOP D INJECTION d o EC d SC 9 CLOSED THREAD DRAIN SC 8 CLOSED 5 9 CLOSED s 6 DISCHARGE 10 THREAD DRAIN THREAD DRAIN PRESSURE OIL DRAIN HERMOWELL DISCHARGE
4. Normal Maintenance General maintenance Compressor Shutdown And Start Up General Instructions For Replacing Compressor Unit Components Oil Filter OF 1 Cartridge Style Strainer Demand Oil Strainer Liquid Injection Coalescer Filter 5 Changing Olle Demand Pump Disassembly Demand Pump Thrust Bearing 1 Installation Of Carbon Graphite Bushings Troubleshooting The Demand Pump Preventive Maintenance Schedule Recommended Maintenance Vibration Analysis Cil Quality And Analysis Oil Sampling Procedure Operating Log wt aid ein Motor Bearings Grease Compatibility esee Troubleshooting Guide Abnormal Operation Analysis And Correction Servicing The Cold Start Valve Pressure Transducers Pressure Transducers Replacement Capacity Linear Transmitter Slide Valve
5. EMI FILTER 4GND TERM DC POWER SUPPLY 120 240 V IN 120 V OUT SOLA 63 23 112 4 120 VA 60 HZ SHOWN HERE CONSULT FRICK FOR OTHER VOLTAGES HZ Figure 14 Recommended Regulator Installation Frick BY JOHNSON CONTROLS OPERATION AND STARTUP INSTRUCTIONS The Fricke RWF Rotary Screw Compressor Unit is an inte grated system consisting of seven major subsystems 1 Quantum HD Control Panel See publications 090 040 0 M amp CS Compressor Compressor Lubrication System Compressor Oil Separation System Compressor Hydraulic System Compressor Oil Cooling System Compressor Easy Start System The information in this section of the manual provides the logical step by step instructions to properly start up and operate the RWF Rotary Screw Compressor Unit NOTICE THE FOLLOWING SUBSECTIONS MUST BE READ AND UNDERSTOOD BEFORE ATTEMPTING TO START OR OPERATE THE UNIT SGC COMPRESSOR The Frick RWF rotary screw compressor utilizes mating asymmetrical profile helical rotors to provide a continuous flow of refrigerant vapor and is designed for both high pressure and low pressure applications The compressor incorporates the following features 1 High capacity roller bearings to carry radial loads at both the inlet and outlet ends of the compressor 2 Heavy duty four point angular contact ball bearings to carry
6. 19 11 NPTF 1 2 14 NPTF 1 2 14 NPTF 3 8 18 NPTF 3 8 18 NPTF 1 8 27 NPTF SUCTION PORT SD 1 COALESCER BLEED 14 CLASS 300 ELANGE 1 11 SP 1 HIGH LER 17 117 NPTF PRESSURE d 1 2 14 OIL 114 1172 NPTF SB 3 ij 14 1172 NPTF DISCHARGE 4 BEARINGS p 1 2 SQ FLANGE Eje 3 4 14 NPTF 3 SQ FLANGE 3 4 14 NPTF 3 4 14 NPTF EEG r SL 2 HIGH Vi LIQUID ST 1 THERMOWELL SUCTION SC 5 INLET PRESSURE INJECTION SB 2 INLET BEARINGS AND BALANCE PISTON 0 DISCHARGE PORT 10 CLASS 300 FLANGE Frick RWF ROTARY SCREW COMPRESSOR UNITS IOM NOV 14 070 610 HOSS3HdNWOO JAIS WOW SV9 dufiSSdud HOIH SATWALLINW 30 NI NOLLO3NNOO OL G3LO3NNOO E 38 01 15155 H3MOd do ge 1 rus n NI H31VM HO 1NVH39IHg33H 3025 209M 10 S
7. Figure 42 Temperature Transmitter vt If reading top end the sensor is being shunted and full signal is coming back to the board Check the wiring by unplugging the connector at the sensor disconnecting from the analog board and doing a continuity test across the wires removed from the board If this is open the shunt is in the sensor It is always a good idea to physically inspect the wiring of the DIN Plug REPLACEMENT 1 Shut off control power 2 Remove DIN connector plug from transmitter See Figure 38 3 Unscrew knurled ring and remove transmitter unit 4 Apply thermal compound to new sensor assembly insert into thermal well and tighten knurled ring 5 Apply DIN connector plug to transmitter 6 Turn on control power RWF ROTARY SCREW COMPRESSOR UNITS Page 38 MAINTENANCE Frick BY JOHNSON CONTROLS NOTICE The temperature sensor is factory set If calibration is required refer to Calibration Instructions in publication 090 040 0 for service technicians OIL LEVEL TRANSMITTER This device is static sensitive Please follow proper ESD procedures when handling TROUBLESHOOTING Are the red indicator lights on at the sensor If yes check that 2CR or OLCR is energized and that module 13 of digital board 1 is energized as well as the status of module 13 is ON at the service screen for digital board 1 Correct as necessary If No is there
8. 5 310 1 SI 497009 dl NOLLO3 LOHd 531199 SNITIVLSNI ANY SNIGIAOWd 371815304599 SI HAWOLSND 841000 31V ld 9009 000M 2051 1 1NVH3OIH 3H i egi LSISSV MAINTENANCE P amp DIAGRAM o LSISSV H3MOd SSVdA8 IMYA 23H29 NOILONS SANIWA 8015 t NOILONS 1 8 NO Q3QVHS 0801 958 9 9 96 53215 GNA 059399 09 2 1 lt 9L NIVL NIVL N o e 0801 022 5325 eX 91 ae eem 8 222 221 uolyuvaas SAZIS 1nodlAnd v LINN 5 39und AIGWASSV 3NIVA MO3HO dOLS 1NSA o e gt HYL y Page 50 y y Sv9 NOILONS L HdlNOO OD 38001 5 NOILONS See Legend next ld TWd Wd ANWA NOISNVdX3 9L 3un9l3 OIJVIN3HOS OrTOvHGAH 33S Frick BY JOHNSON CONTROLS RWF ROTARY SC
9. I 1 Toth di ds E SL 2 ST 1 THERMOWELL SUCTION SC 5 INLET PRESSURE HIGH Vi LIQUID INJECTION rg rpm ates py SB 2 INLET BEARINGS AND BALANCE PISTON p pE DISCHARGE PORT 10 CLASS 300 FLANGE Frick RWF ROTARY SCREW COMPRESSOR UNITS 070 610 IOM NOV 14 ev J HN ON CONTROLS MAINTENANCE Page 49 COMPRESSOR PORT LOCATIONS RWF 1080 SM 1 MAIN OIL SC 3 INJECTION SL 1 LOW Vi MOVEABLE an LIQUID INJECTION SLIDE mu SV 1 VAPOR STOP 4 J INJECTION 3 d SC 9 CLOSED 1 THREAD m DRAIN SC 9 CLOSED SC 6 DISCHARGE SC 10 THREAD DRAIN PRESSURE OIL DRAIN SC 7 SEAL SC 4 INLET D WEAPAGE OIL DRAIN 3 4 14 NPTF 4 4 TW 1 THERMOWELL DISCHARGE SC 8 CLOSED THREAD DRAIN
10. The RWF II unit has compressor to motor alignment through the use of a machined cast iron tunnel This tunnel is factory set through machining tolerances ensuring motor compres sor alignment No alignment is required in the field See Figure below DISK PACK SET SCREW LOCKNUTS HUB CLAMPING BOLTS HA KR KEYWAYS LOCATED SET SCREW 180 OPPOSITE Figure 1 BP Coupling RWF ROTARY SCREW COMPRESSOR UNITS Page 6 INSTALLATION Frick BY JOHNSON CONTROLS BP COUPLING INSTALLATION PROCEDURE 1 Install the motor and compressor coupling hubs and keys on their respective shafts Ensure that they can slide hori zontally so that once the disc packs are installed no axial stress is transferred to the disc packs by a stuck coupling hub Use no lubricants 2 Rotate both hubs so that the keys are 180 opposed With the hubs mounted and the axial spacing set proceed to place the spacer between the two hub flanges Care should be taken when handling the spacer Be sure the spacer is fully supported at this time Damage to the unitized flex discs may result after they have been installed if the spacer is not fully supported Install the unitized flex disc at this time Start a bolt through a bolt hole in the spacer Put the unitized flex disc between the hub and spacer until a bushing hole in the unitized flex disc lines up with the bolt
11. Volume Ratio Control Transmitter Slide Stop Temperature Oil Level Transmitter 0 Troubleshooting the RWF Compressor Troubleshooting The Demand Pump System Troubleshooting The Oil Separation System Troubleshooting The Hydraulic System Motor And Bare Compressor Replacement Shutdown Due To Improper Oil Pressure High Stage And Booster 41 SAE Straight Thread O Ring Fittings Assembly Procedure Compressor Port Locations P amp I Diagram iei edente als INSTALLATION OF ELECTRONIC EQUIPMENT Wire SIZING iii ice Voltage Source Grounding ap eiei aneii anarai iata ia ein VFD Applications Conduit Wiring Practices Communications UPS Power and Quantum HD 57 Operating Log 2 2 2 RWF Il Compressor Prestart Checklist Vibration Data General Information PREFACE This manual has been prepared to acquaint the owner and serviceman with the INSTALLATION OPERATION and MAIN TENANCE procedures as recommended by Johnson Controls for Fricke RWF Rotary Screw Compressor Units For information about the functions of the Quantum H
12. SE 1 ELECTRICAL CONNECTOR SL 2 HIGH Vi LIQUID INJECTION t SC 6 DISCHARGE PRESSURE SL 1 LOW Vi LIQUID INJECTION SM 1 MAIN OIL VAPOR INJECTION INJECTION je P HE SC 11 CLOSED THREAD DRAIN SC 8 CLOSED THREAD DRAIN Hem SC 13 OIL DRAIN CYCLINDER SC 9 INLET HOUSING OIL DRAIN SC 7 SEAL WEAPAGE 070 610 IOM NOV 14 RWF ROTARY SCREW COMPRESSOR UNITS Frick Page 44 MAINTENANCE BY JOHNSON conTROLs COMPRESSOR PORT LOCATIONS RWF II 316 399 PORT THREAD SIZE O RING D 1 COALESCER BLEED Ru SC 14 LIQUID INJECTION BLEED 5 5 3 4 16 UNF 2B 980A0012K62 14 5 6 9 16 18 UNF 2B 98040012 60 1 6 12 UN 2B 980 0012 69 SC 9 9 16 18 2 980A0012K60 SC 13 9 16 18 UNF 2B 980A0012K60 SC 14 9 16 18 UNF 2B 980A0012K60 12 UN 2B 980A0012K66 1 6 12 UN 2B 980A0012K69 1 6 12 UN 2B 980A0012K69 AGH U EOE sc 5 INLET PRESSURE QQ V m 21 COMPRESSOR 5 96 OIL SUPPLY Ro 09 SN SE 1 ELECTRICAL CONNECTOR
13. Form 070 610 IOM NOV 2014 r INSTALLATION OPERATION MAINTENANCE File SERVICE MANUAL Section 70 Replaces 070 610 IOM AUG 2014 BY JOHNSON CONTROLS sese RWF Il ROTARY SCREW COMPRESSOR UNITS ALL REFRIGERANTS MODELS 100 through 1080 THIS MANUAL CONTAINS RIGGING ASSEMBLY START UP AND MAINTENANCE INSTRUCTIONS READ THOROUGHLY BEFORE BEGINNING INSTALLATION FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR DEATH DAMAGE TO THE UNIT OR IMPROPER OPERATION Please check www jci com frick for the latest version of this publication 070 610 IOM NOV 14 RWF ROTARY SCREW COMPRESSOR UNITS Frick Page 2 INSTALLATION OPERATION MAINTENANCE SY JORNSON CONTROLS Contents GENERAL INFORMATION Preface sis iei enp neptem Design Limitations Job Inspection Transit Damage Claims Unit Identification Compressor Identification INSTALLATION FouridatiOrn reete ede Rigging And Handling se Skid Removal eis ten Checking Motor Compressor Rotation Compressor Motor Coupling Installation Oil Pump e Holding Charge And Storage Oil Change Olli eaters Oil Filter s Suction Valve Mounting Thermosyphon Oil Cooling Liquid Injection O
14. ry c n 9 070 610 IOM NOV 14 RWF ROTARY SCREW COMPRESSOR UNITS Frick Page 48 MAINTENANCE BY JOHNSON CONTROLS COMPRESSOR PORT LOCATIONS RWF II 856 SM 1 MAIN OIL SC 3 INJECTION MOVEABLE SL 1 LOW Vi LIQUID INJECTION SLIDE STOP SV 1 VAPOR INJECTION s N SC 9 CLOSED THREAD DRAIN SC 8 CLOSED THREAD DRAIN SC 6 DISCHARGE SC 10 THERMOWELL THREAD DRAIN PRESSURE OIL DRAIN DISCHARGE SC 7 SEAL SC 4 INLET _ Eb 5 WEAPAGE OIL DRAIN y q 3 4 14 NPTF 17 11 NPTF i 1 2 14 NPTF mns 1 2 14 NPTF H 3 8 18 NPTF 3 8 18 NPTF 1 8 27 NPTF SUCTION PORT 174 117 NPTF SD 1 COALESCER BLEED o LANCE E ANTE SP 1 HIGH m 17 11 NPTF PRESSURE 1 2 14 NPTF OIL SB 3 A 114 112 NPTF DISCHARGE 9 1 11 NPTF BEARINGS p 2 SQ FLANGE gt qo 3 4 14 NPTF 3 SQ FLANGE 3 4 14 NPTF 3 4 14 NPTF
15. There must be a ground for the three phase power wiring This must be sized in accordance to the NEC and any local codes relative to the highest rated circuit overload protec tion provided in the circuit The manufacturer may require a larger ground conductor than what is required by the NEC for proper steering of EMI from sensitive circuits This conduc tor must also be insulated to avoid inadvertent contact at multiple points to ground which could create Ground Loops In many installations that are having electronic control prob lems this essential wire is usually missing is not insulated or improperly sized RWF ROTARY SCREW COMPRESSOR UNITS Page 54 PROPER INSTALLATION OF ELECTRONIC EQUIPMENT Frick BY JOHNSON CONTROLS NEC size ratings are for safety purposes and not necessarily for adequate relaying of noise EMI to earth ground to avoid possible interference with sensitive equipment Therefore sizing this conductor 1 2 sizes larger than required by code will provide better transfer of this noise Johnson Controls Frick requires that the ground conductor meet the following Stranded Copper Insulated One size larger than NEC requirements for conventional starters Two sizes larger than NEC requirements for VFD starters Conduit must be grounded at each end This circuit must be complete from the motor to the starter continuing in a seamless manner back to the plant supply transformer power source F
16. tion of the oil separator This valve causes the oil separator to develop oil pressure rapidly on initial start in order to lubricate the compressor without requiring an oil pump even in cold ambient temperatures with all pressures equalized For high stage packages the cold start valve is equipped with a large spring that creates 30 psi of pressure in the oil separator above suction pressure for lubrication of the compressor Once the compressor is running it will begin to force gas to the condenser at connection P2 As the condenser heats up it will begin to rise in pressure as the compressor suction pulls down in pressure As soon as differential pressure is devel oped between the condenser and suction these pressures act across a piston inside the cold start valve to partially overcome the spring force When the differential pressure reaches and exceeds 30 psi the piston fully overcomes the spring force and powers the valve fully open for very low operating pressure drop For booster applications the valve is equipped with a lighter spring which produces 7 psi oil pressure above suction pres sure before it fully powers open An oil pump is required to ensure compressor lubrication RWF Il package is also equipped with a suction check valve bypass The oil separator will slowly bleed down to ap proximate system suction pressure when the unit is stopped This allows the compressor drive motor to have an easier start an
17. 070 610 10 NOV 14 Page 52 RWF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE Frick BY JOHNSON CONTROLS P amp I DIAGRAM LIQUID INJECTION SINGLE PORT LIQUID REFRIGERANT gt SOLENOID STRAINER COMPRESSOR LOW VI HIGH VI ECONOMIZER OR CLOSED THREAD SIGHT LA GLASS MOTORIZED EXPANSION VALVE VALVE gt FROM RECEIVER LIQUID LINE LIQUID REFRIGERANT L4 STRAINER SOLENOID lt gt TUBING LINE D COMPRESSOR LOW VI 3 WAY MOTORIZED VALVE COMPRESSOR HIGH VI MOTORIZED EXPANSION VALVE 5 FROM RECEIVER COMPRESSOR LIQUID LINE SIGHT GLASS SUCTION PRESS ON LIQUID REFRIGERANT la FROM RECEIVER L STRAINER 7 IQUID LINE SOLENOID VALVE COMPRESSOR LOW VI TUBING LINE COMPRESSOR HIGH VI MOTORIZED EXPANSION C VANE gt SIGHT GLASS TUBING LINE SEPARATOR Frick BY JOHNSON CONTROLS RWF ROTARY SCREW COMPRESSOR UNITS PROPER INSTALLATION OF ELECTRONIC EQUIPMENT Page 53 070 610 IOM NOV 14 PROPER IN
18. Discharge pressure higher than calculated check with pressure gauge Increase size or reduce length of pipe reduce speed capacity or get bigger motor d Pump misaligned Extra clearance on pumping elements may not be sufficient for operating conditions Check parts for evidence of drag or contact in pump and increase clearance where necessary 6 Rapid Wear a Examination of a pump that has gradually lost its ability to deliver capacity or pressure would show a smooth wear pattern on all parts Rapid wear shows up as heavy grooving galling twisting breaking or similar severe signs of trouble PREVENTIVE MAINTENANCE Performing a few preventive maintenance procedures will extend the life of your pump and reduce the cost per gallon pumped 1 Lubrication Grease all zerks after every 500 hours of operation or after 60 days whichever occurs first If service is severe grease more often Do it gently with a hand gun Use 2 ball bearing grease for normal applications For hot or cold applications use appropriate grease 2 Packing Adjustment Occasional packing adjustment may be required to keep leakage to a slight weep if impos sible to reduce leakage by gentle tightening replace pack ing or use different type See Technical Service Manual on particular model series for details on repacking 3 End Clearance Adjustment After long service the run ning clearance between the end of the rotor teeth and the head
19. Recover or transfer all refrigerant vapor in accordance with local ordinances before opening to atmosphere 3 Measure the voltage of PE 4 on connector P6A terminals WHT and BLK on the Analog Board 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 O 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 Isolate the oil pressure transducer 1 from the package and open it to atmosphere 6 Measure the voltage of PE 1 on connector P5A terminals WHT and BLK on the Analog Board 7 voltage reading should be between 1 1 VDC and 1 29 VDC at standard atmospheric pressure PE 1 PE 2 and PE 3 all have a span of 500 PSI as compared to PE 4 with a span of 200 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 8 Isolate transducer PE 2 from the package and depressurize NOTICE Recover or transfer all refrigerant vapor in accordance with local ordinances before opening to atmosphere 9 Measure the voltage of PE 2 on connector P5
20. Slide the bolt through the bushing hole in the unitized flex disc Install the locknut until it is snug Make sure that all bolt threads are clean and lightly oiled Do not torque any locknuts at this time Now pivot the unitized flex disc until the other bushing holes in the flex disc are in line with the bolt holes in the spacer Install the rest of the spacer bolts at this time The remaining bolts for this end of the coupling can be installed through the hub bolt holes and flex disc bushing holes Install the unitized flex disc in the other end of the coupling The unitized flex disc as installed should look flat and parallel with the mating hub and spacer flanges Torque the disc pack locknuts as recommended in the BP SERIES COUPLING DATA TABLE The bolts should be held in place while the locknuts are torqued 3 Center the coupling between the shafts Ensure that the keys are fully engaged in their keyways 4 Tighten the motor and compressor shaft clamping bolts evenly Torque to the recommended specification in the BP coupling data table 5 Torque the keyway setscrews as recommended in the BP SERIES COUPLING DATA TABLE NOTICE Only after the shaft clamping bolts are tightened to their final torque can the keyway set screws be tightened If the keyway set screws are tightened before the shaft clamping bolts are tightened then the hubs can be cocked on the shaft BP SERIES COUPLING DATA TABLE DISC PACK LOCKNUT SI
21. WHEREVER POSSIBLE APPLY THE POLYUREA PRODUCT CHEVRON OIL CO SRI 2 MOBILE POLYREX EM Figure 37 Motor Lubrication Schedule GREASE COMPATIBILITY If it becomes necessary to mix greases be careful not to combine different oil bases or thickeners DO NOT mix a mineral oil base grease with a synthetic oil base grease Also a grease with a lithium thickener should not be mixed with one containing a sodium thickener The table illustrates the compatibility of various types of grease based on results by National Lubricating Grease Institute NLGI The chart indicates a great variance in compatibility with the greases tested x x 2 2 a E 2 z 2 2 5 S REGERE lt 5 Aluminum Complex Barium I Calcium I Calcium efet tetetete Lithium ________ Lithium 12 Lithium ____ I j Compatible Borderline Compatibility Standard Table 11 Grease Compatibility Chart Incompatible TROUBLESHOOTING GUIDE Successful problem solving requires an organized approach to define the problem identify the cause and make the proper correction Sometimes it is possible that two relatively obvi ous
22. asimsayjo 01 pue 4 Ul SHUN pue 310 5 eJnssaJg one Y00304 Dui see Mold dq eunssejq UO Wd 4 dq einss ig 1enno Peppy IO IIO eunjejeduue 1010095 1 eDexyee 1 4 TA LA 5 94011 55 4 48 eJnssaJg 10 eDjeuosiq enjoy eanjejeduue Buipuodsauio euinssejg eDjyeuosiq uonong ejnjejeduje eJnsseJg uonong 100pino dwa wooy 1ueuudinb3 Buipeeyu 1819 N JnoH 105 Hun S104 1NO2 NOSNHOF 48 ON ig dwog 19945 ON ELOS HOSS3Hudlloo 25 9 RWF 11 ROTARY SCREW COMPRESSOR UNITS 070 610 1OM NOV 14 Frick FORMS Page 59 READ THIS FIRST RWF COMPRESSOR PRESTART CHECKLIST The following items MU
23. coolers 5 cooling tower water 10 cooling water 10 coupling 12 Coupling Data Table 6 coupling hubs 6 CPT 13 crane 5 CT 13 CT ratio 13 Current Transformer 13 cutout parameters 16 cycle time 17 D Daisy chaining 57 dead band 17 Demand Pump Troubleshooting Grease leaks from vent port 39 Insufficient oil pressure 39 Main filter PSID too high 39 Noise and Vibration 39 Oil pressure drops as head pressure increases 39 Oil pressure fluctuates 39 Oil pressure rapidly drops 39 Viking Pump 28 D Flange adapter 15 demand oil pump strainer 26 Demand Pump Assembly 29 ball bearing 29 single row ball bearing 30 bearing retainer washer 28 30 bearing spacer 28 30 bearing spacer collar 30 carbon graphite bushings 28 29 30 casing 29 demand pump 15 16 Disassembly 28 End Clearance 30 idler 28 idler pin 28 29 lip seal 29 30 Mechanical Seal 29 O ring gasket 29 Preventative Maintenance end clearance 31 end clearance adjustment 31 grease 31 lubrication 31 070 610 IOM NOV 14 Page 65 pump head 29 refrigeration oil 29 seal face 29 seal seat 29 seal spring 29 shaft snap ring 30 snap ring 28 30 tapered installation sleeve 29 thrust bearing assembly 28 30 Thrust Bearing Adjustment 30 Troubleshooting bent shaft 31 cavitating 31 cavitation 31 Discharge Port 31 Discharge pressure 31 discharge valve 31 Fluttering 31 Gate valve 31 High viscosity 31 jumping 31
24. external controller 12 external oil cooler 7 External Oil Cooling 24 external strainer 15 F filter elements 8 26 27 filter assembly 26 filter canister 26 filter cartridge 26 fixed bulkhead 17 flashing liquid 10 flash economizer system 11 flash gas 12 flash tank 10 flash vessel 11 float level control 10 forklift 5 Foundation 5 15 Foundation Anchor bolts 5 epoxy grout 5 grout 5 housekeeping pads 5 I beams 5 reinforced concrete 5 foundation 5 Freeze up protection 23 frequency range 24 G gas bypassing 15 gas compression 5 RWF ROTARY SCREW COMPRESSOR UNITS INDEX gas flow 16 gas outlet connection 16 gauges 7 General Maintenance 25 H hard water conditions 10 heat exchanger 10 helical rotors 15 high frequency vibrations 5 high pressure discharge gas 23 high stage applications 16 Hot oil 9 hydraulic cylinder 17 Hydraulic System compressor suction 17 Compressor Vi 17 cycle time 17 dead band 17 double acting hydraulic cylinders 17 Double Acting Mode 17 fixed bulkhead 17 hydraulic cylinder 17 microprocessor 17 movable slide stop 17 MSS 17 MSV 17 MSV solenoid 17 Needle Valve 17 proportional band 17 slide valve 17 solenoid valve 17 Vi 17 volume ratio 17 identification data plate 4 infinitely variable volume ratio 15 inlet service valve 26 isolation valve 11 Ss ey Frick BY JOHNSON CONTROLS Low 20 Med 20 MMI Man Mach
25. information Following correct wiring procedures will ensure proper installation and consequently proper operation of your electronic equipment WIRE SIZING Control power supply wires should be sized one size larger than required for amperage draw to reduce instantaneous voltage dips caused by large loads such as heaters contac tors and solenoids These sudden dips in voltage can cause the electronic control panel whether it is 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 amps or 12 gauge wire for circuits of up to 20 amps Therefore when connecting the power feed circuit to an electronic control panel 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 panel VOLTAGE SOURCE Selecting the voltage source is extremely important for proper operation of electronic equipment in an industrial env
26. troubleshooting and correction guides and typical P and diagrams For typical wiring diagrams and information about the Quantum HD control panel consult publication 090 040 M THIS SECTION MUST BE READ AND UNDER STOOD BEFORE ATTEMPTING TO PERFORM ANY MAINTENANCE OR SERVICE TO THE UNIT NORMAL MAINTENANCE OPERATIONS When performing maintenance you must take several precautions to ensure your safety 1 IF UNIT IS RUNNING PRESS STOP KEY 2 DISCONNECT POWER FROM UNIT BEFORE PER FORMING ANY MAINTENANCE 3 WEAR PROPER SAFETY EQUIPMENT WHEN COM PRESSOR UNIT IS OPENED TO ATMOSPHERE 4 ENSURE ADEQUATE VENTILATION 5 TAKE NECESSARY SAFETY PRECAUTIONS REQUIRED FOR THE REFRIGERANT BEING USED CLOSE ALL COMPRESOR PACKAGE ISOLATION VALVES PRIOR TO SERVICING THE UNIT FAILURE TO DO SO MAY RESULT IN SERIOUS INJURY GENERAL MAINTENANCE Proper maintenance is important in order to assure long and trouble free service from your screw compressor unit Some areas critical to good compressor operation are 1 Keep refrigerant and oil clean and dry avoid moisture contamination After servicing any portion of the refrigera tion system evacuate to remove moisture before returning to service Water vapor condensing in the compressor while running or more likely while shut down can cause rusting of critical components and reduce life 2 Keep suction strainer clean Check periodically par ticularly on new systems
27. 0 for proper heat exchanger life After initial start up of the compressor package the strainer at the inlet of the oil cooler should be cleaned several times in the first 24 hours of operation In some applications the plate and shell oil cooler may be subjected to severe water conditions including high tem perature and or hard water conditions This causes acceler ated scaling rates which will penalize the performance of the heat exchanger A chemical cleaning process will extend the life of the Plate and Shell heat exchanger It is important to establish regular cleaning schedules Cleaning A 3 solution of Phosphoric or Oxalic Acid is rec ommended Other cleaning solutions can be obtained from your local distributor but they must be suitable for stainless steel The oil cooler may be cleaned in place by back flushing with recommended solution for approximately 30 minutes After back flushing rinse the heat exchanger with fresh water to remove any remaining cleaning solution ECONOMIZER HIGH STAGE OPTIONAL The economizer option provides an increase in system capac ity 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 s
28. HJ HL Remove inner snap ring and single row ball bearing from casing AS AK AL Remove single row ball bearing from casing 13 Remove seal seat or stationary part of seal from casing 14 Disassemble thrust bearing assembly GG HJ HL Remove outer snap ring from bearing housing and remove ball bearing See Figure 29 AS AK AL Loosen two set screws in flange outside di ameter Rotate end cap and lip seal counterclockwise and remove Remove ball bearing See Figure 30 The casing should be examined for wear particularly in the area between ports All parts should be checked for wear before pump is put together When making major repairs such as replacing a rotor and shaft it is advisable to also install a new mechanical seal head and idler pin idler and bushing See INSTALLATION OF CARBON GRAPHITE BUSHINGS Clean all parts thoroughly and examine for wear or damage Check lip seals ball bearings bushing and idler pin and replace if necessary Check all other parts for nicks burrs excessive wear and replace if necessary Wash bearings in clean solvent Blow out bearings with com pressed air Do not allow bearings to spin turn them slowly by hand Spinning bearings will damage race and balls Make sure bearings are clean then lubricate with refrigeration oil and check for roughness Roughness can be determined by turning outer race by hand Replace bearings if bearings have roughness Be sure shaft is free from n
29. Skip Frequency Bands Bearing Type Shutdown Sec Bottom Top Motor Coupling Low Motor Amps Shut Down Delay Sec Confirmed Running Motor Amps Starting Motor Amps Ignore Period Sec Vyper Coolant Setpoints Vyper Standby Time Vyper Coolant Low Temp Alarm Delay Shutdown Delay High Temp Alarm Delay Shutdown Delay PHD Monitoring Setpoints Condenser Control Compressor Bearing Condenser Control Setpoint Suction End Delay Discharge End Delay Digital Controls Step Order High Warning gF Sec High Warning gF Sec Module A High Shutdown gF Sec High Shutdown gF Sec Module B Module C Motor Bearing Module D Shaft Side Delay Opposite Shaft Side Delay Step Up Dead Band PSI High Warning F Sec High Warning F Sec Step Up Delay Sec High Shutdown F Sec High Shutdown F Sec Step Down Dead Band PSI Step Down Delay Sec Motor Stator High Pressure Override PSI High Pressure Override Delay Sec Stator 1 Delay Stator 2 Delay High Warning F Sec High Warning F Sec Analog Controls Analog Output A High Shutdown F Sec High Shutdown F Sec Analog Output B Proportional Band PSI Stator 3 Delay Integration Time Sec High Warning F Sec High Limit PSI High Shutdown F Sec Low Limit Sec Miscellaneous Remote Capacity Deadband Max Slide Valve Timer 1 10 Sec High Compressor Oil Pressure Shutdown PSI Delay Sec Max Discharge Pressure PSI Max Discharge and Oil Temp F Frick RWF ROTARY SCREW COMPRESSOR UNITS 070 610 IOM NOV 14 CONTABLA FORMS Pag
30. above or below the Control Setpoint Within this region the Proportional component of the PI Output value is the number between 0 and 100 that directly corresponds to the difference between the Control Input Actual and the Control Setpoint Setpoint Outside of this region the Proportional component is either 100 or 0 If the PI s Action is Forward the Proportional Band extends above the Control Setpoint If the PID s Action is Reverse the Proportional Band extends below the Control Setpoint Integration Time This setpoint controls the influence that the Integral component exerts on the Output value The Integral component works to push the Control Input toward the Control Setpoint by tracking the difference be tween the Control Input and the Control Setpoint over time High Limit The highest value that the output can be Low Limit The lowest value that the output can be Board One of the following will be shown None Analog Board 1 Analog Board 2 3 Pa Package gt Liquid Injection LIOC Configuration Channel The output channel that will be used will be shown Port Multiplier The standard value is 1 one DIGITAL CONTROL An output is provided for an optional Liquid Injection sole noid valve The function of this output is only available if the compressor has Liquid Injection oil cooling and it has been enabled Liquid Injection controls the supply of liquid refrig erant to
31. 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 Main oil injection throttling valve too wide open or oil pressure OFF WHEN COMPRESSOR STARTS regulating valve improperly adjusted Readjust both valves RESULTS IN COMPRESSOR DIFFERENTIAL ALARM 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 Normal leakage which will cease after initial operation Black oil leaking IN THE SIDE OF THE PUMP BODY 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 Normal behavior Set main oil injection and oil pressure for maximum head PRESSURE INCREASES 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 070 610 10 NOV 14 Page 40 RWF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE Frick TROUBLESHOOTING THE OIL SEPARATION SYSTEM SYMPTOM GRADUAL OIL LOSS WITH AN OIL LEVEL IN THE COALESCE
32. activation Up arrow push button Increases parameter number by 1 at each activation Open Mod High Med Low Down arrow Enter Up arrow Figure 22 ICAD MMI Display Enter push button Gives access to the Parameter list by keeping the push button activated for 2 seconds A Parameter list example is shown below parameter 108 Figure 23 Gives access to change a value once the Parameter list has been accessed RWF Il ROTARY SCREW COMPRESSOR UNITS Page 20 OPERATION el Frick BY JOHNSON CONTROLS Open T Figure 23 ICAD Parameter List Display Example Acknowledge and save change of value of a parameter To exit from the Parameter list and return to the display of Opening Degree OD keep the push button activated for 2 seconds Display Normally the Opening Degree OD 0 100 of the ICM valve is displayed No activation of push buttons for 20 seconds means that the display will always show OD Figure 24 Open Mod Figure 24 ICAD Opening Degree Displays the parameter Displays the actual value of a parameter Displays the function status by means of text Figure 21 Mod represents that ICAD is positioning the ICM valve according to an analog input signal Current or Voltage Low represents that ICAD is operating the ICM valve like an ON OFF solenoid valve with low speed according to a digital input signal repres
33. axial loads are mounted at the discharge end of com pressor 3 Balance pistons located in the inlet end of the compressor to reduce axial loads on the axial load bearings and increase bearing life 4 Movable slide valve to provide fully modulating capacity control from 100 to approximately 10 of full load capacity 5 Volume ratio control to allow infinitely variable volume ratio from 2 2 to 5 0 during compressor operation for all models 6 A hydraulic unloader cylinder to operate the slide stop and slide valve 7 Bearing and casing design for 400 PSI discharge pres sure This PSI rating applies only to the compressor and does not reflect the design pressure of the various system components 8 All bearing and control oil vented to closed thread in the compressor instead of suction port to avoid performance penalties from superheating suction gas 9 Shaft seal design to maintain operating pressure on seal well below discharge pressure for increased seal life 10 Oil injected into the rotors to maintain good volumetric and adiabatic efficiency even at very high compression ratios 11 Shaft rotation clockwise facing compressor suitable for all types of drives SEE FOLLOWING WARNING RWF ROTARY SCREW COMPRESSOR UNITS OPERATION Page 15 070 610 IOM NOV 14 Compressor rotation is clockwise when facing the compressor drive shaft See Figure 15 The compressor should never be operated in reverse rotation as
34. charge reservoir One or more coalescer filter elements then COALESCE the oil mist into droplets which fall to the bottom of the coalescer section of the oil separator See Figure 16 The return of this oil to the compressor is controlled by a throttling valve on both high stage and booster applications NOTICE Open throttling valve only enough to keep coalescer end of separator free of oil The sight glass located near the bottom of the coalescer sec tion of the oil separator should remain empty during normal operation If an oil level develops and remains in the sight glass a problem in the oil return separation system or com pressor operation has developed Refer to MAINTENANCE for information on how to correct the problem NOTICE The normal operating level is midway between the two sight glasses located midway along the oil separator shell a Ox THROTTLING VALVE MOTOR Fd COMPRESSOR COALESCENT FILTER Y SEPARATOR gt OIL CHARGE OIL LEVEL SENSOR TO OIL FROM COOLER OIL COOLER Figure 16 Oil Separation System RWF ROTARY SCREW COMPRESSOR UNITS Page 16 OPERATION Frick BY JOHNSON CONTROLS COLD START SYSTEM The RWF Il package is equipped with a special cold start discharge check valve Figure 17 on the gas outlet connec
35. factory setting 1 Remove the power supply 2 Activate down arrow and up arrow push buttons at the same time 3 Connect the power supply 4 Release down arrow and up arrow push buttons 5 When the display on ICAD Figure 21 is alternating between showing and 1 the factory resetting is complete Frick BY JOHNSON CONTROLS Display Factory ICM OD 100 9 ICM valve Opening Degree is displayed during normal operation Opening Degree 9 Running display value see 01 05 RWF ROTARY SCREW COMPRESSOR UNITS OPERATION 070 610 IOM NOV 14 Page 22 ERG M Digital Input function m Old Alarms A99 Speed at ON OFF and Modulating Mode Analog Output signal 2 1 50 Table 8 Parameter List 3 5 D D a 5 o E 3 o Internal main switch 1 Normal operation 2 Manual operation Valve Opening Degree will be flashing With the down arrow and the up arrow push buttons the OD can be entered manually Operation mode 1 Modulating ICM positioning according to Analogue input see j03 2 ON OFF operating the ICM valve like an ON OFF solenoid valve controlled via Digital Input See also jo9 Type of Analog input signal from external controller 1 0 20mA 2 4 20mA 3 0 10V 4 2 10V Speed can be decreased Max speed is 100 Not active when 01 2 If jO2 2 the display will indicate speed
36. for compressors with External Oil Cooling Thermosyphon Water Cooled and Glycol Cooled Before the initial startup of the compressor close the hand expansion valve completely Open the valve back up and count the turns that it takes to fully open the valve After the initial startup close the valve to achieve approximately 180 F discharge temperature or the theoretical temperature from CoolWare Do not fully close the valve at any time while the compressor is running The second method is used for compressors with Liquid Injection Oil Cooling Because the discharge temperature is controlled by the Liquid Injection Thermal Expansion Valve you will not be able adjust for the correct oil flow by using the discharge temperature Before the initial startup of the compressor close the hand expansion valve completely Open the valve back up and count the turns that it takes to fully open the valve After the initial startup close the valve 1 way If it took 10 turns to open the valve completely then turn it in 5 turns If it took 7 turns to open then close the valve 31 turns The valve may need to be closed further to reduce excessive noise and vibration However DO NOT fully close the valve RWF ROTARY SCREW COMPRESSOR UNITS Page 24 OPERATION Frick BY JOHNSON CONTROLS Failure to properly adjust this valve can lead to exces sive noise and vibration of the compressor and package premature failure of the bearings liquid loa
37. in display Low Med and High also means ON OFF operation If 04 lt 33 Low is displayed 33 lt If jO4 lt 66 Med is displayed If 04 gt 67 High is displayed Not active before j26 has been operated Always auto reset to O CA will flash in the display during calibration Type of AO signal for ICM valve position 0 No signal 1 0 20mA 2 4 20mA Define condition at power cut when fail safe is installed 1 Close valve 2 Open valve 3 Maintain valve position 4 Go to OD given by j12 Define function when DI is ON short circuited DI terminals when 02 2 1 Open ICM valve DI OFF gt Close ICM valve 2 Close ICM valve DI OFF gt Open ICM valve Enter number to access password protected parameters j26 Old alarms will be listed with the latest shown first Alarm list can be reset by means of activating down arrow and up arrow at the same time for 2 seconds Only active if 07 4 If fail safe supply is connected and powercut occurs ICM will go to entered OD NB Password protected Password 11 At first start up A1 will flash in display Enter valve type O No valve selected Alarm A1 will become active 1 ICM20 with ICAD 600 2 ICM25 with ICAD 600 3 ICM32 with ICAD 600 4 ICM40 with ICAD 900 5 6 You must get number off Valve Body ICM50 with 900 ICM65 with ICAD 900 ICM valve Opening Analog input signal Analog input signal Analog output signal Digital Inp
38. kit The power assist kit Figure 27 is factory installed with the discharge gas pressure being supplied from the high stage discharge gas The kit consists of a strainer mounted and wired solenoid valve timer and metering valve The timer limits the high pressure gas feed to the suction check valve to thirty seconds via the solenoid valve This is sufficient time to warm the suction check valve piston and provide proper operation The metering valve is provided for use as a service valve and to allow discharge gas flow regulation to prevent excessive force and resulting closure hammering The valve should be adjusted accordingly to prevent such an occurrence 3 8 OD YY POWER ASSIST BE CONNECTED TO ow J CONN IN CENTER OF MV END PLATE gt HI gt x3 12 ya 1 2 STR 4 HIGH PRESSURE GAS FROM HIGH SIDE COMPRESSOR DISCHARGE Figure 27 Power Assist Kit BALANCE PISTON PRESSURE REGULATOR A Balance Piston Pressure Regulator may be required on Models 496 1080 to reduce the extended overbalance from the thrust balance piston at part load High Stage SB 2 Oil Supply Line Diagram Figure 28 shows the three additions described below arranged in parallel 954A0014H01 PRESSURE REGULATING VALVE A4ALE pu L COMPRESSOR COMPRESSOR DISCHARGE OR PORT E OIL MANIFOLD _951A0007H01 OR SOLENOID VALVE 534B0325H01 1 8 RESTRICTION
39. locknut prevents accidental release of oil maintain oil and system integrity Oil Analysis Kit part number 5 Record all necessary sample data and identification on 33300001853 forms and labels and send promptly to the lab for results 2 Oil samples for analysis should be taken after the oil filter OPERATING LOG A 1 4 purge valve is provided in the oil filter canister head E The use of an operating log as included in this manual see Table of Contents permits thorough analysis of the operation Locknut of a refrigeration system by those responsible for its mainte nance and servicing Continual recording of gauge pressures Valve Cap temperatures and other pertinent information enables the amp Spout 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 recom mended that readings be taken at least every four hours MOTOR BEARINGS Follow the motor manufacturer s maintenance recommenda tions for lubrication See Figure 36 Figure 36 Oil Sampling Valve Make sure the motor bearings are properly lubricated before start up as required by the motor manufacturer 070 610 IOM NOV 14 RWF ROTARY SCREW COMPRESSOR UNITS Page 34 MAINTENANCE Frick BY JOHNSON CONTROLS LUBRICATION SCHEDULE INSTRUCTIONS FRAME SERVICE CYCLE BALL BEARING LUBRICATE BEARINGS WITH POWER IN THE OFF CONDITIO
40. may have increased through wear to the point where the pump is losing capacity or pressure Resetting end clear ance will normally improve pump performance See Technical Service Manual on particular model series for procedure on adjusting end clearance for the pump involved Frick BY JOHNSON CONTROLS 070 610 IOM NOV 14 RWF ROTARY SCREW COMPRESSOR UNITS Page 32 MAINTENANCE MAINTENANCE SCHEDULE EE schedule for Frick screw compressor package preventive maintenance operations E VL OR Mns OF eS e MAINTENANCE i me Q Change Oil As Directed By Oil Analysis Oil Analysis HLI Every 6 Months Replace Oil Filters g As Directed By Oil Analysis Clean Oil Strainers Clean Liquid Strainers E Replace Coalescers_ MJ Check and Clean Suction Strainer Wi m m NM N Check Coupling a Annually Regardless of Operating Hours Annually Regardless of Operating Hours Suction amp Disch Flange Bolts 4 MJN N N W M VFD Units Check Skip Freq f Check Annually Check Electrical Connections t Check Sensor Calibration c Vibration Analysis e Every 6 Months More Frequen
41. oil present in the lower sight glass of the separator If No add oil to the separator If Yes confirm that 24 VDC is getting to the sensor for excitation If yes replace the oil level sensor If No check the fuse of wire 1001 If blown check for shorts of wire 1001 correct and replace the fuse If the fuse is good check for 24 VDC immediately upstream of the fuse back to the power supply Correct as necessary REPLACEMENT The Oil Level Transmitter is located on the front of the sepa rator near the bottom center See Figure below The linear transmitter with hermetic enclosure is based on the capacitive measuring principle It features removable electronics from the sensor well eliminating the need to evacuate the compressor for replacement This transmitter is dedicated to oil level control and has no user adjustments 1 Shut off control power Remove DIN connector plug from transmitter Loosen set screws Remove transmitter unit Install new transmitter unit Tighten set screws Apply DIN connector plug to transmitter 6 M ann pwn Turn on control power DIN PLUG FRONT STATUS LED s 4 SET SCREW 2 nmm m c SENSOR WELL DIN PLUG ie TRANSMITTER UNIT Figure 43 Oil Level Transmitter Frick RWF ROTARY SCREW COMPRESSOR UNITS 070 610 IOM NOV 14 JOHNSON conTROLS MAINTENANCE Page 39 TROUBLESHOOTING THE RWF COMPRESS
42. or ground wires to electronic control panels Each electronic control panel must have its own control power supply and ground wires back to the power source Plant Transformer Multiple electronic control panels on the same power wires create current surges in the supply wires which may cause control ler malfunctions Daisy chaining ground wires taking them to ground at each device allows ground loop currents to flow between electronic control panels which also causes malfunctions See Figure below TRANS 5 5 BUS PLANT SUPPLY b 3 PHASE FORMER GROUND BUS 3 PHASE BUS GROUND BUS ELECTRONIC ELECTRONIC ELECTRONIC CONTROL CONTROL CONTROL Figure 48 Electronic Control Panel Power Supplies Frick BY JOHNSON CONTROLS COMMUNICATIONS The use of communications such as serial and ethernet in industrial environments are commonplace The proper installation of these networks is as important to the proper operation of the communications as all of the preceding practices are to the equipment Serial communications cable needs to be of the proper gauge based on the total cable distance of the run Daisy chaining is the only acceptable style of running the communications cable While Star Networks may use less cable they more often than not cause problems and interruptions in communi cations due to varying impedances over the varying lengths of cable Ground or drain wires of the communications cabl
43. problems combine to provide a set of symptoms that can mislead the troubleshooter Be aware of this possibility and avoid solving the wrong problem ABNORMAL OPERATION ANALYSIS AND CORRECTION Four logical steps are required to analyze an operational problem effectively and make the necessary corrections 1 Define the problem and its limits 2 Identify all possible causes 3 Test each cause until the source of the problem is found 4 Make the necessary corrections The first step in effective problem solving is to define the limits of the problem If for example the compressor pe riodically 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 in jection system may have a tendency to overfeed The high suction superheat condition moreover may only be tem porary When system conditions return to normal the unit s liquid injection will overfeed and oil temperature will drop I
44. rule applies for 120 volt wires and 220 volt wires Also never run low voltage wires for DC analog devices or serial communications in the same conduit with any AC wiring including 120 volt wires See Figure below 480 VOLT 3 PHASE BUS GROUND BUS iai N SEPARAT CONDUIT ELECTRONIC CONTROL Figure 47 Separation Of Different Voltage Circuits 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 panel An extreme example of this would be to run 480 volts from the starter through the electronic control panel to an oil pump motor When running conduit to the electronic control panel use 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 con troller boards since this will almost always cause problems 070 610 IOM NOV 14 Do not drill into an electronic control panel to locate conduit connections You are probably not entering the panel where the manufacturer would like you to since most manufactur ers recommend or provide prepunched conduit connections You may also be negating the NEMA rating of the enclosure Drilling can cause
45. 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 optimally located on the compressor This minimizes the performance penalty incurred with liquid injection oil cooling The dual port system contains all the components of the single port system with the addition of a 3 way motorized valve and operates as outlined The liquid injection solenoid valve is energized by the microprocessor when the temperature sensor installed in the compressor discharge exceeds the setpoint Then liquid refrigerant flows through the motorized expansion valve to the 3 way motorized valve Depending on the com pressor s operating volume ratio Vi the microprocessor will select the flow of the liquid refrigerant to the optimum compressor port RWF ROTARY SCREW COMPRESSOR UNITS 070 610 IOM NOV 14 Frick OPERATION Page 19 QUANTUM HD EZ COOL LIQUID INJECTION ADJUSTMENT PROCEDURE Figure 20 Liquid Injection Adjustment Screen ACCESSING DESCRIPTION This screen allows the user to enter and view the basic operating parameters related to EZ Cool LIOC PI control The following are the EZ Cool LIOC Setup screen selections available on this screen EZ COOL PI CONTROL Setpoint Enter the value that you wish to control to Proportional Band This setpoint determines the size of a region either
46. 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 condi tions The following points should be kept in mind during initial start up 1 It is imperative that during the initial start up of the package that the hand expansion valve on the main oil injection line is fully open to ensure adequate oil flow There is still an orifice installed in the compressor to control maximum oil flow At initial start up of the package the hand expansion valve must be fully open After initial start up of the package the hand expansion valve should be adjusted There are two methods of determining the correct adjust ment of this valve The best method to determine target discharge temperature is to run CoolWare with the operating conditions of the compressor The program will give you a theoretical discharge temperature of the compressor Once this temperature is known you may adjust the hand expansion valve The ideal discharge temperature is within 5 F or of the theoretical discharge temperature Adjust the valve to achieve the theo retical discharge temperature If you do not have access to CoolWare 180 F is a good target discharge temperature for a high stage ammonia compressor Booster applications and compressors using HFC and HCFC refrigerants may run cooler Compressors with high discharge pressure may run hotter The first method is used
47. the cylinder and over comes the decrease spring tension Simultaneously oil flows from SC4 port through valve ports B and T to compressor suction On models 496 676 856 and 1080 the SC4 port does not exist The inboard side of the slide stop piston is at suction pressure Compressor Vi decrease The volume ratio Vi is decreased when MSS solenoid valve YY4 is energized and oil flows from the oil manifold through valve ports P and B to compressor port SC4 enters the decrease side of the cylinder Simultane ously oil flows form SC3 port through valve ports A and T to compressor suction On models 496 676 856 and 1080 the SC4 port does not exist On these models YY4 is energized which permits oil to vent from port A to T with assistance from the unloader spring TO CONTROL THE RATE OF VI CHANGE THROTTLE THE NEEDLE VALVE AT SC3 PORT COMPRESSOR OIL COOLING SYSTEMS The RWF unit can be equipped with one of several 5 5 tems for controlling the compressor oil temperature They are single or dual port liquid injection and thermosyphon or water cooled oil coolers Each system is automatically controlled independent of compressor loading or unloading 070 610 10 NOV 14 Page 18 SCREW IN FLOW REGULATING NEEDLE VALVE DIRECTION CONTROL HYDRAULIC SCHEMATIC SIZES 100 480 546 Pa B Valve2 YY4
48. the suction pipe c Vibrating from cavitation misalignment or damaged parts Pressure Gauge Discharge Port 1 High reading would indicate a High viscosity and small and or long discharge line b Gate valve partially closed c Filter plugged d Vertical head did not consider a high specific gravity liquid e Line partially plugged from buildup on inside of pipe f Liquid in pipe not up to temperature g Liquid in pipe has undergone a chemical reaction and has solidified h Relief valve set too high 2 Low reading would indicate a Relief valve set too low b Relief valve poppet not seating properly c Too much extra clearance d Pump worn 3 Fluttering jumping or erratic reading a Cavitation b Liquid coming to pump in slugs c Air leak in suction line d Vibrating from misalignment or mechanical problems Some of the following may also help pinpoint the problem 1 Pump does not pump Lost its prime air leak low level in tank Rotating in wrong direction Motor does not come up to speed Suction and discharge valves not open Strainer clogged Relief valve set too low relief valve poppet stuck open Pump worn out Any changes in the liquid system or operation that would help explain the trouble e g new source of supply added more lines inexperienced operators etc i Tighten end clearance j Head position incorrect 2 Pump starts then loses its pr
49. this position Withdrawal of rotor and shaft may displace the carbon seal rotating face and result in damage to the seal 9 Place O ring gasket on head and install head and idler assembly on pump Pump head and casing were marked before disassembly to ensure proper reassembly If not be 070 610 IOM NOV 14 RWF ROTARY SCREW COMPRESSOR UNITS Frick Page 30 MAINTENANCE BY sure idler pin which is offset in pump head is positioned up and equal distance between port connections to allow for proper flow of liquid through pump 10 Tighten head capscrews evenly 11 Pack inner ball bearing with multipurpose grease NLGI 2 GG HJ HL Install bearing in casing with sealed side towards head end of pump Drive the bearing into the bore Tap the inner race with a brass bar and lead hammer to position bearing Install inner snap ring AS AK AL Install bearing retainer washer over the shaft before installing ball bearing Install ball bearing in casing with sealed side towards head end of pump Drive the bearing into the bore Tap the inner race with a brass bar and lead hammer to position bearing 12 GG HJ HL Install shaft snap ring in groove in the shaft See Figure 29 AS AK AL Install bearing spacer over shaft and against single row ball bearing See Figure 30 13 Pack lubrication chamber between inner ball bearing and double row ball bearing in the thrust bearing assembly ap proximately one
50. unload side of the cylinder flows out cylinder port SC1 through valve ports A and T to compressor suction Booster Compressor Unloading The compressor unloads when MSV solenoid YY1 is energized and oil flows from the oil manifold through valve ports P and A to cylinder port SC1 and enters the unload side of the cylinder Simultaneously oil contained in the load side of the cylinder flows out of compressor port SC2 through valve ports B and T to com pressor suction RWF ROTARY SCREW COMPRESSOR UNITS OPERATION Page 17 070 610 IOM NOV 14 NOTICE To control the rate of loading and unloading change cycle time proportional band and dead band setpoints with Quantum control If additional control is needed throttle SC2 or BP SEE HYDRAULIC SCHEMATIC FOR FUNCTIONAL VIEW OF VALVE OPERATION 5 E s A ie M AN Figure 18 Solenoid Valves And Cylinder NEVER open valve BP and valve SC2 at the same time during compressor operation VOLUME RATIO CONTROL See Figure 19 for port references Open valve at SC3 Open valve at SC4 not used on models 496 676 856 1080 Compressor Vi increase The volume ratio Vi is increased when MSS solenoid valve YY3 is energized and oil flows from the oil manifold through valve ports P and A to compressor port SC3 enters the increase side of
51. where welding slag or pipe scale could find its way to the compressor suction Excessive dirt in the suction strainer could cause it to collapse dumping particles into the compressor 3 Keep oil filters clean If filters show increasing pressure drop indicating dirt or water stop the compressor and change filters Running a compressor for long periods with high filter pressure drop can starve the compressor for oil and lead to premature bearing failure 4 Avoid slugging compressor with liquid refrigerant While screw compressors are probably the most tolerant to ingestion of some refrigerant liquid of any compressor type available today they are not liquid pumps Make certain to maintain adequate superheat and properly size suction accumulators to avoid dumping liquid refrigerant into compressor suction Keep liquid injection valves properly adjusted and in good condition to avoid flooding compressor with liquid Liquid can RWF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE Page 25 070 610 IOM NOV 14 cause a reduction in compressor life and in extreme cases can cause complete failure 5 Protect the compressor during long periods of shut down If the compressor will be sitting for long periods without run ning it is advisable to evacuate to low pressure and charge with dry nitrogen or oil This is particularly true on systems known to contain water vapor 6 Preventive maintenance inspection is recommended any time a compr
52. 0 will not load or unload 40 will not move 39 will unload but not load 40 Troubleshooting Guide 34 Troubleshooting The Demand Pump System 39 Troubleshooting The Hydraulic System 40 Troubleshooting The Oil Separation System 40 Troubleshooting The RWF II Compressor 39 tunnel 6 turbine drive 5 two pass oil coolers 9 U uninterrupted power supply 57 Unit Data Plate 3 unitized flex disc 6 unloader spring 17 unshielded 55 UPS 12 57 V A4ALE Pressure Regulating Valve 23 valve HV 1 23 valve 2 23 vapor 8 vapor line 11 variable frequency drives 55 VFD 24 VFD Applications 54 VFD output 54 Vi 17 Vibration Data Sheet 64 voltage isolation 57 volume ratio 17 volume ratio control 15 Volume Ratio Control Transmitter Slide Stop 37 Replacement 37 linear transmitter 37 Troubleshooting 37 slide stop linear transmitter 37 slide valve transmitter 37 water cooled 15 water cooled oil cooler 10 Water Cooled Oil Cooling 10 water treatment 10 water vapor 25 wye delta 12 13 JOHNSON CONTROLS 100 CV Avenue Waynesboro PA 17268 1206 USA Phone 717 762 2121 FAX 717 762 8624 www jci com frick
53. 0 610 IOM NOV 14 on a back pressure regulator based on percent of slide valve travel This will direct all the flash vapor to the other loaded compressors 2 A dual setpoint back pressure regulator valve can be used in each of the individual economizer vapor lines When a compressor is running near full load the BPR valve will operate on the desired setpoint or basically wide open to minimize pressure drop in the line When one compressor unloads below the slide valve position where the economizer output on the microprocessor turns on the dual setpoint feature of the regulator can be actuated by this output to control the pressure on the vessel side of the regulator to be a few psi higher Consequently the flash gas will be sent to the loaded compressors first until they can t handle all the vapor and the pressure in the vessel starts to rise Then some of the vapor will go to the unloaded compressor to help maintain the vessel at the desired pressure An example of a back pressure regulator with electric shutoff and the dual setpoint feature is an R S A4ADS ELECTRICAL NOTICE Before proceeding with electrical installation read the instructions in the section Proper Installation of Elec tronic Equipment in an Industrial Environment RWF Il units are supplied with a Quantum HD control sys tem Care must be taken that the controls are not exposed to physical damage during handling storage and installation Th
54. 0 IOM NOV 14 UPS POWER AND QUANTUM HD PANELS Johnson Controls Inc does not advise nor support the use of uninterrupted power supply systems for use with the Quantum HD panel With a UPS system providing shutdown protection for a Frick Quantum panel the panel may not see the loss of the 3 phase voltage on the motor because the UPS may prevent the motor starter contactor from dropping out With the starter contactor still energized the compressor auxiliary will continue to feed an okay signal to the Quantum HD panel This may allow the motor to be subjected to the fault condition on the 3 phase bus A couple of fault scenarios are 1 The 3 phase bus has power and off in a continuous cycle manner which may cause the motor to overheat due to repeated exces sive in rush current experiences 2 The motor cycling may damage the coupling or cause other mechanical damage due to the repeated high torque from rapid sequential motor bumps 3 Prolonged low voltage may cause the motor to stall and possibly overheat before the motor contactor is manually turned off Under normal conditions the loss of 3 phase power will shut down the Quantum HD panel and it will reboot upon proper power return If the panel was in Auto it will come back and return to running as programmed If the unit was in Remote the external controller will re initialize the panel and proceed to run as required If the panel was in Manua
55. 070 610 1OM NOV 14 SUCTION INTERMEDIATE PRESSURE 4 GAS COMPRESSOR t 5 ECONOMIZER STR VCK COOLER HIGH PRESSURE SUBCOOLED LIQUID HIGH PRESSURE LIQUID TO EVAPORATOR Z SUGTION INTERMEDIATE PRESSURE GAS COMPRESSOR HIGH HV 2 PRESSURE LIQUID 1 9 STR VCK m SUBCOOLED Lac WIRING Y HIGH PRESSURE LIQUID TO EVAPORATOR phe ply lt ECONOMIZER COOLER Figure 9 Direct Expansion Economizer System Z SUCTION INTERMEDIATE PRESSURE GAS TO COMPRESSOR let A iet VCK BPR A HIGH PRESSURE CONTROLLED PRESSURE SATURATED LIQUID TO EVAPORATOR ECONOMIZER VESSEL lt Z SUCTION INTERMEDIATE PRESSURE GAS TO COMPRESSOR X ECONOMIZER VESSEL 11 lt A lt CONTROLLED PRESSURE lt SATURATED LIQUID TO EVAPORATOR Figure 11 Multiple Compressor Economizer System ECONOMIZER LOAD BALANCING The most energy efficient manner to operate an economizer system when using multiple compressors on a common economizer vessel is to take as much of the flash gas as possible to the compressors that are fully loaded This can be done in at least two ways 1 Use the economizer output from the microprocessor to turn off a solenoid or to actuate the electric shutoff option 07
56. 388 5 856 1 495 5 100 134 177 270 316 399 480 546 676 856 1080 100 134 177 270 R 507 316 399 High Stage 480 546 676 856 100 134 177 270 R 507 316 399 Booster 480 546 676 856 R 717 Booster Table 5 Liquid Line Size amp Receiver Volume CONDITIONS HI Stage O F Evap and 95 F Cond 10 F suc tion line superheat Booster 40 F Evap 95 F Cond and 20 F Intermediate 10 F suction line superheat Based on 100 foot liquid line For longer runs increase line size accordingly Unloaded slide valve RWF ROTARY SCREW COMPRESSOR UNITS Page 10 INSTALLATION Frick BY JOHNSON CONTROLS WATER COOLED OIL COOLING OPTIONAL The plate and shell type water cooled oil cooler is mounted on the unit complete with all oil piping The customer must supply adequate water connections Determine the size of the water cooled oil cooler supplied with the unit as outlined on the Frick diagram and arrangement drawings The water supply must be sufficient to meet the required flow A closed loop system is recommended for the waterside of the oil cooler Careful attention to water treatment is essential to ensure adequate life of the cooler if cooling tower water is used It is imperative that the condition of cooling water and closed loop fluids be analyzed regularly and as necessary and maintained at a pH of 7 4 but not less than 6
57. 9 Open outlet service valve and leak test 10 Filter is ready to place in service Frick BY JOHNSON CONTROLS STRAINER DEMAND OIL PUMP To clean the demand oil pump strainer the unit must be shut down The procedure is as follows 1 Push STOP key on microprocessor panel to shutdown unit then open disconnect switches for compressor and oil pump motor starters 2 Close strainer inlet service valve 3 Open drain valve located in the strainer cover and drain oil into a container 4 Remove capscrews securing strainer cover strainer cover gasket and element Retain gasket 5 Wash element in solvent and blow clean with air 6 Wipe strainer body cavity clean with a lint free clean cloth 7 Replace cleaned element gasket and reattach cover using retained capscrews 8 Close drain valve and open strainer inlet service valve 9 Check for leakage 10 Close disconnect switches for compressor and oil pump motor starters 11 Start the unit STRAINER LIQUID INJECTION To clean the liquid injection strainer the unit must be shut down The procedure is as follows 1 Push STOP key on microprocessor panel to shut down unit then open disconnect switches for compressor and oil pump motor starters 2 Close liquid supply service valve located before liquid solenoid Excessive pressure from expanding refrigerant trapped between stop valve and solenoid may cause gasket and O ring failure and uncontrolle
58. 900000152 GLOBAL ADDITIONAL PLANT DECADE MONTH YEAR SEQ NO REMARKS 1024 9 000005 zZz Month A JAN B FEB C MAR APR E MAY F JUN G JUL H AUG K SEP L OCT M NOV N DEC Additional Remarks R Remanufactured Z Deviation from Standard Configuration GEOMETRICAL SWEPT VOLUME Geometrical Rotor Swept Volume Compressor Diameter Drive Shaft End CFM m h Model 3550 RPM 2950 RPM GC1913 0 16653 0 004713 SGC 1918 0 22204 0 006284 SGC 2313 0 29301 0 008292 SGC 2317 0 36897 0 010442 SGC 2321 0 45580 0 012899 SGC 2813 0 52501 0 014858 SGC 2817 0 66115 0 018711 SGC 2821 0 79546 0 022512 SGC 2824 0 89858 0 025430 SGCH B 3511 0 82248 0 023276 SGCH B 3515 5 1 12154 0 031739 SGCH B 3519 1 42748 0 040398 SGCB 3524 1 80328 0 051033 Table 1 Geometrical Swept Volume Frick BY JOHNSON CONTROLS Installation FOUNDATION If RWF Rotary Screw Compressor Unit is shipped mounted on a wood skid it must be removed prior to unit installation Allow space for servicing the unit per factory drawings 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 m
59. Apply DIN connector plug to transmitter 8 Turn on control power NOTICE For calibration instructions refer to Quantum HD Op erator s Manual 090 040 O TROUBLESHOOTING THE SENSOR Ensure that the channel is properly configured on the Cali bration or Analog board setup screen for the type sensor being used Check that supply voltage to the sensor is 12 15 VDC on red and black wire for Channel 14 P7A terminal strip of the Analog Board Check for a returning signal of 1 5 VDC for a transducer 4 20mA for a linear transmitter 0 5 VDC for a Potentiometer 273 mA for an ICTD at OC or ice water VOLUME RATIO CONTROL TRANSMITTER SLIDE STOP TROUBLESHOOTING Confirm the setup of channel 15 on the calibration or analog board 1 setup screen Troubleshoot the slide stop linear transmitter on channel 15 of the P7B terminal strip of the analog board in the same manner as the slide valve transmitter REPLACEMENT The Volume Ratio Control Transmitter is located on the right side of the compressor facing the shaft at the inlet end See Figure 39 The linear transmitter with hermetic enclosure is based on the inductive measuring principle It features removable electronics from the sensor well eliminating the need to evacuate the compressor for replacement This type of transmitter is dedicated to volume ratio control and has no user adjustments 1 Shut off control power Remove DIN connector plug from transmitte
60. B terminals WHT and BLK on the Analog Board 10 The voltage reading should be between 1 1 VDC and 1 29 VDC at standard atmospheric pressure see Step 12 11 Since the discharge pressure PE 3 cannot be closed off from its sensing point code requirements close all trans ducers from atmosphere and open them to their sensing points so all transducers can equalize to separator pressure 12 Measure the voltage of PE 3 on connector P5B terminals WHT and BLK on the Analog Board 13 Measure the voltage of PE 1 on connector P5A terminals WHT and BLK on the Analog Board 14 These two voltages should be within 04 VDC of one another 15 Test is complete PRESSURE TRANSDUCERS REPLACEMENT 1 Shut off control power 2 Close the applicable transducer isolation valve NOTICE To change the discharge pressure transducer PE 3 it will be necessary to depressurize the entire compres sor package Follow General Instructions For Replacing Compressor Unit Components before going to step 3 Frick BY JOHNSON CONTROLS CABLE COLOR CODE PIN 1 SUPPLY PIN 2 DC COMMON PIN 3 SIGNAL CASE GND Figure 39 Pressure Transducer Color Key 3 Refer to Fig above to identify wiring harness connectors 4 Loosen screw and disconnect wiring harness connector from transducer 5 Unscrew the transducer using a wrench on the metal hex at the base of the transducer DO NOT ATTEMPT TO LOOSEN OR TIG
61. CA are always open NOTICE The solenoid coils can be serviced or replaced without evacuating the package However if the hydraulic sole noid valves or manifold block needs to be serviced or re placed then the compressor package must be evacuated SINGLE ACTING MODE High Stage Close valve at SC2 Open valve at BP bypass High stage compressor loading The compressor loads when MSV solenoid YY2 is energized and oil flows from the unload side of the cylinder out port SC1 through valve ports A and T to compressor suction Simultaneously discharge pressure loads the slide valve High stage compressor unloading The compressor unloads when MSV solenoid YY1 is energized and oil flows from the oil manifold through valve ports P and A to cylinder port SC1 and enters the unload side of the cylinder Simultaneously gas on the load side of the cylinder is vented through port SC2 and valve BP to compressor suction NOTICE To control the rate of loading and unloading change cycle time proportional band and dead band setpoints with Quantum control If additional control is needed throttle SC2 or BP DOUBLE ACTING MODE Booster Open valve at SC2 Close valve at BP bypass Booster Compressor Loading The compressor loads when MSV solenoid YY2 is energized and oil flows from the oil manifold through valve ports P and B to cylinder port SC2 and enters the load side of the cylinder Simultaneously oil contained in the
62. D control panels communications specifications and wiring diagrams see publication series 090 040 090 040 090 040 CS and 090 040 SPC It is most important that these units be properly applied to an adequately controlled refrigeration system Your authorized Frick representative should be consulted for their expert guidance in this determination Proper performance and continued satisfaction with these units is dependent upon CORRECT INSTALLATION PROPER OPERATION REGULAR SYSTEMATIC MAINTENANCE To ensure correct installation and application the equipment must be properly selected and connected to a properly de signed 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 s
63. D BARE COMPRESSOR REPLACEMENT Refer to publication 070 660 SM SHUTDOWN DUE TO IMPROPER OIL PRESSURE HIGH STAGE AND BOOSTER The compressor must not operate with incorrect oil pressure 1 Refer to CONTROL SETUP OIL SETPOINTS DISPLAY in publication 090 040 0 RWF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE Page 41 070 610 IOM NOV 14 SAE STRAIGHT THREAD O RING FITTINGS ASSEMBLY PROCEDURE When performing maintenance or replacing the compres sor the hydraulic tubing may need to be removed and re installed The following procedure outlines the proper installation of SAE straight thread fittings to SAE straight thread ports The male and female ends of SAE straight thread O ring ports have UN UNF straight threads An elastomeric O ring is fitted to the male end On assembly the O ring is firmly sandwiched between the angular sealing surface of the fe male port and the shoulder of the male end Sealing is thus affected and maintained by the O ring compression which results from the clamping force generated by the tightening action The straight threads do not offer sealing action they provide the resistance holding power for service pressure 1 Inspect components to ensure that male and female port threads and sealing surfaces are free of burrs nicks and scratches or any foreign material 2 Ifthe O ring is not pre installed to the fitting on the male end install the proper size O ring 3 Lubricate the O ri
64. DECREASE VI YY2 LOAD INCREASE VI YY3 UNLOAD YY1 COMPRESSOR TOP VIEW UU INCREASE YY3 1 UNLOAD YY1 Figure 19 Port Locations Oil cooling systems should maintain oil temperature within the following ranges for R 717 Liquid Injection External Oil Cooling Oil Cooling 130 to 170 F 120 to 160 F Thermosyphon oil cooling TSOC or Water cooled oil cooling WCOC SINGLE PORT LIOUID INJECTION The single port liquid injection system is designed to permit liquid refrigerant injection into one port on the compressor at any given moment and operates as outlined The liquid injection solenoid valve is energized by the micro processor when the temperature sensor installed in the compressor discharge exceeds the setpoint High pressure liquid refrigerant is then supplied to the temperature control valve TCV Refer to P amp I DIAGRAMS section for piping and instrumentation drawings RWF ROTARY SCREW COMPRESSOR UNITS OPERATION DIRECTION CONTROL INENEUETM es Frick BY JOHNSON CONTROLS SC 4 NOT USED DIRECTION CONTROL VALVE SCREW IN FLOW REGULATING NEEDLE VALVE HYDRAULIC SCHEMATIC c Valve 1 SIZES 496 676 856 1080 COMPRESSOR TOP VIEW DUAL PORT LIQUID INJECTION The dual port liquid injection
65. ECTION SC 3 SL 1 LOW Vi LIQUID INJECTION MOVEABLE SV 1 VAPOR SLIDE INJECTION STOP u SC 9 CLOSED THREAD DRAIN TW 1 THERMOWELL DISCHARGE SC 8 CLOSED SC 9 CLOSED SC 6 DISCHARGE SC 10 THREAD DRAIN THREAD DRAIN PRESSURE OIL DRAIN SC 7 SEAL SC 4 INLET _ WEAPAGE OIL DRAIN 3 4 14 NPTF 19 11 NPTF 1 2 14 NPTF 1 2 14 NPTF 3 8 18 NPTF 3 8 18 NPTF 1 8 27 NPTF SD 1 COALESCER BLEED SUCTION PORT 1 4 11 NPTF 14 CLASS 300 FLANGE 32 224 SP 1 HIGH E 19 11 NPTF OIL 1 2 14 NPTF SB 3 ij OK 1 11 DISCHARGE 172 117 NPTF BEARINGS 1d 2 SQ FLANGE 3 4 14 NPTF 3 SQ FLANGE TW 1 3 4 14 NPTF SP 1 3 4 14 NPTF SL 2 ST 1 THERMOWELL SUCTION HIGH Vi LIQUID SC 5 INLET PRESSURE INJECTION pugni pop Nene item po WU SB 2 INLET BEARINGS AND BALANCE PISTON T DISCHARGE PORT 10 CLASS 300 FLANGE Te o g q g AG i
66. ER NUMBERS from these data plates Frick BY JOHNSON CONTROLS ROTARY SCREW COMPRESSOR UNIT SALES ORDER eMe ___________ SERIAL NO ____________ REFACE RAN T MAX DESIGN POC PRESSURE ________ 100 CV AVENUE WAYNESBORO 17268 PHONE 717 762 2121 UNIT DATA PLATE DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury serious injury to equipment and or minor injury NOTICE Indicates a potentially hazardous situation or practice which if not avoided will result in death or Indicates a potentially hazardous situation or practice which if not avoided will result in damage Indicates an operating procedure practice etc or portion thereof which is essential to highlight 070 610 IOM NOV 14 RWF ROTARY SCREW COMPRESSOR UNITS Frick Page 4 GENERAL INFORMATION BY JOHNSON conTROLs COMPRESSOR IDENTIFICATION Each compressor has an identification data plate see below containing compressor model and serial number mounted on the compressor body BE SST Frick BY JOHNSON CONTROLS ROTARY SCREW COMPRESSOR MODEL NO SERIAL NO MAX ALLOWABLE DRIVER PRESSURE PSIG SPEED RPM WAYNESBORO 17268 O O COMPRESSOR DATA PLATE Rotary screw compressor serial numbers are defined by the following information EXAMPLE 102404
67. GRAPHITE BUSHINGS 5 Insert a brass bar or piece of hardwood in the port open ing and between rotor teeth to keep shaft from turning Turn the locknut counterclockwise and remove locknut See Figure 29 or 30 INNER BALL BEARING BALL BEARING INNER SNAP RING SNAP RING SHAFT SHAFT SNAP RIN 1 nal BEARING 1322 S HOUSING SETSCREWS BEARING RETAINER WASHER BALL BEARING SETSCREW INNER BALL BEARING R rs SHAFT BEARING SPACER LOCKNUT BEARING HOUSING SETSCREW ea 2 Figure 32 Thrust Bearing assembly AS AL 6 Loosen two setscrews in face of bearing housing and turn thrust bearing assembly counterclockwise and remove from casing See Figure 29 or 30 7 GG HJ HL Remove snap ring from shaft See Figure 29 AS AK AL Remove bearing spacer from shaft See Figure 30 8 Remove brass bar or piece of hardwood from port open ing 9 The rotor and shaft can now be removed by tapping on end of shaft with a lead hammer or if using a regular ham mer use a piece of hardwood between shaft and hammer The rotary member of the seal will come out with rotor and shaft 10 AS AK AL Remove bearing retainer washer The washer may have stayed with rotor and shaft when removed or is against ball bearing See Figure 30 Frick BY JOHNSON CONTROLS 11 Remove the mechanical seal rotary member and spring from rotor and shaft assembly 12 GG
68. HTEN TRANSDUCERS BY THEIR TOP CASING 6 Install new transducer 7 Reconnect the wiring harness to the transducer 8 Reopen the transducer isolation valve 9 Turn on control power NOTICE The Pressure Transducer is factory set If calibration is required refer to Analog Calibration Instruction in publication 090 040 M CAPACITY LINEAR TRANSMITTER SLIDE VALVE SHADED AREA SHOWS pou CAPACITY LINEAR TRANSMITTER ELJI STAINLESS STEEL WELL DIN CONNECTOR F 1 ELM HEAT ISOLATOR us I L COMPRESSOR UNLOAD CYLINDER CAST ALUMINUM HOUSING Figure 40 Capacity Linear Transmitter REPLACEMENT The Capacity Linear Transmitter is located on the end of the compressor unload cylinder see Figure above The linear transmitter with hermetic enclosure is based on the inductive measuring principle It features removable electronics from the sensor well eliminating the need to evacuate the compressor for replacement This type of trans mitter is dedicated to capacity control and is not adjustable 1 Shut off control power 2 Remove DIN connector plug from transmitter 3 Loosen cap screws 4 Remove transmitter unit 5 Install new transmitter unit RWF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE Page 37 070 610 1OM NOV 14 6 Tighten cap screws 7
69. INDICATION CONTROLLER PUMP MOTOR PRESSURE SWITCH CONTROL HIGH PRESSURE SAFETY VALVE SUCTION PRESSURE STRAINER HIGH TEMPERATURE ALARM HIGH TEMPERATURE SHUTDOWN LOW OIL TEMPERATURE ALARM LOW OIL TEMPERATURE SHUTDOWN TEMPERATURE CONTROLLER THERMAL CONTROL VALVE TEMPERATURE ELEMENT TEMPERATURE INDICATOR TEMPERATURE SWITCH TSH TEMPERATURE SWITCH HIGH ALARM TW THERMOWELL VI VI CONTROL SB 2 INLET BEARING amp BALANCE PISTON DISCHARGE BEARINGS amp SEAL SC 1 SLIDE VALVE UNLOAD SC 2 SLIDE VALVE LOAD SC 3 MOVEABLE SLIDE STOP SC 4 MOVEABLE SLIDE STOP SC 5 INLET PRESSURE SC 6 DISCHARGE PRESSURE SC 7 SEAL WEEPAGE SC 8 OIL DRAIN CONNECTION SC 9 INLET HOUSING OIL DRAIN SC 13 OIL DRAIN CYLINDER SE 1 ELECTRICAL CONNECTION SE 2 ELECTRICAL CONNECTION SL 1 LIQUID INJECTION LOW VI SL 2 LIQUID INJECTION HIGH VI SM 1 MAIN OIL INJECTION 5 1 VAPOR INJECTION TONGUE 4 GROOVE SD 1 COALESCER BLEED STR THD O RING PORT TW 1 THERMOWELL PRESSURE TRANSDUCERS INDICATE PE 1 OIL PRESSURE MANIFOLD PE 2 OIL PRESSURE BEFORE FILTER PE 3 DISCHARGE PRESSURE PE 4 SUCTION PRESSURE TEMPERATURE PROBES INDICATE TE 1 SUCTION GAS TEMPERATURE TE 2 DISCHARGE GAS TEMPERATURE TE 3 LUBE OIL TEMPERATURE TE 4 SEPARATOR OIL TEMPERATURE SOLENOID VALVE FUNCTION YY 1 ENERGIZE UNLOAD SLIDE VALVE YY 2 ENERGIZE LOAD SLIDE VALVE YY 3 ENERGIZE INCREASE VOLUME RATIO YY 4 ENERGIZE DECREASE VOLUME RATIO YY 9 DUAL PORT LIQUID INJECTION SOLENOID
70. MPRESSOR UNITS Page 12 INSTALLATION Frick BY JOHNSON CONTROLS return If the panel was in Auto Compressor motor will return to running as grammed Remote The external controller would reinitialize the panel and proceed to run as required Manual The compressor will have to be restarted manually after the 3 phase bus fault has been cleared If the local power distribution system is unstable or prone to problems there are other recommendations to satisfy these problems If power spikes or low or high line voltages are the problem then we recommend the use of a Sola constant voltage CV transformer with a line suppression feature If a phase loss occurs then you will typically get a high motor amp shutdown If problems continue to exist then an examination of the plant s power factor may be in order Unless careful design failure analysis is considered in the implementation of power systems the alternative solutions provide a safer and less expensive implementation In either case only one Sola may be used per compressor Each compressor needs to be individually isolated from each other through a dedicated control transformer Sharing a common control power source is an invitation for ground loops and the subsequent unexplainable problems MOTOR STARTER PACKAGE Motor starter and interlock wiring requirements are shown in the Starter Wiring Diagram All of the equipment shown is supplied by the insta
71. N SERIES 8 HR DAY OPERATION 24 HR DAY OPERATION CLEAR AND CLEAN THE GREASE FITTINGS AND SURROUNDING AREA 360 5800 150 DAYS 1200 HRS 50 DAYS 1200 HRS REMOVE THE PIPE PLUG FROM THE VENTING PORT OPPOSITE THE GREASE 360 390 DAYS 3120 HRS 130 DAYS 3120 HRS FITTING USING A LOW PRESSURE GREASE GUN APPLY 1 OZ 30 GRAMS OF GREASE 400 440 270 DAYS 2160 HRS 90 DAYS 2160 HRS AT EACH FITTING DO NOT OVERGREASE 5000 5800 210 DAYS 1680 HRS 70 DAYS 1680 HRS WITH THE VENT PORTS OPEN OPERATE THE MOTOR FOR A MINIMUM OF 15 360 440 390 DAYS 3120 HRS 1200 130 DAYS 3120 HRS MINUTES AND UNTIL ANY GREASE FLOW HAS CEASED AT THE VENTING PORTS 5000 5800 270 DAYS 2160 HRS 90 DAYS 2160 HRS REMOVE POWER REPLACE THE VENT PIPE PLUGS LUBRICATION SCHEDULE FOR SEVERE SERVICE VIBRATION SHOCK AND OR ENVIRONMENTAL EXTREME 1 3 OF THE ABOVE INTERVALS REPLACE ANY AND ALL GUARDS AND COVERS THAT MAY HAVE BEEN REMOVED TO ACCESS THE MOTOR LUBRICATION SCHEDULE FOR ROLLER BEARINGS 1 3 OF ABOVE INTERVALS THE FACTORY INSTALLED RECOMMENDED LUBRICANT 15 LISTED ON THE MOTOR DATA PLATE THIS IS POLYUREA GREASE AS ARE THE PRODUCTS LISTED BELOW THE INTRODUCTION OF LUBRICANTS OF ALTERNATE CHEMICAL MAKEUP IS NOT RECOMMENDED AND WILL CAUSE MECHANICAL FAILURE WITHOUT THE COMPLETE PURGE OF THE FACTORY PRODUCT FROM THE BEARING AND RESERVOIR
72. OR 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 undercompression 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 4 way hydraulic control valve failed Repair or replace Slide stop indicator rod stuck Contact Frick Factor Frick service for assistance Check both S V and S S feedback devices for wiring and resistance Compressor must be running with sufficient oil pressure Unloader piston stuck Contact Frick Factor or Frick service for assistance Slipper seals worn out or damaged Contact Frick Factor or Frick service for assistance NOTICE Troubleshooting the compressor is limited to identifying the probable cause If a mechanical problem is suspected contact the Service Department DO NOT ATTEMPT TO DISASSEMBLE THE COMPRESSOR TROUBLESHOOTING THE DEMAND PUMP SYSTEM SYMPTOM PROBABLE CAUSES and CORRECTIONS PUMP WILL NOT PRODUCE Check pump rotation ENOUGH OIL PRESSURE TO START COMPRESSOR Check that service valves are open Filter cartridges may be blocked Check PSID
73. ORIFICE y FROM OIL MANIFOLD 4 BLPSPREG Figure 28 High Stage SB 2 Oil Supply Line Diagram PRESSURE REGULATING VALVE Discharge pressure deter mines compressor thrust balance The proper setting for the pressure regulating valve is 50 psi 15 below DISCHARGE pressure when slide valve is less than 65 SOLENOID VALVE Energizing or opening the solenoid valve pressurizes the balance piston with full oil pressure from the oil manifold bypassing the A4ALE Pressure Regulating Valve De energizing or closing the solenoid valve pressurizes the balance piston with oil pressure regulated by the A4ALE Pressure Regulating Valve Signals from the control panel operate the solenoid valve output module 12 on micro panel The solenoid valve should open when the slide valve position is 70 or greater and close when the slide valve position is 65 or less 070 610 IOM NOV 14 ORIFICE The orifice ensures oil supply to the inlet end bear ings during upset conditions such as start up INITIAL START UP Initial start up must be performed under the supervision of a Johnson Controls Frick authorized start up represen tative to prevent voiding the compressor warranty Prior to the start up the prestart check must be accomplished See Prestart Checklist in the Forms section of this manual INITIAL START UP PROCEDURE Having performed the checkpoints on the prestart check list see FORMS section
74. R SECTION SIGHT GLASS RAPID LOSS WITH NO OIL LEVEL IN THE COALESCER SECTION SIGHT GLASS SHAFT SEAL LEAKAGE PROBABLE CAUSES and CORRECTIONS 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 coalescer filter elements Replace oil charge and coalescers Coalescer return valve closed Open return valve Coalescing oil return line strainer blocked Clean 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 Coalescers 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 If leakage exceeds normal allowable rate of 7 drops per minute replace seal TROUBLESHOOTING THE HYDRAULIC SYSTEM SYMPTOM SLIDE VALVE WILL NOT LOAD OR UNLOAD SLIDE VALVE WILL LOAD BUT WILL NOT UNLOAD SLIDE VALVE WILL UNLOAD BUT WILL NOT LOAD SLIDE STOP WILL NOT FUNCTION EITHER DIRECTION PROBABLE CAUSES and CORRECTIONS 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 an
75. REW COMPRESSOR UNITS MAINTENANCE 070 610 IOM NOV 14 Page 51 P amp DIAGRAM OPTIONAL DUAL OIL FILTERS AND DEMAND OIL PUMP TO COMPRESSOR SEPARATOR VALVE CV DP FG HV HTR LG LSLL 1MC 2MC NOS NV OF OP PAH PAHH PAL PALL PDAH PDI PDSLL PE PI PIC PM PS PSV SP STR TAH TAHH TAL TALL TC TCV TE TI TS EXPANSION VALVE Li 1 OPTIONAL DUAL SAMPLING PD _ PE 2 1 2 OIL DRAIN FILL a OPTIONAL DEMAND OIL PUMP STR 2 e 4 OF 1 E 2 Ay 1 REFRIGERANT OR WATER OUT PLATE COOLER TSOC WCOC GCOC CUSTOMER 15 RESPONSIBLE FOR PROVIDING AND INSTALLING RELIEF PROTECTION IF COOLER IS ISOLATED NOTE Strainer is included for WCOC GCOC applications REFRIGERANT OR WATER IN LEGEND Covers all P amp diagrams in this manual COMPRESSOR CHECK VALVE DISCHARGE PRESSURE FLOW GLASS HAND VALVE HEATER LEVEL GLASS SEPARATOR LOW OIL LEVEL SHUTDOWN MOTOR MOTOR CONTROL CENTER MOTOR CONTROL CENTER NO OIL SWITCH NEEDLE VALVE OIL FILTER OIL PRESSURE DEMAND PUMP HIGH DISCHARGE PRESSURE ALARM HIGH DISCHARGE PRESSURE SHUTDOWN LOW PRESSURE ALARM LOW PRESSURE SHUTDOWN HIGH PRESSURE DIFFERENTIAL ALARM PRESSURE DIFFERENTIAL INDICATOR COMPRESSOR LOW DIFFERENTIAL PRESSURE CUTOUT PRESSURE TRANSDUCERS PRESSURE INDICATOR PRESSURE
76. ST be checked and completed by the installer prior to the arrival of the Frick Field Service Supervisor Details on the checklist can be found in this manual Certain items on this checklist will be reverified by the Frick Field Service Supervisor prior to the actual start up Mechanical Checks Electrical Checks Package installed according to Frick publication __ Package installed according to Frick publication 070 210 1B Screw Compressor Foundations 090 400 SB Proper Installation of Electrical Confirm that motor disconnect is open Equipment In An Industrial Environment Isolate suction pressure transducer _ Confirm that main disconnect to motor starter and micro Pressure test and leak check unit is open Evacuate unit Confirm that electrical contractor has seen this sheet Remove compressor drive coupling guard ALL PERTINENT WIRING information and drawings Remove coupling center and DO NOT reinstall __ Confirm proper power supply to the starter package motor rotation must be checked without center __ Confirm proper motor protection breaker sizing Check for correct position of all hand stop and check __ Confirm that all wiring used is stranded copper and is valves PRIOR to charging unit with OIL or REFRIGERANT 14 AWG or larger sized properly Charge unit with correct type and quantity of oil Confirm all 120 volt control wiring is run in a separate Lubricate electric drive motor bearings PRIOR to c
77. STALLATION 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 electromagnetic interference EMI and ground loop currents Therefore installation and wiring were of little consequence and the wiring job con sisted of hooking up the point to point wiring and sizing the wire properly In an electronic system improper instal lation will cause problems that may outweigh the benefits of electronic control Electronic equipment is susceptible to EMI and ground loop currents which can cause equip ment shutdowns processor memory and program loss as well as erratic behavior and false readings Manufacturers of industrial electronic equipment take into consideration the effects of RFI EMI and ground loop currents and incorpo rate protection of the electronics in their designs However these design considerations do not make the equipment immune so manufacturers require that certain installation precautions be taken to protect the electronics from these effects All electronic equipment must be viewed as sensitive
78. U LT Balag SL 2 HIGH Vi LIQUID SC 6 DISCHARGE PRESSURE INJECTION SC 7 SEAL WEAPAGE SC 13 OIL DRAIN CYCLINDER a s Ke E 1 E Nl SC 9 INLET HOUSING OIL DRAIN SC 8 CLOSED THREAD DRAIN A E SL t LOW Vi aw LIQUID INJECTION SV 1 VAPOR INJECTION 3 SM 1 MAIN OIL SE 1 ELECTRICAL CONNECTOR SC 8 CLOSED THREAD DRAIN INJECTION RWF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE 070 610 IOM NOV 14 Frick Page 43 COMPRESSOR PORT LOCATIONS RWF II 177 222 270 PORT THREAD SIZE O RING 1 6 12 UN 2B 980A0012K66 9 16 18 UNF 2B 980A0012K60 9 16 18 UNF 2B 980A0012K60 146 12 UN 2B 980A0012K66 9 16 18 UNF 2B 980A0012K60 1 6 12 UN 2B 980A0012K69 9 16 18 UNF 2B 980A0012K60 9 16 18 UNF 2B 980A0012K60 SD 1 COALESCER BLEED q 1 6 12 UN 2B 980A0012K66 1 6 12 UN 2B Ll s SC 14 LIQUID INJECTION BLEED 980A0012K66 1 6 12 UN 2B 980A0012K66 SC 5 INLET PRESSURE 196 12 UN 2B 980A0012K69 SB 3 COMPRESSOR OIL SUPPLY
79. UBLESHOOTING THE DEMAND PUMP A DANGER BEFORE OPENING ANY PUMP LIQUID CHAMBER PUMP ING CHAMBER RESERVOIR JACKET ETC ENSURE 1 THAT ANY PRESSURE IN CHAMBER HAS BEEN COM PLETELY VENTED THROUGH SUCTION OR DISCHARGE LINES OR OTHER APPROPRIATE OPENINGS OR CON NECTIONS 2 THAT THE DRIVING MEANS MOTOR TURBINE ENGINE ETC HAS BEEN LOCKED OUT OR MADE NONOPERATIONAL SO THAT IT CANNOT BE STARTED WHILE WORK IS BEING DONE ON PUMP FAILURE TO FOLLOW ABOVE LISTED PRECAUTIONARY MEASURES MAY RESULT IN SERIOUS INJURY OR DEATH Mark valve and head before disassembly to ensure proper reassembly If trouble does develop one of the first steps toward find ing the difficulty is to install a vacuum gauge in the suction port and a pressure gauge in the discharge port Readings on these gauges often will give a clue as to where to start looking for the trouble Vacuum Gauge Suction Port 1 High reading would indicate a Suction line blocked foot valve stuck gate valve closed strainer plugged Frick BY JOHNSON CONTROLS b Liquid too viscous to flow through the piping c Lift too high d Line too small 2 Low reading would indicate a Air leak in suction line b End of pipe not in liquid c Pump is worn d Pump is dry should be primed 3 Fluttering jumping or erratic reading a Liquid vaporizing b Liquid coming to pump in slugs possibly an air leak or insufficient liquid above the end of
80. ZE FTLB 17 40 7 16 20 40 7 16 20 60 1 2 20 5 8 18 5 8 18 Table 3 BP Series Coupling Data 5 16 24 41 HUB CLAMPING BOLTS KEYWAY SETSCREW SERIES TORQUE Lube size unr TORRE SIZE UNF NM TORQUE Hem FT LB 22 Frick CH SERIES COUPLING DATA TABLE Coupling Hub CH Face Clamp Bolt Keyway Setscrew Series Spacing Size In mm Ft Lb Nm UNF Ft Lb Nm UNC 1 47 6 130 176 3 2 20 13 17 6 6 18 Table 4 CH Series Coupling Data 9 36 5 55 74 6 24 13 17 6 6 18 10 116 42 9 130 176 3 7 gt 20 13 17 6 18 11 CH COUPLING INSTALLATION PROCEDURE The T B Woods Elastomeric Type CH Coupling is used in most applications This coupling consists of two drive hubs and a gear type Hytrel or EDPM and neoprene 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 Be cause of the use of the motor compressor adapter housing on the RWF Il no field alignment is necessary 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 4 Slide one hub onto each shaft as far as possible It may be necessar
81. acing or repairing components which are exposed to refrigerant pressure including suction strainer proceed as follows 1 Push STOP key on control panel to shut down unit 2 Open disconnect switches for compressor and pump motor starters 3 Close suction and discharge service valves also liquid injection and economizer service valves if applicable 4 SLOWLY vent separator to low side system pressure using the bypass line on the suction trap 070 610 IOM NOV 14 NOTICE 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 sepa rator pressure increase Repeat venting and recovery procedure if necessary 5 Make replacement or repair NOTICE Replace all gaskets and O rings with new ones Suction Strainer remove inspect and clean as necessary and replace using a new gasket 6 Isolate the low pressure transducer PE 4 to prevent damage during pressurization and leak test 7 Pressurize unit and leak test 8 Evacuate unit to 29 88 Hg 1000 microns 9 Open suction and discharge service valves low pressure transducer and also liquid injection and economizer service valves if applicable 10 Close disconnect switches for compressor and oil pump motor starters 11 Unit is ready to put into operation 12 Perform checkpoints on presta
82. al ducts carrying 3 phase power to starters vfd or motors RWF ROTARY SCREW COMPRESSOR UNITS PROPER INSTALLATION OF ELECTRONIC EQUIPMENT Page 55 070 610 IOM NOV 14 Control power communications analog or signal wir ing should be run overhead preferred or in a separate trench If these lines are not in threaded metallic or threaded PVC coated metallic abiding by the separation requirements noted above is necessary Though not recommended if cable trays are used metal lic dividers must be used for separation of conductors of unlike voltages and types AC or DC NOTICE When in doubt contact the factory or use threaded metallic or threaded PVC coated metallic conduit WIRING PRACTICES Do not mix wires of different voltages in the same conduit An example of this would be the installation of a screw compressor package where the motor voltage is 480 volts and the electronic control panel 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 electronic 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 induced onto the 120 volt circuit causing functional problems with the electronic control panel Metallic dividers must be used in wire way systems conduit trays to separate unlike voltages The same
83. and shell oil cooler 8 9 plate and shell type thermosyphon oil cooler 9 Point To Point Wiring Diagram 13 port pressure 11 power feed 55 power fluctuations 14 premature bearing failure 25 Pressure Regulating Valve 23 pressure differential 16 proportional band 17 no pump 15 pump out connection 23 purge valve 26 P amp Diagram 50 PVC conduit 55 Q Quantum HD 3 12 16 25 57 R reboot 57 receiver 9 10 refrigerant charge 5 refrigerant isolation valves 9 refrigerant vapor 27 refrigeration oil 26 regulating control transformer 12 roller bearings 15 Rotary Screw Compressor 5 rotor contact 15 5 safety valve 9 Sales Order Numbers 3 SC2 17 scaling 10 self lubricating 15 separator 5 7 27 serial number 4 service valves 27 setpoint 12 17 severe water conditions 10 SGC Compressor 15 compressor drive shaft 15 D Flange adapter 15 angular contact ball bearings 15 axial loads 15 axial load bearings 15 balance pistons 15 discharge pressure 15 external strainer 15 helical rotors 15 infinitely variable volume ratio 15 movable slide valve 15 roller bearings 15 rotor contact 15 self lubricating 15 Shaft rotation 15 Single Acting Mode 17 slide valve 15 Suction flange 15 suction port 15 Volumizer 15 SGC compressor 17 Shaft rotation 15 070 610 IOM NOV 14 Page 68 shunting device 13 Shutdown 41 shutdowns 25 shutdown cycles 8 s
84. anger when dismantling The spring is compressed with a large bolt 7 If it is nec essary to repair the valve it can be dismantled as follows 1 To manually open the valve mount the hexagon screw 29 the hexagon flange nut 28 and the nylon ring 27 as shown Tighten the nut 28 a few turns in order to redraw the valve cone from the seat NOTICE Step 1 is not strictly necessary when dismantling the valve but will prevent the valve seat gasket from being exposed to a shear load and it will keep all internal valve parts together as a unit 2 Loosen the screws 24 by 0 315 in 8 mm and ensure that the bonnet 2 is not under pressure from the spring If the bonnet is under pressure from the spring 15 after all the screws have been loosened by 0 315 in 8 mm there is a damage inside the valve In this case it is important to remove only two screws one from each side In the threaded holes from which the two screws have been removed insert studs with nuts see table for size and turn the nuts down to meet the bonnet 2 Studs must be about the same length as the valve body Then remove the remaining two screws 24 loosen the nuts on the studs and carefully ease off the bonnet All internal parts can then be safely removed NOTICE If step 1 was followed loosen the hexagon nut 28 carefully holding the hexagon screw 29 in place If the bonnet is not under pressure from the spring all scre
85. anual solenoid 27 manway bolts 27 manway cover 27 microprocessor 10 11 17 18 microprocessor control system 12 mist 16 motor 12 RWF ROTARY SCREW COMPRESSOR UNITS INDEX Motor And Bare Compressor Replacement 41 motor contactor 12 motor rotation 6 motor starters 25 motor starter coils 13 motor starter contactor 12 mounting bolts 5 movable slide stop 17 movable slide valve 15 17 MSS 17 MSV 17 MSV solenoid 17 N neoprene drive spacer 7 nitrogen charge 7 dual oil filters 26 main oil filter 26 oil 5 oil charging valve 28 Oil entrained refrigerant 27 Oil Charge 7 oil charge reservoir 16 oil cooler 9 15 oil filters 25 oil filter cartridges 27 oil foaming 7 26 27 33 oil heaters 8 12 oil leakage 7 26 33 oil level cutout 7 26 27 33 Oil Level Transmitter Replacement 38 Troubleshooting 38 Din Plug 38 oil manifold 17 23 oil pressure loss 7 33 oil pump 15 16 Oil Pump Coupling 7 oil pump starter 12 oil sampling valve 33 oil seal 15 oil separator 12 15 16 oil strainer elements 27 Oil temperature 9 operating level 7 Operating Log Sheet 58 operating volume ratio 18 Optical Isolation 57 Orifice 24 outlet pressure regulator 11 overpressurizing 11 Packaged Refrigerant Recirculation unit 11 package vibration 5 partial load 11 pH 10 pipe hangers 5 piston 16 piston type check valves 11 070 610 IOM NOV 14 Page 67 plate
86. ass 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 insur ance 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 clear ances around the unit for ease of operation and servicing Foundations must be in compliance with local building codes and materials should be of industrial quality The floor must be a minimum of 6 inches of reinforced con crete 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
87. assist the flow of oil into the unit Also fill slowly because oil will fill up in the separator faster than it shows in the sight glass Refer to the table in the OIL CHARGE section for approximate oil charge quantities 12 Open the suction and discharge service valves and also the liquid injection and economizer service valves if ap plicable 13 Close the disconnect switch for compressor motor starter 14 Start the unit DEMAND PUMP DISASSEMBLY A DANGER BEFORE OPENING ANY VIKING PUMP LIQUID CHAM BER PUMPING CHAMBER RESERVOIR JACKET ETC ENSURE 1 That any pressure in the chamber has been completely vented through suction or discharge lines or other ap propriate openings or connections 2 That the driving means motor turbine engine etc Has been locked out or made nonoperational so that it cannot be started while work is being done on the pump FAILURE TO FOLLOW ABOVE LISTED PRECAUTIONARY MEASURES MAY RESULT IN SERIOUS INJURY OR DEATH 1 Mark head and casing before disassembly to ensure proper reassembly The idler pin which is offset in the pump head must be positioned up and equal distance between port connections to allow for proper flow of liquid through the pump 2 Remove the head capscrews 3 Tilt top of head back when removing to prevent idler from falling off idler pin 4 Remove idler and bushing assembly If idler bushing needs replacing see INSTALLATION OF CARBON
88. be per latest edition of the NEC and local codes Figure 13 Point To Point Wiring Diagram CURRENT TRANSFORMER CT RATIOS The CT ratio for various motor sizes with a 5 amp second ary is given in the following table VOLTAGE 200 230 380 460 575 2300 Table 6 CT Ratios By Motor HP 070 610 IOM NOV 14 RWF ROTARY SCREW COMPRESSOR UNITS Frick Page 14 INSTALLATION BY JOHNSON conTROLs 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 MAXIMUM DISTANCE FROM RATING FRICK PANEL VA USING USING USING 14 AWG 12 AWG 10 AWG 2 5 15 ft 5 35 ft 12 5 93 ft Table 7 Burden Rating amp Max Panel Distance CONTROL POWER REGULATOR Compressor units that will be used in areas that suffer brown outs and other significant power fluctuations can be supplied with a control power regulator See Figure 14 Recommended Regulator Installation NOTE AT SOLA ASSEMBLY MAKE WIRES 6 2 GND 6B amp 2B 10 FT LONG CUT WIRES TO LENGTH AT INSTALLATION SEE SOLA CONNECTION CHARTS FOR GND TERM INPUT amp OUTPUT CONNECTIONS IN MICRO H5 H4 2 Hi INPUT GREEN OUTPUT GND LUG IN x1 x2 SOLA ENCLOSURE REMOVE JUMPERS 6 TO 6B amp 2 TO 2B az 6 6B 2B 2 FERRITE WHEN SOLA IS ADDED TUBE REMOVE FERRITE TUBE REGULATOR
89. bearing damage will result COMPRESSOR Figure 15 Shaft Rotation Direction 12 Dual compressor casing design for very low airborne noise transmission 13 Suction flange is 300 psig ANSI type 14 Integral suction strainer is provided on models 100 480 and 546 Models 496 676 856 and 1080 have external strainer 15 D Flange adapter for bolting directly to motor COMPRESSOR LUBRICATION SYSTEM The lubrication system an RWF screw compressor unit performs several functions 1 Provides lubrication to bearings and seal 2 Provides a cushion between the rotors to minimize noise and vibrations 3 Helps keep the compressor cool and prevents overheating 4 Provides an oil supply to hydraulically actuate the slide valve and slide stop 5 Provides oil pressure to the balance pistons to help in crease bearing life 6 Provides an oil seal between the rotors to prevent rotor contact or gas bypassing The compressor unit may be equipped with either a no pump or a demand pump lubrication system Additionally either system may contain dual oil filters and liquid injection water cooled or thermosyphon oil cooler for compressor oil cooling NO PUMP OIL SYSTEM The RWF screw compressor unit is designed to be self lu bricating Oil being supplied to the compressor from the oil separator is at system head pressure Within the compressor oil porting to all parts of the c
90. compressor See Allowable Flange Loads table ALLOWABLE FLANGE LOADS MOMENTS ft Ibf LOAD Ibf AXIAL VERT AXIAL VERT Table 2 Allowable Flange Loads Consult a licensed architect to determine the proper foun dation requirements for any large engine or turbine drive When applying screw compressors at high pressures the customer must be prepared for package vibration and noise higher than the values predicted for normal refrigeration duty Proper foundations and proper installation methods are vital and even then sound attenuation or noise curtains may be required to reduce noise to desired levels For more detailed information on Screw Compressor Foundations please request Frick publication 070 210 RIGGING AND HANDLING This screw compressor package may be top heavy Use caution in rigging and handling The unit can be moved with rigging using a crane and spreader bar by hooking into the four lifting eyes on the oil separator 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 because the center of balance will be affected Refer to supplied engineering drawings to determine the package center of gravity The unit can be moved with a forklift by forking under the skid or it can be skidded into place with pinch bar
91. crew compressor unloads the economizer port will drop in pressure level eventually being fully open to suc tion 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 be low approximately 6096 7096 capacity 8596 9096 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 posi tion 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 assuring that the liquid supply is subcooled In such cases the economizer liquid solenoid can be left open whenever the compressor is running 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 Figure 10 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 Frick BY JOHNSON CONTROLS to drive liquid from the flash vessel to the evaporators since the flash vessel pressure will approach suction pressure at a decrea
92. d 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 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 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 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 Frick BY JOHNSON CONTROLS MOTOR AN
93. d refrigerant release 3 Close service valve located between the compressor and the liquid injection thermovalve 4 Carefully loosen capscrews securing the strainer cover to the strainer Allow pressure to relieve slowly 5 When all entrapped refrigerant has been relieved carefully remove loosened capscrews as liquid refrigerant is sometimes caught in the strainer strainer cover and strainer basket 6 Wash the strainer basket and cover in solvent and blow clean with air 7 Reassemble strainer 8 Open service valve between compressor and liquid injec tion thermovalve and check for leakage 9 Screw out manual solenoid valve stem 10 Carefully open liquid supply service valve 11 Leak test 12 Close disconnect switches for compressor and oil pump motor starters 13 Start unit RWF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE Page 27 070 610 IOM NOV 14 COALESCER FILTER ELEMENT S When changing the coalescer filter element s it is recom mended that the oil be changed cartridge s in oil filters 1 and OF 2 if applicable be changed and the following applicable strainer elements be removed and cleaned NOTICE Use of filter elements other than Frick may cause war ranty claim to be denied 1 Refer to CHANGING OIL Steps 1 through 8 2 Loosen manway cover retainer bolts remove retainers manway cover and cover gasket Discard cover gasket 3 Remove and retain nut securing coale
94. d the discharge check valve will seat more tightly See the SUCTION CHECK VALVE BYPASS section for operation NOTICE For alarm descriptions and shutdown or cutout param eters see publication 090 040 0 P3 TO SUCTION ES CLOSED 5 2 2 9 78 H 1 2 2 2 2 2 e 2 2 2 2 9 ej 10 d sh 1 1 P2 TO CONDENSER 1 FROM OIL SEPARATOR Figure 17 Cold Start Valve Frick BY JOHNSON CONTROLS COMPRESSOR HYDRAULIC SYSTEM The compressor hydraulic system moves the movable slide valve MSV to load and unload the compressor It also moves the movable slide stop MSS to increase or decrease the compressor s volume ratio Vi The hydraulic cylinder located at the inlet end of the SGC compressor serves a dual purpose It is separated by a fixed bulkhead into two sections The movable slide valve MSV section is to the left of the bulkhead and the movable slide stop MSS to the right Both sections are considered double acting hydraulic cylinders as oil pressure moves the pistons in either direction Both sections are controlled by double acting four way solenoid valves which are actuated when a signal from the appropriate microprocessor output energizes the solenoid valve Valves V1 V2 SC1 SC3 and S
95. ding of the rotors liquid starvation of the rotors and catastrophic failure of the compressor 2 For proper and safe operation the compressor must be run at the proper speed and discharge pressure Exceeding design conditions creates a potential hazard 3 Rotate and lubricate motor bearings according to manufac turer s recommendations PRIOR to initial start up as required 4 After running the unit for approximately three hours ad just liquid injection oil cooling if applicable If unit has water cooled oil cooling adjust water control valve to cooler 5 The compressor slide valve and slide stop linear transmit ters should be calibrated 6 Perform vibration analysis if equipment is available NORMAL START UP PROCEDURE 1 Confirm system conditions permit starting the compressor 2 Press the RUN key 3 Allow the compressor to start up and stabilize Press the AUTO key immediately below the V ratio label on the oper ating display screen Press the AUTO key immediately below the SV POS label on the operating display The compressor is now operating in the automatic mode 4 Observe the compressor unit for mechanical tightness of the external piping bolts and valves Ensure that the ma chine is clean from oil and refrigerant leaks If any of these occur shut down the compressor and correct the problem as necessary using good safety precautions 5 RETIGHTEN MANWAY BOLTS at condenser design pressure while syst
96. dings carefully as the instrument range and function used can vary Findings can be easily misinterpreted 4 Vibration readings can be influenced by other equipment operating in the vicinity or connected to the same piping as the unit TRAP ASSEMBLY BOLT STRAINER TRAP MULTIVALVE INLET MULTIVALVE OUTLET d Figure 35 Multivalve Arr 496 676 856 amp 1080 Frick RWF ROTARY SCREW COMPRESSOR UNITS 070 610 IOM NOV 14 JOHNSON conTROLS MAINTENANCE Page 33 RWF II Compressor Discharge Flange to Separator Flange Torque ft Ib Torque ft Ib Torque ft Ib SGC 1913 M20 X 2 5 M20 X 2 5 SGC 1918 M20 X 2 5 M20 X 2 5 SGC 2313 M20 X 2 5 M20 X 2 5 SGC 2317 M20 X 2 5 M22 X 2 5 SGC 2321 M20 X 2 5 M22 X 2 5 SGC 2813 M22 X 2 5 M22 X 2 5 SGC 2817 M22 X 2 5 M24 X 3 0 SGC 2821 M22 X 2 5 M24 X 3 0 SGC 2824 M22 X 2 5 M24 X 3 0 SGC 3511 M24 X 3 0 M30 X 3 5 SGC 3515 M24 X 3 0 M30 X 3 5 SGC 3519 M24 X 3 0 M30 X 3 5 SGC 3524 M24 X 3 0 M30 X 3 5 Based on Gaskets Garlock Blue Gard 3300 Bolts class 8 8 or stronger hex head bolts lightly oiled and clean Table 10 RWF II Bolt Sizes And Torque Values OIL QUALITY AND ANALYSIS OIL SAMPLING PROCEDURE High quality refrigeration oil is necessary to ensure compres sor longevity and reliability Oil quality will rapidly deteriorate in refrigeration systems containing moisture and air or other Exercise extreme caution in the vicinity of operating contam
97. e are to be tied together at each daisy chain connection and only taken to ground in the central control system panel It is important to carefully consider the type of cable to be used Just because a cable has the proper number of conduc tors and is shielded does not mean it is an acceptable cable Johnson Controls Frick recommends the use of Belden 9829 for RS 422 communications and Belden 9841 for RS 485 up to 2000 feet 600 Meters total cable length Refer to Frick drawing 649D4743 for more detail Comm Port Protection Surge suppression for the comm ports may not be the best method since suppression is re quired to divert excess voltage current to ground Therefore the success of these devices is dependent on a good ground covered earlier in this section This excess energy can be quite high and without a proper ground it will access the port and damage it Isolation or Optical Isolation is the preferred comm port protection method With optical isolation there is no con tinuity between the communications cable and the comm port There is no dependence on the quality of the ground Be sure to know what the voltage isolation value of the optical isolator is before selecting it These may range from 500 to 4000 Volts Frick Optical Isolation Kits are offered under part number 639C0133G01 One kit is required per comm port RWF ROTARY SCREW COMPRESSOR UNITS PROPER INSTALLATION OF ELECTRONIC EQUIPMENT Page 57 070 61
98. e 63 Page 4 Unit Serial Frick Order No P amp ID Setpoints Name Control Action Control Point Device Source Device Channel Setpoint Dead Band Prop Band Integral Gain Communications Compressor ID Comm 1 Comm 2 Comm 3 Baud Rate Baud Rate Baud Rate Data Bits Data Bits Data Bits Stop Bits Stop Bits Stop Bits Parity Parity Parity RS 485 Connection RS 485 Connection RS 485 Connection Protocol Protocol Protocol Use Map File Ethernet IP Data Naming Data Protocols Address Type Host Name ModBus TCP IP Address Work Group Ethernet I P Gateway Address Comments Profinet Subnet Mask Web Server Port Compressor Operating Log Sheet Starter Operating Log Sheet Date Average Current Time Current Phase A Hour Meter Reading Current Phase B Equip Room Temp Current Phase C Suction Pressure Full Load Amps Suction Temperature Output Frequency Suction Superheat Output Voltage Discharge Pressure DC Bus Voltage Discharge Temperature Input Power kW Corresponding Temperature Actual Speed Cil Pressure Speed Command Oil Temperature Ambient Temp F Oil Filter Pressure Drop Convert Heatsink Temp F Separator Temperature Baseplate Temp F Slide Valve Position VSD Operating Mode Volume Ratio VI Harmonic Filter Present Motor Amps FLA 96 Harmonic Filter Mode Capacity Control Setpoint Water Pump Energized Oil Level Precharge Relay Energized Oil Added Trigger SCR s Energized Seal Leakage Drops Min DC Inverter Link Current E
99. e cone button see Figure 3 BOTTOM Please design your system piping accordingly SEE CAUTION BELOW After removing the suction sealing disc confirm that the check valve hinge pin is in the vertical position If the hinge pin is not in a vertical position then failure of the check valve may occur INCORRECT CORRECT Figure 3 Valve Installation THERMOSYPHON OIL COOLING 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 that is partially vaporized at the condenser tem perature in a plate and shell vessel cooling the oil to within 35 F 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 Frick BY JOHNSON CONTROLS EQUIPMENT The basic equipment required for a ther mosyphon system consists of 1 source of liquid refrigerant at condensing pressure and temperature located in close proximity to the unit to mini mize piping pressure drop The liquid level in t
100. e motor This should only be done by authorized Factory Field Service Technicians Summary The Frick Field Service Supervisor should arrive to find the above items completed He should find an uncoupled compressor drive unit to verify motor rotation and alignment and energized oil heaters with the oil at the proper standby temperatures Full compliance with the above items will contribute to a quick efficient and smooth start up The Start up Supervisor will 1 Verify position of all valves 6 Verify and finalize alignment if applicable 2 Verify all wiring connections 7 Calibrate slide valve and slide stop 3 Verify compressor motor rotation 8 Calibrate temperature and pressure readings A Verify oil pump motor rotation 9 Correct any problem in the package 5 Verify the of FLA on the micro display 10 Instruct operation personnel NOTE Customer connections are to be made per the electrical diagram for the motor starter listed under the installation section and per the wiring diagram listed under the maintenance section of the Please complete and sign this form amp fax to 717 762 8624 as confirmation of completion Frick Sales Order Number Print Name Compressor Model Number Company Unit Serial Number Job Site Contact End User Name Contact Phone Number Address of Facility City State Zip Signed 070 610 IOM NOV 14 RWF ROTARY SCREW COMPRESSOR UNITS Page 60 FORMS Frick Start up Report Frick Ord
101. e single box control door must be kept tightly closed to prevent moisture and foreign matter from entry NOTICE All customer connections are made in the single box control mounted on the oil separator This is the ONLY electrical enclosure and it should be kept tightly closed whenever work is not being done in it VOLTAGE PROTECTION NOTICE Johnson Controls Fricke does not advise nor support the use of UPS power systems in front of the Ouantum HD panel With a UPS power system providing shutdown protection for the Ouantum HD the panel may not see the loss of the 3 phase voltage on the motor because the UPS could prevent the motor starter contactor from dropping out With the starter contactor still energized the compressor auxiliary will continue to feed an Okay signal to the panel This will allow the motor to be subjected to a fault condition on the 3 phase bus Some fault scenarios are 1 The 3 phase bus has power on and off in a continu ous cyclic manner which may cause the motor to overheat due to repeated excessive in rush currents 2 Motor cycling may damage the coupling or cause other mechanical damage due to the repeated high torque motor bumps 3 Prolonged low voltage may cause the motor to stall and overheat before the motor contactor is manually turned off Under normal conditions the loss of 3 phase power will shut down the Quantum HD panel and it will restart upon power RWF ROTARY SCREW CO
102. ed Industrial Control Valve 20 magnetic field 55 Maintenance Abnormal Operation Analysis and Correction 34 abnormal system conditions 34 abnormal vibration 32 Frick BY JOHNSON CONTROLS Capacity Linear Transmitter 37 compressor unload cylinder 37 condensed refrigerant 35 DIN connector plug 37 filter elements 33 Grease Compatibility 33 leaks 32 linear transmitter 37 lubrication 33 Lubrication Schedule 33 Maintenance Schedule 32 Main Operating Screen 34 moisture 33 Motor Bearings 33 NLGI Grease Compatibility Chart 33 noise 32 oil base grease 33 oil analysis 33 oil level control 38 Oil Level Transmitter 38 Oil quality 33 Operating Log 33 Potentiometer 37 Pressure Transducers discharge pressure 36 discharge pressure transducer 36 oil pressure transducer 36 Pressure Transducer 37 Replacement 36 Testing 36 transducer isolation valve 37 voltage reading 36 Proper Installation of Electronic Equip ment 53 P amp Diagram 50 Recommended Maintenance Program 32 refrigeration oil 33 sensor well 37 Servicing the Cold Start Valve 35 bonnet 35 Bonnet Cap Screw Torque Values 35 valve body 35 valve housing 35 stop valve 35 Temperature Transmitter 38 Troubleshooting See Index Trouble shooting Troubleshooting Guide 34 Vibration Analysis 32 Vibration Data Sheet 64 vibration readings 32 volume ratio control 37 Volumizer unit 37 main oil injection port 16 m
103. ed and charged with dry nitrogen to ensure the integrity of the unit during shipping and short term storage prior to installation Care must be taken when entering the unit to ensure that the nitrogen charge is safely released Holding charge shipping gauges on separator and external oil cooler are rated for 30 PSIG and are for checking the shipping charge only They must be re moved before pressure testing the system and before charging the system with refrigerant Failure to remove these gauges may result in catastrophic failure of the gauge and uncontrolled release of refrigerant resulting in serious injury or death All units must be kept in a clean dry location to prevent corrosion damage Reasonable consideration must be given to proper care for the solid state components of the mi croprocessor Please contact Frick service for long term storage requirements COMPRESSOR UNIT 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 NOTICE The Frick 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 Oil publication 160 802 SPC OIL CHARGE The normal charging level is RWF Il BASIC midway in t
104. em is running to 180 ft lb RESTARTING COMPRESSOR UNIT AFTER CONTROL POWER INTERRUPTION PLANT POWER FAILURE 1 Check variable setpoints 2 Follow normal start up procedure VFD SKIP FREQUENCIES Criteria for Identifying Elevated Energy on VFD Packages and Establishing Skip Frequencies With the RWF II running loaded at full speed the entire package must be physically checked for elevated energy including any corresponding extremities such as valves liquid injection piping brackets tubing oil cooler and oil piping The VFD speed is to be decreased by 100 rpm increments and the entire package physically checked for elevated energy at each stage until the minimum speed range is reached As the high energy hot spots are identified they are to be checked with a vibration meter and any readings that meet or exceed one inch per second must have that frequency range skipped in the microprocessor for the VFD eliminating the ability of the package to operate within that frequency range Each identified range needs to have the skip set to as narrow a frequency band as possible only making it wider until full range is accommodated Please also reference 070 902 for acceptable package vibration readings Skip frequencies should be reviewed per Maintenance Schedule Frick BY JOHNSON CONTROLS Maintenance GENERAL INFORMATION This section provides instructions for normal maintenance a recommended maintenance program
105. ents that ICAD is operating the ICM valve like an ON OFF solenoid valve with medium speed according to a digital Input signal High represents that ICAD is operating the ICM valve like an ON OFF solenoid valve with high speed according to a digital input signal Figure 25 RWF Il ROTARY SCREW COMPRESSOR UNITS 070 610 1OM NOV 14 Frick OPERATION Page 21 Figure 25 ICAD High Function Status Alarms ICAD can handle and display different alarms ICM No valve type At start up 1 and CA will be Selected displayed Controller fault Internal fault inside electronics fail safe suppl lt 18 V d c to ICAD If an alarm has been detected the ICAD display Figure 21 will alternate between showing Actual alarm and present Opening Degree ___ 2 All input error Not active if 101 2 102 2 When j03 1 and Al A gt 22 mA When j03 2 and Al A gt 22 mA Or AL A lt 2mA When 103 3 and AI A gt 12V When 103 4 and AI A gt 12V lt 1 If more than one alarm is active at the same time the alarm with the highest priority will take preference 1 has the highest priority A5 the lowest Any active alarm will activate the Common Digital Alarm output Normally Open All alarms will automatically reset themselves when they physically disappear Old alarms alarms that have been active but have physically disappeared again can be found in parameter 111 Reset to
106. er No Sold To Contact Name Date End User Contact Name Phone End User Address Fax No City State Zip Start up Representative Unit General Information Unit Model Customer Package Identification Compressor Serial Separator National Board Unit Serial Oil Cooler National Board Evaporator National Board Serial Condenser National Board Serial Oil Pot National Board H P Receiver National Board Economizer National Board Suction Accumulator National Board Refrigerant Oil Filters Lube Oil Type Design Operating Conditions Oil Cooling 9 Suct Disch Micro Information Micro Type Program Software Ver and Date UL Serial Digital I O Board 1 Serial 3t Software Ver and Date Digital Board 2 Serial Software Ver and Date Analog Board 1 Serial Software Ver and Date Analog Board 2 Serial Software Ver and Date Compressor Motor Starter Drive Information Manufacturer Part Model Starter Type Serial Input Voltage Voltage Range Phase Hz Current Output Voltage Phase Hz Max FLA Max LRA Min Load FLA Job Logic Board Serial U33 Prog Ver Date P N U34 Prog Ver Date P N U45 Prog Ver Date P N Harmonic Filter Serial Prog Ver Date P N Frick Interface Serial Prog Ver Date P N CT Location Checked Phase CT Ratio Transition Time DBS Ver Oil Pump Information Pump Mfg Model Serial Motor Mfg H P Motor RPM Service Factor Volt HZ FLA Design ___ Code Starter Size Coolin
107. essor exhibits a noticeable change in vibration level noise or performance COMPRESSOR SHUTDOWN AND START UP For seasonal or prolonged shutdowns the following procedure should be followed 1 Reduce the system pressure to the desired condition 2 Press STOP key to cease operation of the compressor 3 Open disconnect switches for compressor motor and oil pump starters 4 Turn on oil heater circuit breaker 5 Close suction and discharge service valves also liquid injection and economizer service valves if applicable Attach CLOSED TAGS 6 Shut off cooling water supply valve to oil cooler if ap plicable Attach CLOSED TAG 7 Protect oil cooler from ambient temperatures below freezing or remove water heads To start up after a seasonal or prolonged shutdown the fol lowing procedure should be followed 1 Any water necessary for the operation of the system that may have been drained or shut off should be restored and turned on 2 Open suction and discharge service valves also liquid injec tion and economizer service valves if applicable Remove tags 3 Close disconnect switches for compressor motor and oil pump starters 4 Turn off oil heater circuit breaker 5 Perform checkpoints on prestart check list then start unit GENERAL INSTRUCTIONS FOR REPLACING COMPRESSOR UNIT COMPONENTS NOTICE See Publication 070 660 SM for procedures covering replacement motor and compressor mounting When repl
108. g Fan Information Motor HP RPM Service Factor Volt Hz FLA Cooling Fans Special Options Prestart Checks 0 Installation Foundation Compressor PHD Setup 0 Coolant Installed 0 Position of all valves 0 Motor PHD Setup 4 20 Coolant Loop Pump Setup Proper oil charge 0 Motor Winding RTD s Setup 0 Coolant Loop Temp Setup O All wiring connections 0 Motor Bearing RTD s Setup 0 Cooling Fan Motor I O Setup 0 Starter Cleanliness 0 Motor Temperature Thermistor Setup Cooling Fan Rotation Checked All micro settings 4 20 Motor Drive Signal Calibrated 0 Oil pump motor rotation 0 4 20 CT Channel 16 Setup 0 Cold alignment 0 Motor rotation 4 20 Output Calibration Liquid Makeup Valve Coolant Temp Valve Economizer Makeup Valve Configuration Capacity Channel Direction Package Mode 1 Compressor Mode 2 Pump Mode 3 Dual Pump Mode 4 Drive VFD Hi amp Low PI Control Refrigerant K Factor Miscellaneous Filter Sequencing PowerPac Condenser Screen Saver FORMS Page 61 Page 2 Unit Serial Frick Order No Mode Capacity Control Setpoints Mode Setpoint Regulation Safeties Setpoint Regulation Safeties High Low Load Inhibit High Low Load Inhibit Prop Band Force Unload Prop Band Force Unload Dead Band Warning Dead Band Warning Cycle Time Sec Sec Warning Delay Sec Cycle Time ___5 ___ Warning Delay VFD Prop Band Shutdown VFD Prop Band Shutdown VFD Integ Time Sec Shutdow
109. half full of multipurpose grease NLGI 2 The thrust bearing assembly will take the remaining space See Figure 29 and 30 14 Pack double row ball bearing with multipurpose grease NLGI 2 GG HJ HL Install ball bearing into bearing housing with shield side toward coupling end of shaft See Figure 30 Install snap ring into bearing housing to retain ball bearing This snap ring has a tapered edge to fit tapered groove in bearing housing The tapered edge is located away from ball bearing AS AK AL Install ball bearing into bearing housing Install lip seal in bearing housing end cap The lip should face to wards end of shaft Put bearing spacer collar in lip seal and install in bearing housing and tighten setscrews securely See Figure 30 15 Insert brass bar or hardwood through port opening be tween rotor teeth to keep shaft from turning 16 Start thrust bearing assembly into casing Turn by hand until tight This forces rotor against head Replace and tighten locknut or shaft 17 Remove brass bar or hardwood from port opening 18 Adjust pump end clearance A DANGER BEFORE STARTING PUMP ENSURE THAT ALL DRIVE EQUIPMENT GUARDS ARE IN PLACE FAILURE TO PROPERLY MOUNT GUARDS MAY RESULT IN SERIOUS INJURY OR DEATH THRUST BEARING ADJUSTMENT See Figures 29 and 30 Loosen two screws in face of thrust bearing assembly If shaft cannot be rotated freely turn thrust bearing assembly counterclockwise until shaft ca
110. he refrigerant source must be 6 to 8 feet minimum above the center of the oil cooler 2 A plate and shell oil cooler with Plate Side Oil 400 psi design Shell Side Refrigerant 400 psi design Due to the many variations in refrigeration system design and physical layout several systems for assuring the above criteria are possible TO SYSTEM 2 5 9407 524 2 2 240 0 2 TS RECEIVER HOT OIL IN 120 140 F FROM OIL OUT SEPARATOR Figure 4 Thermosyphon Receiver System SYSTEM OPERATION Liquid refrigerant fills the cooler shell side up to the Thermosyphon receiver liquid level Hot oil above the liquid temperature flowing through the cooler will cause some of the refrigerant to boil and vapor ize The vapor rises in the return line The density of the refrigerant liquid vapor mixture in the return line is consid erably less than the density of the liquid in the supply line This imbalance provides a differential pressure that sustains a 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 Current thermosyphon systems are using two pass oil coolers and flow rates based on 3 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 rel
111. he 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 tem perature readings on a display 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 SERVICING THE COLD START VALVE Figure 38 Cold Start Valve RWF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE Page 35 070 610 1OM NOV 14 Before beginning to disassemble the valve the refrigerant must be removed from all associated piping Start room ventilation and put on a safety mask Be extremely careful when dismantling the cold start valve on the discharge side of the unit as condensed refrigerant often is trapped between the cold start valve and the stop valve A bleed valve on the side of the check valve is used to vent the space between the check valve and stop valve Exposure to refrigerant fumes can cause injury or death Inside the valve see Figure 37 there is a very heavy tight spring 15 Provided the valve is intact the spring presents no d
112. he top sight glass MODEL CHARGE located midway along the NO gal oil separator shell Normal operating level is midway between the top sight glass and bottom sight glass The table gives the approximate oil charge quantity Add oil by attaching the end of a suitable pressure type hose to the oil drain valve located under the oil separator see Figure 2 Using a pressure type pump and the recom mended Frick oil open the drain valve and pump oil into Includes total in horizontal oil the separator separator and piping Add 5 gal for oil cooler up to Model 270 10 gal for 316 1080 070 610 IOM NOV 14 NOTICE Evacuation of the oil separator will assist the flow of oil into the unit Also fill slowly because oil will fill up in the separator faster than it shows in the sight glass Figure 2 Oil Drain Valve 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 NOTICE The sight glass located in the coalescing end of the separator near the discharge connection should remain empty OIL HEATER S Standard units are equipped with one to three 1000 watt oil heaters providing sufficient heat to maintain the oil temperature for most indoor applications during shutdown cycles to permit safe start up Should additional heating capacity be req
113. hedule Vibration analysis is recommended every 6 months to ensure that the internal components of the screw compressor are in compliance with expected vibration levels based on the initial full spectrum baseline performed at start up If the Frick PhD on board vibration monitoring system is utilized the 6 month vibration analysis is not required Frick PhD provides continuous vibration monitoring that fulfills the maintenance requirement Should the Frick PhD have an alarm or shut down event a full spectrum vibration analysis would then be required to specifically identify the cause of the alarm or shut down In addition a Frick compressor package without PhD moni toring already in operation can be retrofitted with the Frick PhD on board vibration monitoring system to fulfill the vibration maintenance recommendation However it is also necessary to establish a current baseline vibration with a full spectrum analysis in order for the PhD retrofit to be compliant VIBRATION ANALYSIS Periodic vibration analysis can be useful in detecting bearing wear and other mechanical failures If vibration analysis is used as a part of your preventive maintenance program take the following guidelines into consideration 1 Always take vibration readings from exactly the same places and at exactly the same percentage of load 2 Use vibration readings taken from the new unit at start up as the base line reference 3 Evaluate vibration rea
114. her mosyphon Oil Cooling SYSTEM CONDENSER STATIC HEAD SAFETY OVERCOME VALVE CONDENSER 2 _ THERMOSYPHON PRESSURE DROP RECEIVER LIQUID OVERFLOW OIL TEMP DRAIN TO RECEIVER CONTROL VALVE a HOT COOL A A OL TO SYSTEM PLATECOOLER _ EVAPORATOR TSOC gt REFRIGERANT OUT HOT OIL IN lt Y A RECEIVER jJ Mounted below Thermosyphon receiver level peFRIGERANT N 1 SYSTEM Figure 5 TSOC Piping Arrangement 1 The thermosyphon oil cooler is supplied with oil side piped to the compressor unit and stub ends supplied on the refrigerant side 2 Arefrigerant 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 3 The system receiver must be below the thermosyphon receiver in this arrangement LIQUID INJECTION OIL COOLING OPTIONAL The liquid injection system provided on the unit is self contained but requires the connection of the liquid line sized as shown in the Table below It is IMPERATIVE that an uninterrupted supply of high pres sure liquid refrigerant be prov
115. icks burrs and foreign particles that might damage mechanical seal Scratches on shaft in seal area will provide leakage paths under mechanical seal Use fine emery cloth to remove scratches or sharp edges DEMAND PUMP ASSEMBLY Assembly Notes On Standard Mechanical Seal Synthetic Rubber Bellows Type NOTICE READ CAREFULLY BEFORE REASSEMBLING PUMP The seal used in this pump is simple to install and good performance will result if care is taken during installation The principle of mechanical seal is contact between the rotary and stationary members These parts are lapped to a high finish and their sealing effectiveness depends on complete contact Prior to installing rotary portion of mechanical seal prepare and organize rotor shaft head and idler as semblies and appropriate gaskets for quick assembly Once rotary portion of mechanical seal is installed on rotor shaft it is necessary to assemble parts as quickly as possible to ensure that the seal does not stick to shaft in wrong axial position The seal will stick to the shaft after several minutes setting time Never touch sealing faces with anything except clean hands or clean cloth Minute particles can scratch the seal faces and cause leakage RWF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE Page 29 070 610 IOM NOV 14 1 Coat idler pin with refrigeration oil and place idler and bushing on idler pin in head If replacing a carbon graphite bushing
116. ided 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 The dual dip tube method Figure 6 uses two dip tubes in the receiver The liquid injection tube is below the evapor ator tube to ensure continued oil cooling when the receiver level is low 070 610 IOM NOV 14 FROM CONDENSER lt gt COMPRESSOR OIL COOLING SYSTEM RECEIVER LOCATE TO PROVIDE 5 MIN LIQUID SUPPLY Figure 6 Dual Dip Tube The level control method Figure 7 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 EVAPORATOR KING VALVE RECEIVER FROM CONDENSER LOW LEVEL FLOAT SWITCH LOCATE TO PROVIDE 5 MIN LIQUID SUPPLY r TO COMPRESSOR gt OIL COOLING SYSTEM Figure 7 Level Control ENDE umm Dum MODEL SIZE SUPPLY Ib CU FT 100 134 3 4 75 5 2 1 177 270 1 151 0 4 1 R 717 316 399 1 219 5 High Stage 480 546 1 300 0 676 1
117. ies to both the line side and load side of the drive When VFD rated cable is not used threaded metallic or threaded PVC coated metallic must be used When threaded metallic or threaded PVC coated metallic is used it must be grounded at both ends When not required to be in metal or other material by national or local codes conduits for the power feed 3 phase of constant speed starters may be PVC When not required to be in metal or other material by national or local codes conduits between a constant speed starter and the motor 3 phase may be PVC Any unshielded control voltage signal analog or com munication wiring that does not maintain 12 inches of separation from any 3 phase conductors for every 33 feet 10 meters of parallel run must be in metal conduit which will be grounded Separation 0 33 feet 0 10 meters 12 inches 3 meters 33 66 feet 10 20 meters 24 inches 6 meters Since PVC conduit does absolutely nothing to protect lower voltage lines from the magnetic field effects of higher voltage conductors running either the lower or the higher voltage lines in PVC does not reduce these requirements on separation Only running in metal conduit can relieve these requirements Due to the level of EMI that can be induced onto lower voltage lines when running multiple feeders in a trench control power communications analog or signal wiring cannot be run in trenches that house multiple conduits electric
118. ight glass 7 8 16 28 single box control 12 single port liquid injection 18 Skip frequencies 24 slide stop 15 slide stop piston 17 slide valve 12 15 17 slide valve position 24 slugging 25 Sola constant voltage CV transformer 12 solenoid 11 27 solenoid valve 10 17 18 23 solid state 12 spacer 6 spring isolators 5 Star Networks 57 Starter Operating Log Sheet 63 Start up CoolWare 24 discharge temperature 24 hand expansion valve 24 initial start up 24 manway bolts 24 prestart checklist 24 start up 8 theoretical discharge temperature 24 water control valve 24 starter coil 13 starter package 12 Starter Wiring Diagram 12 stop valve 27 strainer 10 11 27 strainer basket 27 strainer cover 26 27 strainer elements 27 strainer inlet service valve 26 subcooled liquid 11 subcooling 10 suction 16 suction accumulators 25 suction bypass 11 suction check valve 8 23 suction check valve bypass 16 suction check valve bypass line 11 Suction Check Valve Power Assist Kit 23 Suction flange 15 November 2014 Form Revisions RWF ROTARY SCREW COMPRESSOR UNITS INDEX suction isolation valve 8 suction port 15 suction pressure 11 suction strainer 15 25 suction trap 26 superheat 25 superheating 15 Surge suppression 57 system head pressure 15 18 temperature control valve 18 Temperature Sensor Replacement 38 DIN connector plug 38 thermal well 38 transmitter
119. il Cooling Optional Water Cooled Oil Cooling Optional Economizer High Stage Optional Economizer Load Balancing Motor Starter Package Current Transformer CT Ratios Minimum Burden Ratings Control Power Regulator OPERATION Operation And Startup 15 SGC Compressor Compressor Lubrication System No Pump Oil System eee Demand Pump Oil System sene Compressor Oil Separation System Cold Start Syst m ncaa asides Compressor Hydraulic Volume Ratio Control Compressor Oil Cooling Systems Single Port Liquid Injection eeeeeee Dual Port Liquid Injection Quantum HD EZ COOL Liquid Injection Adjustment Procedure da cedet terc een eere ees 19 Operation Of Danfoss Liquid Injection Valve 20 Suction Check Valve Bypass Low Ambient Operation Suction Check Valve Power Assist Kit Balance Piston Pressure Regulator Initial 53 Initial Start Up Procedure Normal Start Up Procedure Skip Frequencies MAINTENANCE General
120. ime a Low level in tank b Liquid vaporizing in the suction line c Air leaks or air pockets in the suction line leaking air through packing or mechanical seal d Worn out 3 Pump is noisy a Pump is being starved heavy liquid cannot get to pump fast enough Increase suction pipe size or reduce length b Pump is cavitating liquid vaporizing in the suction line Increase suction pipe size or reduce length if RWF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE Page 31 070 610 IOM NOV 14 pump 15 above the liquid raise the liquid level closer to the pump if the liquid is above the pump increase the head of liquid c Check alignment d May have a bent shaft or rotor tooth Straighten or replace e May be a foreign object trying to get into the pump through the suction port 4 Pump not up to capacity a Starving or cavitating increase suction pipe size or reduce length b Strainer partially clogged clean Air leak in suction piping or along pump shaft Running too slowly is motor the correct speed and is it wired up correctly Relief valve set too low or stuck open Pump worn out Tighten end clearance Head position incorrect so 5 Pump takes too much power a Running too fast is correct motor speed reducer ratio sheave size etc being used b Liquid more viscous than unit sized to handle heat the liquid increase the pipe size slow the pump down or get a bigger motor c
121. inants In order to ensure the quality of the refrigera equipment Skin contact with lube oil or inhalation of tion oil in the compressor unit vapors can cause serious injury or death consider gloves and eye protection Sample hot active fluid while the equipment is operating DO NOT MIX OILS of different brands manufacturers or Sample after 30 minutes of compressor operation types Mixing of oils may cause excessive oil foaming nuisance oil level cutouts oil pressure loss gas or oil 1 Unthread the oil sampling valve cap and locknut Figure 34 leakage and catastrophic compressor failure NOTICE The Frick 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 2 Unthread the bottle cap and carefully position under the operating pressures or temperatures refer to Fricke Oil oil sampling valve spout Place the spout inside the bottle publication 160 802 SPC for guidance 3 Push the oil sampling valve to open and release to close Only use Frick oil filter elements or warranty claim spring actuated see Figure 34 inset Fill the bottle full may be denied DO NOT UNTHREAD THE VALVE FROM THE FILTER HOUSING OR PIPING OR UNCONTROLLED RELEASE OF OIL WILL RESULT 4 Retighten bottle cap sampling valve cap and locknut 1 Participate in a regular periodic oil analysis program to Please note that the
122. ine Interface 20 Mod 20 Opening Degree OD 20 parameters 20 Parameter list 22 Analog Input signal 22 Analog Output signal 22 Automatic calibration 22 Digital Input function 22 Fail safe 22 ICM configuration 22 Main Switch 22 Mode 22 Modulating Mode 22 Old Alarms 22 Password 22 digital Input signal 20 Display 20 Enter push button 20 ICAD Industrial Control Actuator with Display 20 ICM valve 20 MMI Man Machine Interface 20 Mod 20 Motorized Industrial Control Valve 20 Opening Degree 20 parameters 20 Parameter list 22 Analog Output signal 22 Automatic calibration 22 Digital Input function 22 Fail safe 22 ICM configuration 22 Main Switch 22 Mode 22 Modulating Mode 22 Old Alarms 22 Password 22 solenoid valve 20 J liquid injection oil cooling 10 liquid injection strainer 27 jack 5 liquid injection system 9 K liquid injection tube 9 liquid injection valves 25 keyway setscrews 6 liquid level 9 liquid refrigerant 18 L liquid solenoid 10 27 leak test 26 level control method 10 LICO 18 liquid feed solenoid 11 liquid injection 15 17 Alarms 20 analog input signal 20 liquid supply service valve 27 locknut 6 low differential oil pressure 16 low pressure transducer 26 low voltage 12 lubrication system 15 Common Digital Alarm 21 M Danfoss Liquid Injection Valve 20 High 20 ICAD Industrial Control Actuator with Display 20 ICM Motoriz
123. instrumentation and therefore requires careful attention to installation procedures These procedures are well known to instrumentation networking and other professions but may not be followed by general electricians There are a few basic practices that if followed will minimize the potential for problems resulting from RFI EMI and or ground loop currents The National Electric Code NEC is a guideline for safe wiring practices but it does not necessarily deal with procedures used for electronic control installation Use the following procedures for electronic equipment instal lation These procedures do not override any rules by the NEC but are to be used in conjunction with the NEC code and any other applicable codes With exclusion of the three phase wire sizing Frick drawing 649D4743 should be used as a reference for properly sizing control wires and other wiring specifications Throughout this document the term Electronic Control Panel is used to refer to the microprocessor mounted on the com pressor package or a Central Control System panel NOTICE 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 request the proper instructions and drawings Every manufacturer of elec tronic equipment should have a knowledgeable staff willing to answer your questions or provide additional
124. iquified since it is still at condenser pressure Figure 4 OIL TEMPERATURE CONTROL Oil temperature will gen erally run about 15 35 F above condensing temperature In many cases an oil temperature control is not required if condensing temperature is above 65 F as oil temperature can be allowed to float with condenser temperature 65 F 105 F 80 F 140 F Condensing Temperature Oil Temperature INSTALLATION The plate and shell type thermosyphon oil cooler with oil side piping and a thermostatically controlled mixing valve 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 con sideration given to the following RWF ROTARY SCREW COMPRESSOR UNITS INSTALLATION Page 9 070 610 IOM NOV 14 1 The refrigerant source thermosyphon or system receiver should be in close proximity to the unit to minimize piping pressure drop 2 The liquid level in the refrigerant source must be 6 to 8 feet minimum above the center of the oil cooler 3 A safety valve should be installed if refrigerant isolation valves are used for the oil cooler NOTICE The component and piping arrangement shown in Figure 5 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 070 900 E for additional information on T
125. ironment Standard procedure for electronic instrumenta tion is to provide a clean isolated separate source voltage in order to prevent EMI from other equipment in the plant from interfering with the operation of the electronic equip ment Connecting electronic equipment to a breaker panel also known as lighting panels or utility panels subjects the electronic equipment to noise generated by other devices connected to the breaker panel This noise is known as elec tromagnetic 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 power transformer of the proper VA rating usually provided in the compressor drive motor starter to isolate the electronic control panel from other equipment in the plant that generate EMI See Figure below CONTROL Loud TRANSFORMER ISOLATED CIRCUIT ELECTRONIC CONTROL CORRECT CONTROL TRANSFORMER NONISOLATED CIRCUIT ELECTRONIC CONTROL INCORRECT Figure 44 Voltage Source Circuit To Prevent EMI 070 610 IOM NOV 14 GROUNDING Grounding is the most important factor for successful opera tion and is typically 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 in no way acceptable for electronic control equipment Conduit is made of
126. l mode the compressor will have to be restarted manually after the 3 phase bus fault interruption has been cleared restored If the local power distribution system is unstable or prone to problems there are other recommendations to satisfy these problems If power spikes or low or high line voltages are the problem then a constant voltage CV transformer with a noise suppression feature is recommended Johnson Controls Inc can provide these types of transformers for this purpose Contact Johnson Controls for proper sizing VA Rating based on the requirement of the job If a phase loss occurs then you will typically get a high motor amp shut down If the problem continues an analysis of the facility s power supply quality may be necessary NOTICE It is very important to read the installation instructions thoroughly before beginning the project Make sure you have drawings and instructions for the equipment being installed If not call the manufacturer to receive the proper instructions and draw ings Every manufacturer of electronic equipment should have a knowledgeable staff willing to answer your questions or provide additional information Following correct wiring procedures will ensure proper installation and consequently proper operation of your electronic equipment Frick BY JOHNSON CONTROLS RWF ROTARY SCREW COMPRESSOR UNITS FORMS OPERATING LOG SHEET 070 610 IOM NOV 14 Page 58
127. ller unless a starter package is purchased separately from Johnson Controls Frick Starter packages should consist of 1 The compressor motor starter of the specified HP and voltage for the starting method specified across the line wye delta or solid state NOTICE If starting methods other than across the line are de sired a motor compressor torque analysis must be done to ensure that sufficient starting torque is available particularly in booster applications Contact Johnson Controls Frick if assistance is required 2 specified the starter package be supplied as a combination starter with circuit breaker disconnect However the motor overcurrent protection disconnection device can be applied by others usually as a part of an electrical power distribution board 3 The oil pump starter with fuses or in the case where the compressor motor is a different voltage from the oil pump motor with a circuit breaker disconnect suitable for separate power feed 4 A 3 0 KVA control power transformer CPT to supply 120 volt control power to the microprocessor control sys tem and separator oil heaters is included If environmental conditions require more than the usual two 500 watt oil heaters an appropriately oversized control transformer will be required If frequent power fluctuations are anticipated or extremely noisy power lines are encountered a regulating control transformer should be considered Contact John
128. mbols 3 phase ground 55 3 phase supply 55 A Abnormal Operation Analysis and Correction 34 across the line 12 atmospheric pressure 26 27 axial loads 15 axial load bearings 15 back feeding 23 back flushing 10 back pressure regulator 12 back pressure regulator valve 11 balance piston 15 23 Balance Piston Pressure Regulator 32 balancing load 11 bleed valve 26 booster application 12 16 booster compressor 23 booster systems 23 BP 17 BP coupling data table 6 BPR valve 11 brownouts 14 cable trays 55 CH Coupling Data Table 7 check valve 11 23 chemical cleaning process 10 circuit breaker 12 circuit breaker disconnect 12 clamping bolts 7 closed loop fluids 10 closed loop system 10 coalescer filter element 16 27 coalescer filter retainer 27 codes 55 Cold Start System 16 cold start valve 16 35 Comm Port Protection 57 Communications 57 Compressor compressor 11 discharge 16 drive shaft 15 hydraulic system 17 lubrication 16 motor 12 13 oil temperature 17 suction 17 Vi 17 Compressor Operating Log Sheet 63 Compressor Port Locations 42 Compressor Prestart Checklist 59 condenser 16 RWF ROTARY SCREW COMPRESSOR UNITS INDEX Index condenser inlet 8 condensing pressure 8 condensing temperature 9 Conduit 55 cone button 8 constant speed starters 55 control power regulator 14 control power transformer 12 control transformer 12
129. metal filings to land on the electronics and create a short circuit when powered is applied If you must drill the panel take the following precautions First call the panel manufacturer before drilling into the panel to be sure you are entering the panel at the right place Take measures to avoid ESD electrostatic discharge to the electronics as you prep the inside of the Electronic control panel This can be done by employing an antistatic wrist band and mat connected to ground Cover the electronics with plastic and secure it with masking or electrical tape 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 filings Clean all of the remaining filings from the panel before removing the protective plastic 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 a NEMA 4 hub type fitting between the conduit and the enclosure so that if water gets on top of the enclosure it cannot run in bet
130. misalignment 31 Pressure Gauge 31 Relief valve 31 Relief valve poppet 31 Starving 31 Strainer 31 suction port 30 Suction valve 31 vacuum gauge 30 Vibrating 31 demand pump 15 16 disc type check valves 11 discharge check valve 16 23 discharge pressure 15 disconnect switches 25 disc drive spacer 6 disc packs 6 double acting hydraulic cylinders 17 Double Acting Mode 17 double acting solenoid valve 18 drain valve 26 drive coupling 23 drive hubs 7 dry nitrogen 7 25 dual port liquid injection 17 dual setpoint 12 dual dip tube method 9 dual oil filters 15 DX economizer 10 DX vessel 11 E Economizer back pressure regulator valve 11 balancing load 11 BPR valve 11 check valve 11 DX economizer 10 DX vessel 11 economizer port 10 11 070 610 10 NOV 14 Page 66 economizer vessel 11 electric shutoff option 11 flashing liquid 10 flash economizer system 11 flash gas 12 flash tank 10 flash vapor 12 heat exchanger 10 isolation valve 11 liquid feed solenoid 11 liquid solenoid 10 microprocessor 10 outlet pressure regulator 11 overpressurizing 11 Packaged Refrigerant Recirculation Unit 11 partial load 11 piston type check valves 11 port pressure 11 strainer 11 subcooled liquid 11 subcooling 10 suction bypass 11 suction pressure 11 economizer port 10 11 economizer vessel 11 elastomeric gear 7 electric shutoff option 11 entrapped refrigerant 27 evaporator 10
131. n be turned easily 1 While turning rotor shaft rotate thrust bearing assem bly clockwise until noticeable drag occurs This is zero end clearance 2 Mark position of bearing housing with respect to the casing 3 Rotate thrust bearing assembly counterclockwise the distance listed below as measured on outside of bearing housing 4 Tighten two setscrews in face of bearing housing after adjustment is made to secure thrust bearing assembly posi tion For viscosities above 2500 SSU add additional end clearance 0 004 for GG HJ m HL size pumps and 0 005 for AS AK and AL size pumps Distance in on O D End Clearance of Bearing Housing in 7 16 003 mm um 9 16 003 AS AK AL 1 2 003 Table 9 Thrust Bearing Assembly Adjustment INSTALLATION OF CARBON GRAPHITE BUSHINGS When installing carbon graphite bushings extreme care must be taken to prevent breaking Carbon graphite is brittle and easily cracked If cracked the bushing will quickly disinte grate Using a lubricant and adding a chamfer on the bushing and the mating part will help in installation The additional precautions listed below must be followed for proper instal lation 1 A press must be used for installation 2 Be certain bushing is started straight 3 Do not stop pressing operation until bushing is in proper position Starting and stopping will result in a cracked bush ing 4 Check bushing for cracks after installation TRO
132. n Delay Sec VFDInteg Time ___5 Sec Shutdown Delay Channel Channel Auto Cycle Low Suction Auto Cycle Low Suction Start Load Inhibit Start Load Inhibit Start Delay Min Force Unload Start Delay Min X Force Unload Stop Warning Stop Warning Stop Delay Min Warning Delay Sec Stop Delay Min Warning Delay Sec Shutdown Shutdown Shutdown Delay Sec Shutdown Delay Sec Compressor Safeties High Discharge Temperature High Suction Pressure Load Inhibit Load Inhibit PSIG Force Unload Force Unload PSIG Warning Start Differential Warning PSIG Warning Delay Sec Pressure Below Warning Delay Sec Shutdown PSI Shutdown PSIG Shutdown Delay Sec Shutdown Delay Sec High Discharge Pressure Dual Mode Economizer Regulation Modes 1 amp 3 Modes2 amp 4 On When Above Load Inhibit PSIG PSIG Off When Below Force Unload PSIG PSIG Override Discharge Pressure Warning PSIG PSIG Port Value Warning Delay Sec Sec Pressure Input Shutdown PSIG PSIG Fixed Pressure Setpoint Shutdown Delay Sec Sec Maximum Discharge Pressure PSIG Highest Cap To Permit Start Balance Piston Start Period Before Cap Increase On Stopping Period For Cap Unload Off Compressor Auto Mode Min Cap Ignore Delay _ Min Capacity Unload Assist Rate Fail Delay _ Min Separator Velocity Ref Oil Log Delay Sec Compression Ratio Liquid Slug Warning Main Oil Injection On When Discharge Temperature Liquid Slug Shutdown Is Above F for Sec Package Safeties Low Compressor Oil Tempera
133. n and economizer service valves if applicable 4 SLOWLY vent separator to low side system pressure using the bypass line on the suction trap 070 610 IOM NOV 14 RWF ROTARY SCREW COMPRESSOR UNITS Frick Page 28 MAINTENANCE JOHNSON conTROLS NOTICE 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 sepa rator pressure increase Repeat venting and recovery procedure if necessary 5 Open the drain valve s located on the underside of the separator and drain the oil 6 Drain the oil filter s OF 1 and if applicable the oil coolers and filter OF 2 7 Remove the old filter cartridges then install new ones as previously described in the section OIL FILTER OF 1 MAIN SINGLE DUAL 8 Remove clean and reinstall strainer elements in the strainers 9 Evacuate unit to 29 88 Hg 1000 microns vacuum 10 Open the suction service valve and pressurize the unit to system suction pressure Close the suction valve and leak test 11 Add oil by attaching a suitable pressure type hose to the oil drain valve located under the separator Using a pressure type oil pump and recommended Fricke oil open the drain valve and fill the separator until the oil level is midway in the top sight glass NOTICE Evacuation of the oil separator will
134. n solving the wrong problem a new problem was created When an operating problem develops compare all operating information on the MAIN OPERATING SCREEN with normal operating conditions If an Operating Log has been main tained the log can help determine what constitutes normal operation for the compressor unit in that particular system The following list of abnormal system conditions can cause abnormal operation of the RWF compressor unit 1 Insufficient or excessive refrigeration load Frick BY JOHNSON CONTROLS Excessively high suction pressure Excessively high suction superheat Excessively high discharge pressure Inadequate refrigerant charge or low receiver level Excessively high low temperature coolant to the oil cooler 7 Liquid return from system slugging 8 Refrigerant underfeed or overfeed to evaporators 9 Blocked tubes in water cooled oil cooler from high min eral content of water 10 Insufficient evaporator or condenser sizing 11 Incorrect refrigerant line sizing 12 Improper system piping 13 Problems in electrical service to 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 T
135. nexplained behavior and possible damage to components Frick BY JOHNSON CONTROLS To install correctly run a separate properly sized 10 or 8 AWG typically insulated ground along with and taken to ground with the 3 phase ground at the 3 phase supply transformer plant This will require that the 3 phase ground and the control power ground be electrically isolated except for the connection at the plant supply transformer This style of grounding should steer the noise EMI RFI to earth ground reducing the potential for it to affect the sensitive equipment which could occur if the grounds were left coupled If all other recommendations for grounding are followed this process should not be necessary CONDUIT All national and local codes must be followed for conduit with regard to materials spacing and grounding In addition Johnson Controls Frick requirements must be followed where they exceed or match national or local codes Con versely there is no allowance for any practices that are substandard to what is required by national or local codes Johnson Controls Frick conduit requirements For variable frequency drives VFDs of any type threaded metallic or threaded PVC coated metallic is required for both the power feed line side from the source and between the VFD output and the motor load side PVC conduit is acceptable only when VFD rated cable of the proper conductor size and ground is used This appl
136. ng with a light coating of system oil or petroleum jelly 4 Screw the fitting into the female port until the hex flat contacts the port face Light wrenching may be necessary 5 Tighten to the appropriate torque value shown in the assembly torque table below Straight and Adjustable Fittings or Plugs steel Assembly Torque 5 16 24 3 8 24 7 16 20 170 10 1 2 20 260 15 9 16 18 320 20 3 4 16 500 25 7 8 14 720 x 30 1e 12 960 50 196 12 1380 75 115 6 0 1 12 2700 150 225 12 0 1 12 Table 14 SAE Port Adjustable Fitting Plug Torque 3000 160 250 12 0 070 610 IOM NOV 14 RWF ROTARY SCREW COMPRESSOR UNITS Frick Page 42 MAINTENANCE BY JOHNSON conTROLs COMPRESSOR PORT LOCATIONS RWF II 100 134 PORT THREADSIZE O RING 1 6 12 UN 2B 980A0012K66 SD 1 COALESCER 9 16 18 UNF 2B 980A0012K60 5 5 INLET 9 16 18 UNF 2B 980A0012K60 PRESSURE 17 12 UN 2B 980A0012K66 9 16 18 UNF 2B 980A0012K60 9 16 18 UNF 2B 980A0012K60 9 16 18 UNF 2B 980A0012K60 1 6 12 UN 2B 980A0012K66 1 6 12 UN 2B 980 0012 66 1 6 12 UN 2B 980A0012K66 E N 1 12 UN 2B 980A0012K66 5 14 LIQUID SB 3 INJECTION COMPRESSOR BLEED OIL SUPPLY Mi US ic ooo H 2 C
137. of air ingress into the system if the system suction pressure 15 below atmospheric PAL PALL PIC 4 4 4 4 SUCTION GAS TO THE COMPR SEPARATOR COLD START VALVE COMPRESSOR END VIEW Figure 26 Suction Check Valve Bypass LOW AMBIENT OPERATION It is recommended that oil separators be insulated as a minimum requirement to preserve the heat generated by the oil heaters It is important that the coalescer end of the separator be insulated to prevent refrigerant condensation On systems located outdoors or in unheated buildings where the ambient temperature could drop below 40 F insulating and or heat tracing of the compressor lube oil systems is highly recommended When low ambient temperatures below 20 F are a pos sibility it is recommended that lube oil lines oil filters oil pumps and oil coolers be heat traced and insulated Freeze up protection must also be provided for all water cooled equipment SUCTION CHECK VALVE POWER ASSIST KIT Low temperature booster compressor applications require hot gas to assist the suction check valve closure for RWF Il RWF ROTARY SCREW COMPRESSOR UNITS OPERATION Page 23 070 610 IOM NOV 14 models 496 676 856 and 1080 This is accomplished by using the high pressure discharge gas from the high pressure side of the system power assist
138. oils the CT and CPT secondaries should be wired as shown on the starter package wiring diagram The load on the control panel for the compressor motor starter coil should not exceed a 2 amp load For larger starters an interposing relay must be used to switch the compressor motor starter coil s NOTICE Do not install a compressor HAND OFF AUTO switch in the starter package as this would bypass the compres sor safety devices 7 The compressor motor Current Transformer CT is in stalled on any one phase of the compressor leads NOTICE The CT must see all the current of any one phase therefore in wye delta applications BOTH leads of any one phase must pass through the CT RWF ROTARY SCREW COMPRESSOR UNITS INSTALLATION Page 13 070 610 IOM NOV 14 3 PHASE LINE FRICK SUPPLIED COMBINATION STARTER PACKAGE CONSULT STARTER AND MOTOR WIRING DIAGRAMS Shane REF QUANTUM LX FOR EXACT WIRING CONFIGURATION MAINTENANCE MANUAL Ti T2 T3 GND GND 711 2 GND 11 T2 T3 GND 20 4 3 2 1 M M 4 3 2 1 HILEVEL CUTOUT AND OR OTHER QUANTUM LX FIELD SAFETY ENCLOSURE REQUIRED IS EB Na 8 CHECK MOTOR STARTER MANUFACTURER S INSTRUCTIONS AND QUANTUM LX MANUAL 590 020 M Refer to motor nameplate for correct motor connection Sepaerate conduit runs for control voltage wiring and motor connection wiring Conduit grounds are not acceptable All wiring must
139. ompressor is vented back to a point in the compressor s body that is at a pressure lower than compressor discharge pressure compressor s nor mal operation makes the compressor unit operate essentially as its own oil pump All oil entering the compressor is moved by the compressor rotors out the compressor outlet and back to the oil separator For normal high stage operation an oil pump is not required 070 610 IOM NOV 14 DEMAND PUMP OIL SYSTEM This system is designed to provide adequate compressor lubrication when there is low differential oil pressure across the compressor suction and discharge for some high stage applications and booster applications as required On start up Quantum HD will calculate the pressure dif ferential between the compressor discharge and the main oil injection port If this differential is less than 35 psi then the demand pump will turn on and will continue to run until 45 psi differential is obtained Then the pump will shut down and start only when the differential pressure falls below 35 psi NOTICE For alarm descriptions and shutdown or cutout param eters see publication 090 040 0 COMPRESSOR OIL SEPARATION SYSTEM The RWF Il 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
140. ompressors 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 ofthe multiple compressors Omit the BPR valve on the flash economizer vessel and use one on each compressor as shown in Figure 11 It is also recommended that the back pressure regulating valves used on economizer lines should be speci fied with electric shutoff option The electric shutoff feature is necessary to prevent flow from the common economizer vessel to the suction side of a stopped compressor through the suction check valve bypass line if the other compressors and the common economizer vessel are still operating and the HV2 valve on the suction bypass is open For refrigeration plants using a Packaged Refrigerant Recir culation Unit and a direct expansion DX economizer system it is necessary to operate the liquid feed solenoid on the unit and the liquid feed solenoid on the DX vessel off of a common signal to avoid liquid overfeed on the DX economizer system If multiple compressors are operated with a common economizer vessel it is necessary to install a back pressure regulator valve with an electric shutoff option in the vapor line piped to the compressor s economizer port RWF ROTARY SCREW COMPRESSOR UNITS INSTALLATION Page 11
141. onduit from all high voltage wiring checking motor rotation Confirm all 120 volt control wiring is run in a separate Check oil pump alignment if applicable conduit from oil pump and compressor motor wiring Check for correct economizer piping if applicable Confirm no high voltage wiring enters the micro panel __ Check separate source of liquid refrigerant supply if at any point applicable liquid injection oil cooling Check current transformer for correct sizing and instal Check water supply for water cooled oil cooler if ap lation plicable water cooled oil cooling Check all point to point wiring between the micro and Check thermosyphon receiver refrigerant level if ap motor starter plicable thermosyphon oil cooling Confirm all interconnections between micro motor Check for PROPER PIPE SUPPORTS and correct foundation starter and the system are made and are correct Check to ensure ALL piping INCLUDING RELIEF VALVES __ Ensure all electrical panels are free from installation is completed debris METAL PARTICLES and moisture After the above items have been checked and verified Close the main disconnect from the main power supply to the motor starter Close the motor starter disconnect to energize the micro Manually energize oil pump and check oil pump motor rotation Leave micro energized to ensure oil heaters are on and oil temperature is correct for start up DO NOT energize compressor driv
142. or Direct Coupled Package Mounted Starters the ground between the motor and the starter may need to be made externally See Figure below The connection on the starter end must be on the starter side of the vibration isolators Be certain the connection is metal to metal Paint may need to be removed to ensure a proper conductive circuit The use of counter sunk star washers at the point of con nection at each end will maximize metal to metal contact STARTER EXTERNAL GROUND Figure 46 Motor And Starter Grounding VFD APPLICATIONS The primary ground conductor that accompanies the three phase supply must be stranded copper insulated and two sizes larger than the minimum required by the NEC or any other applicable codes This is necessary due to the increased generation of EMI which is a characteristic of a VFD output to the motor when compared to a conventional starter For VFD applications isolation of the control power analog devices and communications ground from the 3 phase ground within the starter and the electronic control panel may be necessary This is due to the higher noise RFI EMI levels generated between the VFD output and the motor relative to a conventional starter If these grounds are left coupled by a common back plate in the starter drive this noise can be direct coupled to the control power analog device and communications grounding and may cause u
143. r Loosen set screws Remove transmitter unit Install new transmitter unit Tighten set screws Apply DIN connector plug to transmitter AWN Turn on control power NOTICE For calibration of the volume ratio control unit refer to the Calibration Instructions in publication 090 040 O 070 610 IOM NOV 14 DIN CONNECTOR 43650 A PRINTED CIRCUIT BOARD 22 CAST ALUMINUM HOUSING STAINLESS STEEL SENSOR WELL Figure 41 Volume Ratio Control Transmitter TEMPERATURE SENSOR TROUBLESHOOTING Confirm the setup of the channel on the calibration or analog board 1 setup screen Is the temperature probe reading bot tom end 459 F or top end 463 F If reading bottom end the probe or wire s to the probe are open or the probe is shorted to ground pulling down the power excitation Check the power at the analog board between the and of the channel for that probe In Example discharge temperature would be Channel 2 on the P4A terminal strip of the analog board Is there a signal of 12 15 vdc If yes the probe is not shorted to ground but is most likely open Do continuity tests to determine if it is the wiring or the sensor that is open Correct as necessary DIN CONNECTOR W M3 SCREW SILICONE GASKET SENSOR WELL
144. rt checklist then start unit OIL FILTER OF 1 CARTRIDGE STYLE RWF 11 compressor units are furnished with one main oil filter OF 1 A second oil filter OF 2 is installed as optional equipment to facilitate the changing of the filter element s without unit shutdown NOTICE Use of filter elements other than Frick may cause warranty claim to be denied The procedure to change filter cartridge s is as follows 1 If a single oil filter is installed push STOP key on mi croprocessor panel to shut down unit then open disconnect switches for compressor and oil pump motor starters If dual oil filters are installed open the outlet then inlet service valves of the standby filter Open inlet service valve slowly to prevent a sudden pres sure drop which could cause an oil filter differential alarm 2 Close outlet then inlet service valves of filter being serviced 3 Open bleed valve and purge pressure from the oil filter cartridge NOTICE Recover or transfer all refrigerant vapor in accordance with local ordinances before opening to atmosphere RWF ROTARY SCREW COMPRESSOR UNITS Page 26 MAINTENANCE Frick BY JOHNSON CONTROLS 4 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 5 Fl
145. s by push ing 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 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 10 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 070 610 IOM NOV 14 CHECKING MOTOR COMPRESSOR ROTATION Make sure coupling hubs are tight ened to the shaft before rotatingthe motor to prevent them from flying off and possibly causing serious injury or death Injury may occur if loose clothing etc becomes en tangled on the spinning motor shaft COMPRESSOR ROTATION IS CLOCKWISE WHEN FACING THE END OF THE COM PRESSOR SHAFT Under NO conditions should the motor I E rotation be checked with the COMPRESSOR coupling center installed as damage to the compressor may result Bump the motor to check for correct compressor rotation After verification install disc drive spacer as applicable COMPRESSOR MOTOR COUPLING INSTALLATION
146. scer filter retainer 4 Remove retainer coalescer filter element and 2 O rings Discard filter elements 5 Install new coalescer filter element s NOTICE Frick SuperCoalescer element with drain feature must be installed with the DRAIN DOWN tag on the bottom at the 6 o clock position Seat element in center of locating tabs on separator bulkhead 6 Replace coalescer filter retainer and nut Tighten the nut to 21 ft Ib torque DO NOT OVERTIGHTEN NUT Excessive torque can damage the element and result in oil carryover Install jam nut and tighten 7 Install new manway gasket and replace manway cover 8 Tighten manway bolts to 180 ft lb NOTICE RETIGHTEN AFTER THE COMPRESSOR UNIT IS REPRES SURIZED SINCE MANWAY BOLTS WILL LOOSEN 9 Refer to CHANGING OIL Steps 9 through 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 Shut down the unit when changing oil At the same time all oil filter cartridges must be changed and all oil strainer ele ments removed and cleaned The procedure is as follows 1 Press the STOP key on the microprocessor panel to stop the compressor unit 2 Open the disconnect switch for the compressor motor starter 3 Close the suction and discharge service valves also close the liquid injectio
147. sed slide valve position In cases where wide swings in pressure are anticipated 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 sys tem feeding liquid to the flash vessel in batches The recommended economizer systems are shown in Figures 8 11 Notice that in all systems there should be a strainer STR and a check valve VCK between the economizer ves sel and the economizer port on the compressor The strainer prevents dirt from passing into the compressor and the check valve prevents oil from flowing from the compressor unit to the economizer vessel during shutdown Other than the isolation valve needed for strainer clean ing it is essential that the strainer be the last device in the economizer line before the compressor Also piston type check valves are required for installation in the economizer line as opposed to disc type check valves The latter are more prone to gas pulsation induced failure The isolation and check valves and strainer should be located as closely as possible to the compressor preferably within a few feet For refrigeration plants employing multiple compressors on a common economizing vessel regardless of economizer type each compressor must have a back pressure regulating valve in order to balance the economizer load or gas flow between c
148. see INSTALLATION OF CARBON GRAPHITE BUSH INGS 2 Clean rotor hub and casing seal housing bore Make sure both are free from dirt and grit Coat outer diameter of seal seat and inner diameter of seal housing bore with refrigera tion oil 3 Start seal seat in seal housing bore If force is necessary protect seal face with a clean cardboard disc and gently tap it in place with a piece of wood Be sure seal seat is completely seated in the bore 4 Place tapered installation sleeve on shaft Refer to Figure 31 Sleeve is furnished with GG AS AK and AL replacement mechanical seals Coat rotor shaft tapered installation sleeve and inner diameter of mechanical seal rotary member with a generous amount of refrigeration oil Petrolatum may be used but grease is not recommended SPRING MECHANICAL SEAL ROTARY MEMBER TAPERED SLEEVE COAT WITH LIGHT OIL BEFORE ASSEMBLY Figure 33 Shaft With Sleeve 5 Place seal spring on shaft against rotor hub Refer to Figure below ROTOR HUB SPRING MECHANICAL SEAL ROTARY MEMBER Figure 34 Shaft With Seal Spring 6 Slide rotary member with lapped contact surface fac ing away from spring over installation sleeve on shaft until just contacting the spring Do not compress spring Remove installation sleeve 7 Coat rotor shaft with refrigeration oil Install shaft slowly pushing until the ends of rotor teeth are just below the face of the casing 8 Leave the rotor in
149. son Controls Fricke for assistance 5 For customer supplied across the line starters a shunt ing device must be installed across the Current Transformer terminals 3 amp 4 Frick BY JOHNSON CONTROLS If the shunting device is not installed the Analog I O board on the Quantum HD panel may be severely dam aged at start up See Figure 12 GROUND PHASE LINE NOTE CUSTOMER GROUND REQUIRED SEE THE WIRING DIAGRAM IN 590 020 _ OPTIONAL CIRCUIT BREAKER DISCONNECT USED WITH ACROSS THE LINE ONLY 7N COMPRESSOR COMPR STARTER 4 pm ATL SS AT YD OR PW CURRENT YD or PW ONLY TRANSFORMER 2M 2MOL VOLTAGE 1 72 OIL MONITOR LHX PUMP PROTECTOR Toh MOTOR NOTE WHEN COMPRESSOR MOTOR VOLTAGE 15 DIFFERENT FROM OIL PUMP MOTOR VOLTAGE SUPPLY CIRCUIT BREAKER DISCONNECT FOR SEPARATE FEED SARA 3 KVA IN LIEU OF FUSES DERES ADD TIMER FOR ACROSS 120 VOLT zl THE LINE STARTERS ONLY STARTING CURRENT uv VOLTAGE MONITOR 10 SEC SHUNT TIMER 1M OL ON DELAY 2 M 4 COMPRESSOR STARTER SUPP OR INTERPOSING RELAY 2M OL 471 SUPP OIL PUMP STARTER Figure 12 Starter Wiring Diagram 6 One each normally open compressor motor and oil pump motor starter auxiliary contact should be supplied In addition to the compressor and oil pump motor starter c
150. steel and is a poor conductor relative to an insulated stranded copper wire Electronic equipment reacts to very small currents and must have a proper ground in order to operate properly therefore stranded copper grounds are required for proper operation For proper operation the control power ground circuit must be a single continuous circuit of the proper sized insulated stranded conductor from the electronic control panel to the plant supply transformer See Figure below Driving a ground stake at the electronic control may also cause additional problems since other equipment in the plant on the same circuits may ground themselves to the ground stake causing large ground flow at the electronic control panel Also run ning multiple ground conductors into the electronic control panel from various locations can create multiple potentials resulting in ground loop currents A single ground wire 10 AWG or 8 AWG from the electronic control panel that is bonded to the control power neutral at the secondary side of the control power transformer in the starter and then to the 3 phase ground point will yield the best results 3 PHASE BUS PLANT SUPPLY TRANSFORMER ELECTRONIC CONTROL Figure 45 Control Power Ground Circuit NOTICE Structural grounding can also result in multiple ground potentials and is also a relatively poor conductor Therefore this is not an acceptable method for proper operation of electronic equipment
151. the compressor Liquid Injection is off the solenoid is closed if the compressor is off On When Above When the Discharge Temperature is above this setpoint the Liquid Injection solenoid output will energize until the Discharge Temperature drops below this setpoint Off When Below When the Discharge Temperature is below this setpoint the Liquid Injection solenoid output will de energize until the Discharge Temperature raises above this setpoint STATUS Discharge Temperature The actual Discharge tempera ture is shown here Control Output The value of the Output signal as con trolled by the This is not a setpoint value Valve Position The value shown here represents the po sition of the valve with relationship to the Control Output 070 610 IOM NOV 14 OPERATION OF DANFOSS LIQUID INJECTION VALVE 4 1 Down arrow Enter Up arrow Display Figure 21 ICAD MMI ICAD Industrial Control Actuator with Display is equipped with an MMI Man Machine Interface from which it is possible to monitor and change the setting of parameters to adapt the ICAD and the corresponding ICM Motorized Industrial Control Valve to the actual refrigeration application The setting of parameters is managed by means of the inte grated ICAD MMI Figures 21 and 22 and consists of Down arrow push button Decreases parameter number by 1 at each
152. 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 precau tions should be taken to prevent normal package vibration from being transferred to the building structure It may be necessary to use rubber or spring isolators or a combination of both to prevent the transmission of compressor vibration directly to the structure However this may increase package vibration levels because the compressor is not in contact with any damping mass The mounting and support of suction and discharge lines is also very important Rubber or spring pipe supports may be required to avoid exciting the build ing structure at any pipe supports close to the compressor package It is best to employ a vibration expert in the design of a proper mounting arrangement In any screw compressor installation suction and discharge lines should be supported in pipe hangers preferably within two feet of vertical pipe run so that the lines won t move RWF ROTARY SCREW COMPRESSOR UNITS INSTALLATION Page 5 070 610 1OM NOV 14 if disconnected from the
153. tly If Levels Increase Replace Shaft Seal When Leak Rate Exceeds 7 8 Drops Per Minute Check bolts shim packs center inserts keys and all bolt torques Check and torque all terminals in the processor and starter panel per the specification posted in the enclosure Check calibration of Slide Valve Slide Stop pressures and temperatures Calibration should be conducted with NIST certified devices Verify tightness of bolts on suction and discharge flanges See table below for torque requirements Vibration measurement must be carried out continuously to obtain optimum preventive control on bearings If not continuously controlled then every 6 months more frequently if levels increase See additional notes in Recommended Maintenance Program section below Units with variable speed drives check for excess vibration and skip frequencies anytime unit operating conditions change g The filter may need to be changed more frequently based on differential pressure or as directed by oil analysis RECOMMENDED MAINTENANCE PROGRAM In order to obtain maximum compressor unit performance and ensure reliable operation a regular maintenance program should be followed The compressor unit should be checked daily for leaks ab normal vibration noise and proper operation A log should also be maintained Initial oil analysis and vibration analysis should be done at start up and continued per the mainte nance sc
154. ture Pull Down Warning Delay Sec Capacity Position Shutdown Delay Sec Amount of Time Sec High Compressor Oil Temperature Pump Down Warning Delay Sec On When Suction Above ___ PSIG Delay Min Shutdown Delay Sec DX Circuit Low Compressor Oil Pressure 1 Action Warning PSI Delay Sec Off When Below Shutdown PSI Delay Sec On When Above High Filter Pressure 2 Action Warning PSI Delay Min Off When Below Shutdown PSI Delay Min On When Above Main Oil Injection Liquid Injection Shutdown PSI Delay Sec On When Above Delay Sec Oil Heater Off Above Dual Port Transition High Level Shutdown Delay Sec Low Oil Level Delay Sec Hot Gas Bypass Oil Pump Lube Time Before Starting Sec Power Assist Sec Dual Pump Transition Time Sec RWF ROTARY SCREW COMPRESSOR UNITS 070 610 IOM NOV 14 070 610 IOM NOV 14 RWF ROTARY SCREW COMPRESSOR UNITS Page 62 FORMS Frick Page 3 Unit Serial Frick Order No Compressor Motor Setpoints and Information Motor Name Plate VFD Manufacturer Motor Amps Maximum Drive Output __ 5 Volts Minimum Drive Output __ H P Service Factor Remote Control RPM Horsepower Rate Of Increase Delay Sec Serial CT Factor Rate Of Decrease Delay Service Factor Recycle Delay Min Capacity Control Voltage High Motor Amps When Slide Valve Reaches Hz Load Inhibit Drive Speed Reaches Design Force Unload Variable Speed Min Slide Valve Position Code Warning __ Sec
155. uired because of low ambient temperature contact Johnson Controls Fricke The heaters are energized only when the unit is not in operation DO NOT ENERGIZE THE HEATERS when there is no oil in the unit the heaters will burn out The oil heaters will be energized whenever 120 volt control power is applied to the unit and the compressor is not running unless the 16 amp circuit breaker in the micro enclosure is turned off OIL FILTER S NOTICE Use of filter elements other than Fricke may cause war ranty claim to be denied The oil filter s and coalescer element s shipped with the unit are best suited to ensure proper filtration and operation of the system RWF ROTARY SCREW COMPRESSOR UNITS Page 8 INSTALLATION Frick BY JOHNSON CONTROLS SUCTION VALVE MOUNTING The suction isolation valve is shipped loose from the factory so it can be installed at various positions within the suction line piping to the compressor DO NOT INSTALL the valve at the compressor suction with flow against the cone button see Figure 3 TOP When the isolation valve is installed in this position uneven flow is generated across the suction check valve which is mounted at the inlet to the compressor This uneven flow causes the disks in the check valve to strike against the stop pin and eventually damage the internals of the check valve If the isolation valve is mounted at the compressor suction DO INSTALL with flow across th
156. unit 38 Troubleshooting 38 digital board 1 38 temperature sensor 18 thermosyphon 8 15 thermosyphon oil cooling 9 Thermosyphon Oil Cooling condenser inlet 8 condensing pressure 8 condensing temperature 9 operating level 7 plate and shell oil cooler 8 receiver 9 thermostatically controlled mixing valve 9 thermosyphon oil cooling 8 9 two pass oil coolers 9 vapor 8 thermosyphon oil cooling 8 threaded metallic 55 threaded PVC coated metallic 55 throttling valve 16 thrust balance piston 23 torque analysis 12 Troubleshooting 39 Excessive Noise and Vibration 39 Gradual Oil Loss 40 Rapid Oil Loss 40 Shaft Seal Leakage 40 Slide Stop will not function either direction 40 will not move 39 7 Removed 8 columns that did not apply from CH Coupling Data Table Revised CH Coupling Installation text numbers 5 8 added Notice box 18 Replaced double acting solenoid valve with 3 way motorized valve text Revised last paragraph of Dual Port Liquid Injection text p 26 Revised filter element text 6 amp 6a added figures to clarify 2010 change to filter elements p 32 Added PhD vibration analysis requirement text Form 070 610 2014 11 Supersedes 070 610 IOM 2014 08 Subject to change without notice Published in USA PDF 11 14 2014 Johnson Controls Inc ALL RIGHTS RESERVED Johnson WN Controls Ss ey Frick BY JOHNSON CONTROLS Slide Valve will load but not unload 4
157. uperheated to 10 F above the refrigerant saturation temperature This assures that all refrigerant at the compressor suction is in the vapor state DESIGN LIMITATIONS The compressor units are designed for operation within the pressure and temperature limits as shown in Frick publica tion 070 610 SED SAFETY PRECAUTION DEFINITIONS RWF ROTARY SCREW COMPRESSOR UNITS GENERAL INFORMATION Page 3 070 610 IOM NOV 14 JOB INSPECTION Immediately upon delivery examine all crates boxes and exposed compressor and component surfaces for damage Unpack all items and check against shipping lists for any discrepancy Examine all items for damage in transit TRANSIT DAMAGE CLAIMS All claims must be made by consignee This is an ICC re quirement Request immediate inspection by the agent of the carrier and be sure the proper claim forms are executed Report damage or shortage claims immediately to Johnson Controls Inc Fricke Sales Administration Department in Waynesboro PA UNIT IDENTIFICATION 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 Fricke sales order number is mounted on the side of the Quantum HD control panel NOTICE When inquiring about the compressor or unit or order ing repair parts provide the MODEL SERIAL and FRICK SALES ORD
158. ush the canister with clean compressor oil wipe dry with a clean lint free cloth and replace the plug 6 Install a new one piece filter element Tighten the six 3 8 hex head cap screws to 10 ft lb torque Figure 29 SuperFilter Il Current Design Before January 2010 the SuperFilter ll elements were sepa rate pieces Follow step 6a in lieu of step 6 for this design After January 2010 the rod and nuts were eliminated and the end plate and gasket became part of the filter Refer to the Oil Filter page in the SPL for a detailed graphic 6a Install the new element s on the rod with all necessary hardware Tighten the nut on the end plate to 10 ft Ib torque Then while holding the nut with a wrench apply a second nut to act as a locknut Replace the gasket and reinstall the filter assembly into the canister securing with screws tightened to 30 ft lb torque Figure 30 SuperFilter Il Design Pre 2010 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 Replace the gasket and reinstall the canister cover Torque cover bolts first to finger tight then 65 ft lb then 130 ft lb 7 Evacuate pull a vacuum on the filter canister to eliminate non condensibles 8 Fill the canister with new Frick refrigeration oil as needed
159. ut signal Digital Output Closed status ON when OD 396 Digital Output Open status ON when OD 9796 igital Output alarm status ON when an alarm is detected oftware version for MASTER Microprocessor oftware version for SLAVE Microprocessor gree is disp eration IECEENEST ee Frick BY JOHNSON CONTROLS SUCTION CHECK VALVE BYPASS The RWF II unit is equipped with low pressure drop suction check valve bolted directly to the compressor housing Valve NV 2 must be open in most systems at all times It should normally be cracked open to allow the oil separator to slowly bleed down to approximately system suction pres sure when the unit is stopped having this valve cracked open allows the compressor drive motor to have an easier start and the discharge check valve will seat more tightly If the drive coupling backspins start closing the valve until the backspin stops If the separator oil level foams excessively on shutdown NV 2 should be closed slightly If the separa tor takes more than 20 30 minutes to equalize to suction pressure after shutdown NV 2 can be opened slightly See Figure 26 Check valve CV 4 is installed on all RWF Il packages On high stage systems check valve CV 4 is installed with a 45 psi spring to avoid the possibility of back feeding to a shut down compressor from a common economizer vessel On booster systems check valve CV 4 is installed with a 25 psi spring to avoid the possibility
160. vaporator EWT F Motor Winding Temp F Evaporator LWT F Humidistat RH Condenser EWT F Vyper Coolant Temp F Condenser LWT F Total kWh 070 610 10 NOV 14 RWF Il ROTARY SCREW COMPRESSOR UNITS 64 FORMS Frick BY JOHNSON CONTROLS VIBRATION DATA SHEET Date Sales Order Number End User Installing Contractor Address Service Technician Equipment ID As in Microlog Compressor Model Number Compressor Serial Number Unit Serial Number National Board Number Running Hours Manufacturer and Size of Coupling Motor Manufacturer RAM Motor Serial Number RPM Frame Size H P Refrigerant Ambient Room Temperature F Operating Conditions SUCTION DISCHARGE OIL SEPARATOR Slide Valve Position Compressor Inboard Coupling End Male Axial Direction ____ 5 Overall Compressor Inboard Coupling End Vertical Direction IPS Overall Motor Inboard Coupled End Horizontal IPS Overall Vertical IPS Overall Axial IPS Overall Compressor Inboard Coupling End Female Axial Direction ___ 5 Overall Compressor Outboard Nondrive End Vertical Direction ___ ___ Overall Motor Outboard Noncoupled End Horizontal 5 IPS Overall Vertical IPS Overall Axial 5 IPS Overall Frick BY JOHNSON CONTROLS Sy
161. ween the conduit and the enclosure This is extremely important in outdoor applications NOTICE It is simply NEVER a good practice to enter through the top of an electronic control panel or starter panel that does not already have knockouts provided If knockouts are not provided for this purpose it is obvious this is not recommended and could VOID WARRANTY Never add relays starters timers transformers etc in side 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 Never run refrigerant tubing inside an electronic control panel If the refrigerant is ammonia a leak will totally destroy the electronics RWF ROTARY SCREW COMPRESSOR UNITS Page 56 PROPER INSTALLATION OF ELECTRONIC EQUIPMENT Frick BY JOHNSON CONTROLS 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 Never daisy chain or parallel connect power
162. ws 24 can be removed The bonnet and all internal parts can now be removed from the valve body When internal parts have been taken out of the valve body the spring can be removed by unscrewing the spring bolt 7 NOTICE When assembling the valve the bonnet gasket 17 must be captured in the groove in the bonnet 2 After the bonnet assembly is mounted into the valve housing 1 install and tighten bonnet cap screws 24 The required torque is shown for each valve size in the table below 070 610 IOM NOV 14 RWF ROTARY SCREW COMPRESSOR UNITS Frick Page 36 MAINTENANCE JOHNSON conTROLS BONNET CAP SCREW TORQUE VALUES Table 12 Bonnet Cap Screw Torque Values PRESSURE TRANSDUCERS TESTING 1 Shut down the compressor and allow pressures to equalize 2 Isolate suction transducer PE 4 from the unit and depres surize Ensure that the transducer has proper voltage for exci tation Measure across the red and black wires power and DC common of the transducer Voltage should be 11 8 to 15 VDC PRESSURE TRANSDUCER CONVERSION DATA 200 psi 500 psi Range PSIG Range PSIG Voltage low high low high 1 0 29 92 9 57 29 92 4 1 29 92 0 3 29 92 16 6 5 3 17 10 29 1 Sensor psig 1094 V 1 494 V 0 968 V 1 268 V Table 13 Pressure Transducer Voltage PSI Conversion NOTICE
163. y to use a screwdriver as a wedge in the slot to open the bore before the hubs will slide on the shafts 5 Rotate both hubs so that the keys are 180 opposed 6 Hold the elastomeric gear between the hubs and slide both hubs onto the gear to fully engage the mating teeth Center the gear and hub assembly so there is equal engagement on both shafts Please note that the hubs may overhang the ends of shafts Adjust the Face Spacing between hubs as specified in the CH COUPLING DATA TABLE Ensure that the keys are fully engaged in their keyways 7 Torque the clamping bolts in both hubs to the torque value given in the CH SERIES COUPLING DATA TABLE NOTICE DO NOT USE ANY LUBRICANT ON THESE BOLTS 8 Torque the keyway setscrew in both hubs to the torque value given in the CH SERIES COUPLING DATA TABLE NOTICE Only after the shaft clamping bolts are tightened to their final torque can the keyway set screws be tightened If the keyway set screws are tightened before the shaft clamping bolts are tightened then the hubs can be cocked on the shaft OIL PUMP COUPLING Compressor units with direct motor pump coupled pumps need no pump motor coupling alignment since this is main tained by the close coupled arrangement RWF ROTARY SCREW COMPRESSOR UNITS INSTALLATION Page 7 070 610 IOM NOV 14 HOLDING CHARGE AND STORAGE Each RWF Il compressor unit is pressure and leak tested at the factory and then thoroughly evacuat

RWF II - Johnson Controls Inc.

Contents

Download Pdf Manuals

Related Search

Related Contents