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rotary screw compressor units

1. SUCTION_BYPASS T CV 1 SUCTION VALVE 218 6 9 SHIPPED LOOSE S 1 4 r NV 1 G D aa 6 b z ix 1 10116 Lo PL 0 S p gt 5 M 1 1 ws s YY 4 o e r OO CER x 1 4 VENT Gei 5 3 4 OUT U 2 ZN J PV 1 HAND 11 443 de HTR 11 HTR 2 S VALVE I TA TALL OPTIONAL 1 CE T SECOND A OIL F LTER CV 3 H ED 1 2 OIL DRAIN FILL ON 775 F I BO do E m e e Cem ly 17 7 bo r S i PAL N OF 1 e PM 1 Es eler I GI Te a af SHIP LOOSE T F STRAINER A_ SET 120 F VVCOC ONLY AE R AZ ar n C B VVCOC INLET TSOC OUTLET de ACE WCOC OUTLET STR 1 Mtb _TSOC INLET CONNECTIONS NOTES MAIN OIL SUPPLY 16 OIL PRESSURE 1 PRESSURE TRANSDUCERS INDICATE SLIDE VALVE PISTON 18 CAPACITY VENT VALVE TO SUCTION PE 1 OIL PRESSURE SUCTION PRESSURE PE 3 DISCHARGE PRESSURE DISCHARGE PRESSURE Not all ports are shown See COMPRESSOR PE 4 SUCTION PRESSURE LIQ INJ BLEED LINE PORT LOCATIONS for all ports TEMPRERATURE PROBES INDICATE COALESCER BLEED LINE TE 1 SUCTION GAS TEMPERATURE THERMOWELL SUCT TEMP T
2. H 15 Vent Unloaded 21 Dedicated Closed Thread Port i O e DN KH M IT 5 Economizer Main Oil Injection Orifice Plug 16 Thermowell 3 Low Vi Liquid Injection TT TND BE l t M R u U u U 4 High Vi Liquid Injection 18 Solenoid Feed 070 410 IOM NOV 14 20 Seal VVeepage 5 A Page 39 22 Dedicated Capacity Valve Vent to Suction Pressure 19 Suction Pressure Pressure 2 Slide Valve Piston t 38 18NPIF 22 1 1aNPTF 1 2
3. HAND T EXP Go HTR 11 HTR 2 o VALVE CJ TAM AL N Hi OPTIONAL GNS 1 SECOND 5 OIL F LTER 12 2 1 2 OIL DRAIN FILL rm uu y z 1 _ Ry va KCP 126 5 zr a PA OF 1 a SHIP LOOSE STRAINER A_ SET 120 F WCOC ONLY Q 05 9 B 1 777 WCOC INLET m m TSOC OUTLET oj WCOC OUTLET 2K TSOC INLET Pk Lg e COMPRESSOR PRESSURE ELEMENT TE TEMPERATURE ELEMENT CHECK VALVE PRESSURE INDICATOR Tl TEMPERATURE INDICATOR HEATER PIC TIC PRESS TEMP INDICATING CONTROLLER YY SOLENOID VALVE EVENT VALVE SIGHT OR LEVEL GLASS PM PUMP MOTOR MOTOR PSV PRESSURE SAFETY VALVE See additional Legend items on opposite OIL FILTER STR STRAINER PUMP TAH HIGH TEMPERATURE ALARM Page HIGH PRESSURE ALARM TAHH HIGH TEMP SHUTDOWN HIGH PRESSURE SHUTDOWN TAL LOW TEMPERATURE ALARM LOW PRESSURE ALARM TALL LOW TEMPERATURE SHUTDOWN LOW PRESSURE SHUTDOWN TCV TEMPERATURE CONTROL VALVE 070 410 IOM NOV 14 RXF ROTARY SCREW COMPRESSOR UNITS Erick Page 48 MAINTENANCE BY JOHNSON CONTROLS RXF Models 58 68 85 amp 101 with OIL PUMP and DUAL OIL FILTERS See OIL COOLING ADDITIONS 1 CV 4 7 SUCTION GAS HHH TO COMPR
4. 8 Pressure 12 Main Oil Injection 14 Seal Weepage O 15 Electrical Connection P amp DIAGRAM LIQUID INJECTION COMPRESSOR LOW VI ECONOMIZER OR CLOSED THREAD Page 41 9 Liquid Injection Bleed Line 13 Suction Pressure Bleed Line Economizer SINGLE PORT COMPRESSOR HIGH VI BOOSTER ONLY SIGHT SOLENOID GLASS VALVE STRAINER MOTORIZED EXPANSION TUBING LINE WE LIQUID REFRIGERAN FROM RECEIVER T LIQUID LINE 070 410 IOM NOV 14 Page 42 T y Frick BY JOHNSON CONTROLS RXF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE P 8 I DIAGRAM LIQUID INJECTION DUAL PORT NEW DESIGN LIQUID REFRIGERANT FROM RECEIVER STRAINER COMPRESSOR A LIQUID LINE COMPRESSOR LOW VI 3 WAY MOTORIZED VALVE HIGH V 5 SOLENOID VALVE MOTORIZED EXPANSION VALVE 4 SIGHT GLASS SUCTION PRE
5. ei 5 Economizer Thread Pressure 22 Dedicated Capacity Valve Vent to Suction Pressure 12 Coalescer Bleed Line 7 Suction 2 Slide Valve Piston Pressure 10 Discharge Pressure 11 Liquid Injection Bleed 7 Suction Pressure H CONNECTION SIZE 3 4 14 NPTF 3 4 14 NPTF 3 8 18 NPTF Frick BY JOHNSON CONTROLS 1 Mam Oil Supply e RXF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE COMPRESSOR PORT LOCATIONS RXF 24 50 12 Coalescer Bleed Line
6. 56 RXF COMPRESSOR PRESTART CHECKLIST 57 VIBRATION DATA SHEED zaw RC ROEE 62 NDEX ee AA 65 Frick BY JOHNSON CONTROLS General Information PREFACE This manual has been prepared to acquaint the owner and service person with the INSTALLATION OPERATION and MAINTENANCE procedures as recommended by Frick for RXF Rotary Screw Compressor Units t is most important that these units be properly applied to an adequately controlled refrigeration system Your authorized Frick representative should be consulted for expert guidance in this determination Proper performance and continued satisfaction with these units is dependent upon CORRECT INSTALLATION PROPER OPERATION REGULAR SYSTEMATIC PLANNED 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 su
7. Frick BY JOHNSON CONTROLS becomes most important when one or more compressors run at partial load exposing the economizer port to suction pressure In the case of a flash vessel there is no need for the redundancy of a back pressure regulating valve on the vessel and each of the multiple compressors Omit the BPR valve on the flash economizer vessel and use one on each compressor as shown in Figure 12 INTERMEDIATE PRESSURE GAS TO COMPRESSOR HIGH PRESSURE LIQUID 1 VCK y SUBCOOLED HIGH PRESSURE lt LIQUID TO EVAPORATOR CN To A WIRING ECONOMIZER COOLER Figure 10 Direct Expansion Economizer System INTERMEDIATE PRESSURE GAS TO COMPRESSOR FA LE m VCK BPR ECONOMIZER VESSEL HIGH PRESSURE CONTROLLED LIQUID PRESSURE sz lt SATURATED LIQUID TO EVAPORATOR SUCTION INTERMEDIATE PRESSURE GAS TO COMPRESSOR ECONOMIZER VESSEL HIGH PRESSURE LIQUID aay ee CONTROLLED PRESSURE lt SATURATED LIQUID TO EVAPORATOR Figure 12 Multiple Compressor Flash Economizer System ELECTRICAL NOTICE Before beginning electrical installation read the instruc tions in the section Proper Installation of Electronic Equipment at the back of this manual
8. Frick MAINTENANCE Page 43 RXF MODELS 12 through 19 without OIL PUMP See OIL COOLING ADDITIONS NV 3 CV 4 EEN gt gt m CV 1 7 A Peal FH 12 11 22H NV 1 iD 5 SUCTION VALVE IS NV 2 SM SHIPPED M 1 C 1 OYY3 da 7 LOOSE O YY4 Zum Oa l cee 88 ART SAMPLING D vu VAVE 3 1SAE A Ir E P j d SE WI ai _ZTAHY TAH 4 PUMP OUT SE ee E P 10 A B 4 P pu ege EA SEPARATOR Q YA HTR 1 Z Z TALN TALN STR 1 1 Care z 1 TSOC OUTLET A 5 D A 8 WCOC K me 8 GCOC INLET Buzz oe SET 120 F PRACE PLATE OIL COOLER WCOC 8 GCOC Sec 1 OUTLET TSOC INLET LJ VIBRATION ELEMENT VIBRATION HIGH ALARM VIBRATION HIGH SHUTDOWN POSITION TRANSMITTER POSITION INDICATOR PRESSURE ELEMENT PRESSURE INDICATOR PRESS TEMP INDICATING CONTROLLER PUMP MOTOR PRESSURE SAFETY VALVE PRESSURE VESSEL STRAINER HIGH TEMPERATURE ALARM HIGH TEMP SHUTDOWN LOW TEMPERATURE ALARM LOW TEMPERATURE SHUTDOWN TEMPERATURE CONTROL VALVE TEMPERATURE ELEMENT SOLENOID VALVE EVENT VALVE COMPRESSOR CHECK VALVE FILTER OR FILTER DRIER HEATER SIGHT OR LEVEL GLASS OIL LEVEL SWITCH LOW LOW OIL LEVEL SHUTDOWN MOTOR NEEDLE VALVE PUMP HIGH PRESSURE ALARM HIGH PRESSURE SHUTDOWN LOW PRESSURE ALARM LOW PRESSURE SHUTDOWN Continued following page 070 410 IOM NOV 14 RX F ROTARY SCR
9. 33 09 1 34 0 65 18 28 24 04 HIGH 24 50 as 12 60 10 A8 99 16 3 8 02 H 80 3 8 12 3 3 4 5 R 507 12 19 3 8 1 2 4 3 8 3 8 3 3 8 8 14 3 1 8 0 4 1 0 1 6 0 1 0 2 0 4 R 717 BOOSTER 070 410 IOM NOV 14 Intermediate and 10 F suction superheat R 507 unloaded Slide valve High stage compressor units may be supplied with single port low Vi side or closed thread or dual port low Vi and high Vi liquid injection oil cooling Single port will be furnished for low compression ratio operation and dual port for high compres sion ratio operation Booster compressor units use single port High Vi liquid injection oil cooling due to the typically lower compression ratios The control system on high stage units with dual port liquid Injection oil cooling switches the liquid refrigerant supply to the high port when the compressor is operating at higher compression ratios 3 5 Vi and above for best efficiency Where low compression ratios low condensing pressures are anticipated thermosyphon or water cooled oil cooling should be used It is imperative that an uninterrupted high pressure liquid refrigerant be provided to the injection system at all times Two items of EXTREME IMPORTANCE are the design of the receiver liquid injection supply and the size of the liquid line It is recommended that the receiver be oversized sufficiently to retain a 5 min
10. lt REFRIGERANT IN X SYSTEM TOG RECEIVER Mounted below Thermosyphon receiver level Figure 5 Thermosyphon Oil Cooled System 1 Thermosyphon oil cooler is supplied with oil side piped to the compressor unit and socket weld ends supplied on the refrigerant side 2 A refrigerant side safety valve is required when refriger ant isolation valves are installed between the cooler and thermosyphon receiver If no valves are used between the cooler and thermosyphon receiver the safety valve on the thermosyphon 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 System receiver must be mounted below thermosyphon receiver level in this arrangement 4 The refrigerant source thermosyphon or system receiver should be in close proximity to the unit to minimize piping pressure drop 5 The liquid level in the refrigerant source must not be less than 6 feet above the center of the oil cooler 6 An angle valve should be installed in the piping before the thermosyphon oil cooler to balance the thermosyphon sys tem Sight glasses should also be installed at the TSOC inlet and outlet to aid in troubleshooting The factory mounted plate type thermosyphon oil cooler requires a refrigerant side drain valve to be provided and installed by the customer The component and piping arrangement shown in Figure 5 is intended only t
11. Jo esedas JUIOAJOS Ulwu sdoJp beye 7 jeas V 14 CTA oey 8WUN OA Yo UOHISOd SPIIS 40 4010 SS ld 1911 IO IO 8INSS8Jd IO sInieledwe 8112 siniejedwe 85 9 189 00 uon ons 4012 linss ld UONONS 1055 2 0 wooy luswudinb DulpE H Join JNOH ul UONEOO 1 uf ON S UdLUO ON 1 p10 YOU us Dungiedo YOSSSAYdNOD M3AYOS a1eq 51 NOSNHOT Ad 4 4 m ku m ng pal RXF ROTARY SCREW COMPRESSOR UNITS 070 410 IOM NOV 14 Frick FORMS Page 57 READ THIS FIRST COMPRESSOR PRESTART CHECKLIST The following items MUST 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 1 Screw Compressor Foundations 090 400 SB Proper Installation of Electrical Confirm that motor disconnect
12. dr BEER Form 070 410 IOM NOV 2014 Frick INSTALLATION OPERATION MAINTENANCE File SERVICE MANUAL Section 70 BY JOHNSON CONTROLS Dist 3 3a 3b 3c Replaces 070 410 IOM AUG 2014 ROTARY SCREW COMPRESSOR UNITS MODELS 12 101 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 070 410 IOM NOV 14 RXF ROTARY SCREVV COMPRESSOR UNITS Page 2 INSTALLATION OPERATION MAINTENANCE T y Frick BY JOHNSON CONTROLS Table Of Contents WESTERN 3 DESIGN LIMITATIONS ccccccececececcccececececcecececeeeeeuseceees 3 JOBANSPEGNON san N Di cia NEA RA 3 TRANSIT DAMAGE LAM S SE 3 UNIT IDENTIEICATION ae aaa aan aaaaaanawazaeana 3 COMPRESSOR IDENTIEICATION 4 GEOMETRICAL SWEPT VOLUME TABLE 4 FOUNDATION 5 HANDLING and 5 SKIDREMOVA DEEN 6 COMPRESSOR MOTOR COUPLINGS 6 BBS el OR LEE 6 HOLDING CHARGE and STORAGE 7 COMPRESSOR Olli zada a ENER aa 7 QOLL CE RGB ZN AA A AA AE OLA 7 OTL AEAT EE 7 Olle FIETER 8 SUCTION ISOLATION VALVE M
13. 10 1 11 1 25 3 36 3 Add oil by attaching the end of a suitable pressure type hose to the oil drain valve see Figure 3 located under the oil separator Using a pressure type pump and the recom mended Frick oil open the drain valve and pump oil into the separator 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 Oil distillers and similar equipment which 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 The sight glass located near the bottom of the separator shell at the discharge end should remain empty when the unit is in operation The presence of oil in this end of the vessel during operation indicates liquid carryover or malfunction of the oil return Figure 3 Oil Drain Valve OIL HEATER Standard units are equipped with 500 watt oil heaters which provide sufficient heat to maintain the oil temperature for most indoor applications during shutdown cycles and to permit safe start up RXF 12 50 use one heater while mod els 58 101 use two Should additional heating capacity be required because of an unusual environmental condition contact Johnson Controls Frick The heater is energized only when the unit is not in operation Do not energize the hea
14. 2 Provides lubrication of the bearings and shaft seal 3 Serves to remove the heat of compression from the gas keeping discharge temperatures low and minimizing refriger ant or oil breakdown 4 Fills gas leakage paths between or around the rotors with oil thus greatly reducing gas leakage and maintaining good compressor performance even at high compression ratios 5 Provides oil pressure for development of balance load on the balance pistons to reduce bearing loading and increase bearing life NO PUMP OIL SYSTEM The RXF screw compressor unit is designed to be self lu bricating Oil being supplied to the compressor from the oll separator is at system head pressure Within the compressor oll porting to all parts of the compressor is vented back to a point in the compressor s body that is at a pressure lower than compressor discharge pressure The 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 oll pump is not required COLD START SYSTEM The RXF package is equipped with a special cold start discharge check valve on the gas outlet connection 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
15. 2222 32 MOTOR BEARINGS 32 ORERATING Eelere 32 TROUBLESHOOTING GUIDE d s b a d 32 ABNORMAL OPERATION ANALYSIS and CORRECTION 33 PRESSURE TRANSDUCERS TESTIING 33 PRESSURE TRANSDUCERS REPLACEMENT 33 SLIDE VALVE TRANSMITTER REPLACEMENT SLIDE 5 52 35 TEMPERATURE SENSOR REPLACEMENT 35 OIL LEVEL TRANSMITTER REPLACEMENT 35 TEMPERATURE and or PRESSURE ADJUSTMENT 35 BARE COMPRESSOR MOUNTING 5222 35 TROUBLESHOOTING THE COMPRESSOR 36 Olle eegne 36 LIQUID INJECTION OIL COOLING SYSTEM 36 HYDRAULIC SYSTEM ME 37 COMPRESSOR PORT LOCATIONS RXF 12 19 38 SAE STRAIGHT THREAD O RING FITTINGS ASSEMBLY PROCEDURE FOR 58 101 40 P 8 DIAGRAM LIQUID INJECTION SINGLE PORT 41 RXF COOLING OPTIONS See P 8 Diagrams PLATE OI COOLER 42 WIRING HARNESS External for Analog Devices 49 WIRING HARNESS AC to Heaters and Valves External 50 INSTALLATION OF ELECTRONIC EQUIPMENT WIRE E TEE 51 VOLTAGE SOURCE adas GEO AEG 51 GROUNDING eege b adi 52 52 CONDU II E 53 WIRING PRACTICES 53 COMMUNICATIONS 55 UPS POWER AND QUANTUM HD PANELS 55 OPERATING LOG SHEE
16. Control Output The value of the Output signal as con trolled by the PI 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 OPERATION OF DANFOSS LIQUID INJECTION VALVE The Danfoss ICAD Industrial Control Actuator with Display is equipped with an LED 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 Figures 23 and 24 and consists of RXF ROTARY SCREW COMPRESSOR UNITS Page 18 OPERATION DEE y Frick BY JOHNSON CONTROLS Down arrow push button Figures 23 and 24 Decreases parameter number by 1 at each activation Up arrow push button Figures 23 and 24 ncreases parameter number by 1 at each activation Down arrow Enter Up arrow Display Figure 23 Up arrow Down arrow Figure 24 Enter push button Figures 23 and 24 Glves access to the Parameter list by keeping the push button activated for 2 seconds A Parameter list example is shown below parameter 08 Figure 25 Open Mod Gives access to change a value once the Parameter list has been accessed Acknowledge and save change of value of a parameter Figure 25 Dees Frick
17. Nuisance Oil Level Cutouts 26 32 Oil Charging Valve 26 Oil Cooler 26 Oil Filter Element 26 Oil Filters 24 Oil Foaming 26 Oil Level Control 35 Oil Level Transmitter 35 Oil Pressure Loss 26 32 Oil Pump Strainer 25 Oil Quality 32 Operating Log 32 RXF ROTARY SCREW COMPRESSOR UNITS INDEX P Diagram 41 Pressure Sensors 35 Pressure Transducers 33 Conversion Data 34 Replacement 33 Testing 33 Refrigerant Vapor 24 25 Refrigeration Oil 32 Safety Equipment 23 Sensor Well 35 Service Valves 24 Spin On Oil Filter Element 24 Starting Torque 26 Strainer Elements 26 Strainer Service Valves 26 Suction Check Valve Bypass 24 26 Suction Service Valve 26 Suction Strainer 23 Suction Valve Bypass 26 Superheat 23 Temperature Sensor 35 Temperature Transmitter 34 35 Troubleshooting See Index TROU BLESHOOTING Ventilation 23 Vibration Analysis 32 Vibration Data Sheet 62 Vibration Level 23 Volume Ratio Control 35 Water Vapor 23 Wiring Harness 50 Maintenance Schedule 31 Maximum Oil Flow 21 Mechanical 57 Metal Conduit 53 Microprocessor 10 17 Moments 9 Motor 11 Bearings 21 Contactor 11 Cycling 11 Rotation 6 14 Motor Starter Contactor 11 Mounting Bolts 6 Movable Slide Valve 15 Multiple Compressor Economizer System 11 N Neoprene Drive Spacer 6 Noise Suppression 55 O Dual Oil Filters 24 Main Oil Filter 24 Oil Charge Reservoir 15 Oil Cooling Liquid Injecti
18. RXF units are supplied with a Quantum HD control system Care must be taken that the controls are not exposed to physical damage during handling storage and installation The single box control door must be kept tightly closed to prevent moisture and foreign matter from entry RXF ROTARY SCREW COMPRESSOR UNITS INSTALLATION Page 11 070 410 IOM NOV 14 Customer connections are made in the Quantum HD control panel mounted on the unit The electrical enclosures should be kept tightly closed whenever work is not be ing done inside Or starter panel if provided VOLTAGE PROTECTION Johnson Controls Frick 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 Quantum 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
19. e U 11 22 NV 1 un SUCTION VALVE IS T SHIPPED NV 2 SE LOOSE M 1 C 1 O YY3 7 l O YY4 10N MF Ge HTR 3 l 2 BER SR S i PE PAD PAH 0 PAL N PALN PE SAMPLING GH VALVE MN OSH gie HA F ao TE F 3 1 NPT OUTLET U DISCHARGE GAS 4 4 VENT LATACH 566 FROMUNT ty WIRE ORIFICE a q n fi g PV 1 Sx O p SEPARATOR Q NAS AIE 1 o il T HTR 1 ASL 2 ALTE TAL CFs CU 1 STR 1 CJ Do Yin 1 TSOC OUTLET OG gt C A WGOC 7 amp GCOC INLET X m Tov SET 120 F SHIP LOOSE STRAINER PLATE OIL COOLER WCOC amp GCOC FT l OUTLET z TSOC INLET 55 CHECK VALVE FILTER OR FILTER DRIER PIC TIC HEATER PM SIGHT OR LEVEL GLASS PSV OIL LEVEL SWITCH LOW PV LOW OIL LEVEL SHUTDOWN STR PRESSURE ELEMENT ZT PRESSURE INDICATOR Z PRESS TEMP INDICATING CONTROLLER PUMP MOTOR PRESSURE SAFETY VALVE PRESSURE VESSEL STRAINER HIGH TEMPERATURE ALARM HIGH TEMP SHUTDOWN LOW TEMPERATURE ALARM LOW TEMPERATURE SHUTDOWN POSITION TRANSMITTER POSITION INDICATOR Continued following page MOTOR TAH NEEDLE VALVE TAHH PUMP TAL HIGH PRESSURE ALARM TALL HIGH PRESSURE SHUTDOWN LOW PRESSURE ALARM LOW PRESSURE SHUTDOWN TEMPERATURE CONTROL VALVE TEMPERATURE ELEMENT SOLENOID VALVE EVENT VALVE 070 410 IOM NOV 14 RXF ROTARY SCREW COMPRESSOR UNITS Erick Page 46 MAIN
20. 090 040 0 BARE COMPRESSOR MOUNTING Refer to publication 070 660 SM 070 410 IOM NOV 14 RXF ROTARY SCREW COMPRESSOR UNITS Erick Page 36 MAINTENANCE BY JOHNSON CONTROLS TROUBLESHOOTING THE COMPRESSOR SYMPTOM PROBABLE CAUSES and CORRECTIONS EXCESSIVE NOISE and Loose bolts on compressor mounting Tighten bolts VIBRATION No oil getting to compressor Check oil level oil filter and oil pressure Bearing damage or excessive wear Coupling loose on shaft Tighten coupling Replace if damaged Volumizer not adjusted correctly Readjust Refrigerant flood back Correct system problem TROUBLESHOOTING THE OIL SEPARATOR SYMPTOM PROBABLE CAUSES and CORRECTIONS GRADUAL OIL LOSS WITH AN Maintaining too high an oil level Lower level OIL LEVEL IN THE COALESCER EE SECTION SIGHT GLASS Refrigerant carryover or liquid injection overfeeding Correct operation Contaminated oil or damaged coalescer filter elements Replace oil charge and coalescers Coalescers may be loose Tighten Oil return valve closed Open return valve Return oil strainer blocked Clean strainer RAPID LOSS WITH NO OIL Compressor unit suction check valve did not close on shutdown Repair valve LEVEL IN THE COALESCER SECTION SIGHT GLASS Bypass open around suction check valve Close bypass valve Bypass valve opened too far Tighten Coalescer filter elements not seated properly Replace oil charge and coalescers Oil viscosity too low Verify correct
21. 3 4 D 7 10 11 12 15 16 18 19 20 21 22 11 Liquid Injection Bleed Line 7 Suction Pressure 6 Oil Dram 070 410 IOM NOV 14 RXF ROTARY SCREVV COMPRESSOR UNITS Page 40 MAINTENANCE T y Frick BY JOHNSON CONTROLS SAE STRAIGHT THREAD O RING FITTINGS ASSEMBLY PROCEDURE FOR RXF 58 101 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 If the O ring is not pre installed to the fitting on the male end install the proper size O ring 3 Lubricate the O ring with a light coati
22. 410 IOM NOV 14 Page 61 Use Map File Protocols ModBus TCP Ethernet Up Profinet 070 410 IOM NOV 14 RXF ROTARY SCREW COMPRESSOR UNITS weny pl Page 62 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 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 UV HB Refrigerant Ambient Room Temperature U PE Operating Conditions SUCTION DISCHARGE OIL SEPARATOR Slide Valve Position Compressor Inboard Coupling End Center Vertical Direction PS Overall Compressor Outboard Noncoupled End Axial Direction PS Overall Motor Inboard Coupled End Horizontal IPS Overall Vertical i IPS Overall Axial IPS Overall Compressor Outboard Compressor Inboard Vertical Direction Jackshaft Motor Outboard Noncoupled End IPS Male Horizontal Direction 2 i 7 PS Female 1 5 Overall ertical 08 vera Ax al IPS Overall t RXF ROTARY SCREVV COMPRESSOR UNITS 070 410 IOM AUG 14 Frick NOTES Page 63 070 410 1 AUG 14 RXF ROTARY SCREW COMPRESSOR UNITS m ye Page 64 NOTES Frick Dees Frick BY
23. Figure 28 INITIAL START UP PROCEDURE Having performed the checkpoints on the prestart check list see FORMS section 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 Models 58 101 ONLY 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 RXF ROTARY SCREW COMPRESSOR UNITS OPERATION Page 21 070 410 IOM NOV 14 adequate oil flovv There is still an orifice installed in the compressor to control maximum oll 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 adjustment of this valve The best method to determine target discharge temperature is to run CoolWare with the operating conditions of the compressor he 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 CoolVVare M 180 F is a good target
24. 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 WHEREVER POSSIBLE APPLY THE POLYUREA PRODUCT CHEVRON OIL CO SRI 2 MOBILE POLYREX EM Figure 33 Lubrication Schedule And Instructions 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 at exactly the same percent of load 2 Use vibration readings taken from the new unit at start up as the base line reference 3 Evaluate vibration readings carefully as the instrument range and function used can vary Findings can be easily misinterpreted 4 Vibration readings can be influenced by other equipment operating in the vicinity or connected to the same piping as the unit For additional information request Fricke publica tion 070 902 IB OIL QUALITY and ANALYSIS 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 contaminants In order to ensure the quality of the refrigera tion oil in the compressor unit DO NOT MIX OILS of different brands manufactu
25. RIGHTS RESERVED Control S www jci com frick
26. T 9 COMPRESSOR RA STARTER OR INTERPOSING RELAY NOTICE If starting methods other than across the line are desired a motor compressor torque analysis must be done to ensure sufficient starting torque is available Contact Frick if assistance is required 2M OL OIL PUMP STARTER SUPP 2 If specified the starter package can be supplied as a com bination 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 A 3 0 KVA control power transformer CPT to supply 120 volt control power to the control system and separator oil T2 Ta GND eee STARTER PACKAGE AE e RE e Quantum LX heaters Is included If environmental conditions require more AND MOTOH WIRING DIAGHAMS RWFII REF QUANTUM LX than 2000 watts of heat an appropriately oversized control MANUAL transformer will be required GND Ti T2 T3 GND Ti T2 T3 GND 20 8 5 4 3 2 1 EL E elle lie iriri ir LLJ LEJ LLI LI LL LLJ 4 One normally open compressor motor starter auxiliary contact should be supplied and wired as shown on the starter package wiring diagram In addition the compressor starter coil and the CPT secondaries should be wired as shown on bd a a A cy Ku Nu NA the starter package wiring diagram Figure 13 GND 20 16 5 5 5 SZ FRICK NEE Q
27. 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 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 Sec Low Limit Sec Miscellaneous Remote Capacity Deadband Max Slide Valve Timer 1 10 Sec High Compressor Oil Pressure Shutdown PSI Delay Sec RXF ROTARY SCREW COMPRESSOR UNITS eee dr SS Max Discharge Pressure PSI Max Discharge and Oil Temp F Frick BY JOHNSON CONTROLS Page 4 Name Control Action Control Point Device Source Device Channel Setpoint Dead Band Prop Band Integral Gain Compressor ID Comm 1 Baud Rate Data Bits Stop Bits Parity RS 485 Connection Protocol IP Data Address Type IP Address Gateway Address Subnet Mask Web Server Port RXF ROTARY SCREW COMPRESSOR UNITS Unit Serial Comm 2 Baud Rate Data Bits Stop Bits Parity RS 485 Connection Protocol FORMS Frick Order No PAID Setpoints Communications Comm 3 Baud Rate Data Bits Stop Bits Parity Protocol Ethernet Naming Data Host Name Work Group Comments RS 485 Connection 0 070
28. and 0 005 for AS AK and AL size pumps Distance in on O D End Clearance of Bearing Housing in GG 7 16 HJ HL 9 16 AS AL 1 2 003 INSTALLATION OF CARBON GRAPHITE BUSHINGS When installing carbon graphite bushings extreme care must be taken to prevent breaking Carbon graphite is a brittle material and easily cracked If cracked the bushing will quickly disintegrate 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 installation 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 bushing 4 Check bushing for cracks after installation 070 410 IOM NOV 14 TROUBLESHOOTING THE DEMAND PUMP 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 DIS CHARGE LINES OR OTHER APPROPRIATE 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 Mark val
29. 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 Adjust the space between hubs as specified in the CH Coupling Data Table below SEE NOTICE CH COUPLING DATA TABLE Coupling Hub 5 7m 0 m 07 6 Keyvvay EI Series Min Min Spacing torque OY Size Setscrew Torque Size Size In mm In mm In mm In mm in mm Ft Lb Nm UNC 2 15 2 16 55 74 6 3 8 24 UNF 31 16 55 74 6 3 8 24 UNF 1 2 20 UNF 6 7 2916 30 8 9 10 36 130 Frick BY JOHNSON CONTROLS NOTICE The center section will be a little loose between the hubs This allows for growth during operation 6 Torque the clamping bolts in both hubs to the torque value given in the CH Data Table DO NOT USE ANY LUBRICANT ON THESE BOLTS HOLDING CHARGE and STORAGE Each compressor unit is pressure and leak tested at the John son Controls Frick factory and then thoroughly evacuated and charged with dry nitrogen to ensure the integrity of the unit during shipping and short term storage prior to installation 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 th
30. button The values are as follows 1 for ICM20 2 for ICM25 3 for ICM32 4 for ICM40 5 for ICM50 6 for ICM65 6 The ICAD will store these parameters with the power removed Alarms ICAD can handle and display different alarms IC Comments Alarm Text Description M No valve type Al At start up A1 and CA will be selected displayed Controller fault Internal fault inside electronics A3 All input error input amps are gt 22 mA Reset to factory setting 1 Remove the power supply 2 Activate down arrow and up arrow push buttons at the same time 3 While continuing to push the down and up arrows con nect the power supply 4 Release down arrow and up arrow push buttons 5 When the display on ICAD Figure 23 is alternating between showing CA and A1 the factory resetting is complete 070 410 1 NOV 14 ROTARY SCREW COMPRESSOR UNITS Erick Page 20 OPERATION BY JOHNSON CONTROLS PARAMETER LIST EE ACZ ICM OD 100 o ICM valve Opening Degree is displayed during normal operation Opening Degree Running display value see j01 j05 Internal main switch 1 Normal operation Main Switch 1 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 1 Modulating ICM positioning according to Analogue input see j03 2 ON OFF operating the ICM valve like an ON OFF solenoi
31. 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 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 41 480 VOLT 3 PHASE BUS GROUND BUS CONDUIT ELECTRONIC CONTROL Figure 41 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 t
32. 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 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 ol 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 Y2 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 372 turns Do not close the valve any further than 12 the number of turns required to fully open it Failure to properly adjust this valve can lead to exces
33. 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 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 instanta neous voltage dips caused by large loads such as heaters contactors and solenoids These sudden dips in voltage can cause the electronic control panel whether it is a micropro cessor a computer or a PLC to
34. 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 between the conduit and the enclosure This is extremely important in outdoor applications 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
35. 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 oll Confirm all 120 volt control wiring is run in a separate Lubricate electric drive motor bearings PRIOR to conduit 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 l
36. is the most cost effective of all currently applied cooling systems since no compressor capacity loss or compressor power penalties are incurred The vapor from the cooler need only be condensed not compressed Refrigerant flow to the cooler is automa tic driven by the thermosyphon principle and cooling flow increases as the oil inlet temperature rises TO SYSTEM A 95 F 2 54 FT3 Pr 36 FT 120 140 F wy OIL OUT TS RECEIVER HOT OIL IN FROM SEPARATOR Figure 28 SYSTEM OPERATION Liquid refrigerant fills the cooler Warm or hot oil above the liquid return temperature flowing through the cooler will cause some of the refrigerant to boil and vaporize The vapor rises in the return line The density of the refrigerant liquid vapor mixture in the return line is considerably less than the density of the liquid in the supply line This imbalance provides a differential pressure which 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 single 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 reliquified since it is still at condenser pressure see
37. not compress the spring Re move the installation sleeve 7 Coat the rotor shaft with refrigeration oil Install the rotor and shaft into the casing slowly pushing until the ends of the rotor teeth are just below the face of the casing Take care not to damage the seal seat 8 Leave the rotor in 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 the head and install head and idler assembly on pump Pump head and casing were marked before disassembly to ensure proper reassembly If not be sure the 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 the pump 10 Tighten the head capscrews evenly 11 If the pump was equipped with a relief valve and was removed during disassembly install on the head with new O Rings or gaskets The relief valve adjusting screw cap must always point towards the suction port 12 In 2005 the use of single seal bearings were phased out Pumps now use Sealed for Life bearings that have seals on both sides The new bearings can be installed either side first and do not need to be packed with grease For older models with single seal bearings pack the inner ball bearing with multi purpose grease NLGI 2 GG HJ HL Drive the bearing into the bore Tap the inner race with a brass bar and lead hammer to positio
38. 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 communication 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 When in doubt contact the factory or use threaded metallic or threaded PVC
39. of fault scenarios are 1 he 3 phase bus has power on 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 Manual 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 typ
40. oil replace if incorrect High system CFM System operating out of design conditions High suction and Low discharge pressures Refrigerant flood back Correct system problem Two or more compressors piped to a single economizer vapor port Verify check valves are in working order TROUBLESHOOTING THE LIQUID INJECTION OIL COOLING SYSTEM SYMPTOM PROBABLE CAUSES and CORRECTIONS HIGH OIL TEMPERATURE Insufficient liquid supply Check receiver level Check strainer Suction superheat too high Correct system problem Liquid strainer blocked Clean strainer Operating conditions significantly different from design Malfunctioning Vi Control Solenoids See function check of the compressor Volumizer Il Vi Control for further detail Check motor valve operation and calibration Check calibration of analog output LOW OIL TEMPERATURE Equalizing pressure too low Raise pressure Suction superheat too low or refrigerant flood back on compressor Correct system problem Operating conditions significantly different from design Check motor valve operation and calibration Check calibration of analog output OIL TEMPERATURE System conditions rapidly fluctuate causing liquid injection system to overrespond Stabilize FLUCTUATES system operation Check calibration and operation of motor valve Adjust P amp ID setpoints for analog output Erick RXF ROTARY SCREW COMPRESSOR UNITS 070 410 IOM NOV 14 MAINTENANCE Page 37 BY JOHNSON C
41. sive noise and vibration of the compressor and package premature failure of the bearings liquid loading of the rotors liquid starvation of the rotors and catastrophic failure of the compressor 2 All Models For proper and safe operation the compres sor 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 linear transmitter should be calibrated 6 Perform vibration analysis if equipment is available 7 Pull and clean suction strainer after 24 hours operation If it is excessively dirty repeat every 24 hours until system is clean Otherwise follow the Maintenance Schedule See the RECOMMENDED MAINTENANCE PROGRAM section 070 410 IOM NOV 14 RXF ROTARY SCREW COMPRESSOR UNITS Page 22 OPERATION Frick BY JOHNSON CONTROLS 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 At start up the slide stop volumizer and the slide valve capacity control are in the AUTO mode 4 Observe the compressor unit for mecha
42. 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 T M te See 14 AWG 12 AWG 10 AWG 2 5 15 ft 25 ft 40ft 5 35 ft 55 ft 88 ft 12 5 93 ft 148 ft 236 ft NOTICE Do not install a compressor HAND OFF AUTO switch in the starter package as this would bypass the compres sor safety devices RXF ROTARY SCREW COMPRESSOR UNITS INSTALLATION Page 13 070 410 IOM NOV 14 CONTROL POVVER REGULATOR Compressor units that vvill be used in areas that suffer brovvn outs and other significant power fluctuations can be supplied with a control power regulator See Figure 15 Recommended Regulator Installation NOTE AT SOLA ASSEMBLY MAKE WIRES 6 2 GND 6B 8 2B 10 FT LONG CUT WIRES TO LENGTH AT INSTALLATION SEE SOLA CONNECTION CHARTS FOR GND TERM INPUT amp OUTPUT CONNECTIONS IN MIGRO H5 H4 H3 H2 H1 INPUT GREEN e OUTPUT LUG REGULATOR GND LUG I N X1 X SOLA ENCLOSURE REMOVE JUMPERS 6 TO 6B 8 2 TO 8 6 6B 2B FERRITE WHEN SOLA IS ADDED TUBE REMOVE FERRITE TUBE EMI FILTER GND TERM 6A 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 15 Recommended R
43. 0 64 10 71 60 79 10 86 60 94 10 101 60 109 10 116 60 124 10 131 60 139 10 146 60 154 10 161 60 169 10 176 60 184 10 191 60 199 10 206 60 214 10 221 60 229 10 236 60 244 10 251 60 259 10 266 60 274 10 1 046 V 19 10 26 60 34 10 41 60 49 10 56 60 64 10 71 60 79 10 86 60 94 10 101 60 109 10 116 60 124 10 131 60 9 57 4 48 0 30 2 80 20 530 21 ze 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 7 80 1 8 1 9 2 0 2 10 30 5 6 7 8 9 1 x 4 gt 7 al 2 4 D 6 7 8 H 5 0 10 30 12 80 15 30 17 80 20 30 22 80 25 30 27 80 30 30 32 80 35 30 37 80 40 30 42 80 45 30 47 80 50 30 52 80 55 30 57 80 60 30 62 80 65 30 67 80 70 30 72 80 75 30 77 80 80 30 82 80 85 30 87 80 NO m 12 80 24 1530 25 17380 20 30 22 80 25 30 EEEE N R w O 7 w O N LI 27 80 30 30 139 10 146 60 154 10 161 60 169 10 176 60 184 10 191 60 199 10 206 60 214 10 32 80 35 30 911 37 80 w LA 40 30 42 80 36 4530 47 80 38 50 30 39 5280 40 5530 57 80 60 30 62 80 65 30 67 80 49 LA O R W W O 00 221 60 229 10 236 60 244 10 251 60 259 10 266 60 70 30 72 80 75 30 4 77 80 bn 80 30 90 30 1 388 V 1 788 V Below O PSIG measured in inches of mercury NOTICE To change the discharge pressure transducer PE 3 it will be necessary to depressurize th
44. 28 29 Tapered Installation Sleeve 29 Thrust Bearing Assembly 28 Troubleshooting 30 Air Leak 30 Alignment 30 Cavitation 30 Discharge Port 30 Discharge Pressure 30 End Clearance 30 Filter 30 Foot Valve 30 Gate Valve 30 Head 30 Misalignment 30 Motor 30 Motor Speed 30 Pressure Gauge 30 Pump 30 Relief Valve 30 Sheave Size 30 Strainer 30 Suction Line 30 Suction Pipe 30 Suction Port 30 Vacuum Gauge 30 Valve 30 Vaporizing 30 Vibrating 30 Differential Pressure 14 Direct Expansion Economizer System 11 Direct Motor Drive 6 Discharge Temperature 21 Drive Hubs 6 Dry Nitrogen 7 DX Economizer 10 E Economizer Back Pressure Regulator Valve 10 Balancing Load 10 Check Valve 10 DX Economizer 10 Economizer Port 10 070 410 IOM NOV 14 Page 65 Flashing Liquid 10 Flash Vessel 10 Isolation Valve 10 Microprocessor 10 Outlet Pressure Regulator 10 Strainer 10 Subcooling Liquid 10 Elastomeric Gear 6 EMI 53 External Controller 11 External Oil Cooling 21 F Filter Elements 8 Flexible Drive Coupling 6 Forklift 6 Foundation 3 5 14 51 56 Anchor Bolts 5 Grout 5 Housekeeping Pads 5 I Beams 5 Pipe Supports 5 Reinforced Concrete 5 Vibration Expert 5 H Hand Expansion Valve 21 Handling And Moving 5 Crane 5 Forklift 5 Lifting Ring 6 Rigging 5 Hard Water Conditions 9 Heat Exchanger 9 Heat Sink Paste 9 High Stage Operation 14 Hydra
45. 7 Clean strainer 8 Reinstall the strainer in the proper direction outboard end is marked and replace the gasket If the strainer is installed backwards it will be damaged 9 Pressurize and leak test Evacuate unit to 29 88 Hg 1000 microns 10 First reset solenoid valves to automatic position then open all valves previously closed Remove tags Close dis connect switches for compressor Start 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 DIS CHARGE LINES OR OTHER APPROPRIATE 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 con nections 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 GRAPHITE BUS
46. BY JOHNSON CONTROLS To exit from the Parameter list and return to the display of Opening Degree OD keep the push button activated for 2 seconds e Display Figure 26 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 O Figure 25 Open Mod Figure 26 Displays the parameter Displays the actual value of a parameter e Displays the function status by means of text Figure 23 Mod represents that ICAD is positioning the ICM valve according to an analog input signal Current Low represents that ICAD is operating the ICM valve like an ON OFF solenoid valve with low speed according to a digital input signal Med represents 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 27 Figure 27 e Alarms If an alarm has been detected the ICAD display Figure 23 will alternate between showing Actual alarm and present Opening Degree If more than one alarm is active at the same time the alarm with the highest priority will take preference A1 has the highest priority A3 the lowest All alarms will automatically reset themselves when they physically disappear Old alarms
47. Cooling Suct Disch Micro Information Micro Type Program Software Ver and Date UL Serial Digital I O Board 1 Serial Software Ver and Date Digital I O 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 FLA 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 L1 CT 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 Cooling Fan Information Motor HP RPM Service Factor Volt Hz FLA Cooling Fans Special Options TT ET ET Ll Prestart Checks LJ Installation Foundation LT Compressor PHD Setup LJ Coolant Installed LI Position of all valves LJ Motor PHD Setup LJ 4 20 Coolant Loop Pump Setup C Proper oil charge LJ Motor Winding RTD s Setup LI Coolant Loop Temp Setup LJ All wiring connections 1 Motor Bearing RTD s Setup C Cooling Fan Motor I O Setup LJ Starter Cleanliness C Motor Temperature Thermistor Setup _ Cooling Fan Rotation Checked C All micro settings C 4 20 Motor Drive Sig
48. E 58 101 RXF 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 oil filters other than Frick may cause warranty claim to be denied To change the filter cartridge proceed as follows 1 If a single oil filter is installed push STOP key to shut down the unit Open disconnect switches for the compressor and if applicable 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 Frick BY JOHNSON CONTROLS 2 Close outlet then inlet service valves of filter being serviced 3 Open bleed valve and purge pressure from the oil filter cartridge 4 Close discharge service valve SLOWLY vent the separator to low side system pressure using the suction check valve bypass Close suction valve and suction check valve bypass 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 pres sure increase Repeat venting and recovery procedure if necessary 5 Close oil filter isolation valves
49. E 2 DISCHARGE GAS TEMPERATURE MAIN OIL INJECTION TE 3 LUBE OIL TEMPERATURE SUCTION PRESSURE TE 4 SEPARATOR OIL TEMPERATURE TERMINATIONS A THROUGH C REFER TO CONNEC TION POINTS FOR VARIOUS OPTIONS RXF ROTARY SCREW COMPRESSOR UNITS 070 410 IOM NOV 14 Page 49 Frick MAINTENANCE BY JOHNSON CONTROLS WIRING HARNESS External for Analog Devices SUCTION PRESSURE QUANTUM ONLY CABLE 9 DISCHARGE CABLE 14 CABLE 1 PIN 2 BLK CABLE 8 PIN 1 RED 5 PIN 1 RED Eee PIN 2 BLK PIN 2 BLK PIN 2 WHT GRND SHLD PIN 3 WHT PIN 3 RED GRND SHLD DIN CONNECTOR PIN OUT FOR WIRING DETAIL A CABLE 1 SHLD CABLE 2 SHLD DETAIL B CABLE 3 SHLD CABLE 4 SHLD DETAIL C CABLE 14 SHLD 13 OIL TEMP SEPARATOR CABLE 3 TEMPERATURE PIN 1 RED OIL LEVEL OIL PRESSURE PIN 1 RED CABLE 4 CABLE 6 PIN 2 BLK PIN 1 RED PIN 2 BLK CABLE 16 PIN 1 RED PIN 2 BLK PIN 2 BLK PIN 3 WHT PIN 3 WHT GRND SHLD GRND SHLD 070 410 IOM NOV 14 Page 50 VIEW A A Y A PIN 1 BLK PIN 1 BLK PIN 1 BLK PIN 1 BLK PIN 2 WHT PIN 2 WHT PIN 2 WH
50. EW COMPRESSOR UNITS n n xu s Page 44 MAINTENANCE 7 RXF MODELS 12 through 19 with OIL PUMP See OIL COOLING ADDITIONS SUCTION GAS TO THE COMPR NV 3 O Raj gt GWI 7 ape 7 T H7 12 Dy 2 fi SE i 1 11 22H l NV 1 b SUCTION mu VALVE IS Wa SHIPPED Met Gu owm WB U 5 LOOSE HTR 3 o YY4 ak 1 pa 1 DISCHARGE GAS FROM UNIT U U C 4 oO a gt AGS SAMPLING mm xi cv zu VAVE E 3 3 V1 I 4 Gs ae hF ORIFICE ANA a qd E AA 5 Ea db R q b P SEPARATOR S HTR 1 STR 1 C F 7 KH d 1 N E 15 cv 2 d H TSOC OUTLET 75 2 _ eet WCOC amp GCOC INLET 5 uni NE PLATE OIL COOLER WCOC 8 GCOC SC OUTLET ag TSOC INLET OW ran SET 120 F CONNECTIONS
51. G COMPRESSOR UNIT COMPONENTS When replacing or repairing components which are exposed to refrigerant proceed as follows 1 Push STOP key to shut down the unit 2 Open disconnect switches for compressor motor starter and oil pump motor starter if applicable 3 Isolate the package by closing all package valves to the system Tag all closed valves Open any solenoid valves or other valves that may trap liquid between the isolation valves and other package valves to prevent injury or damage to components 4 SLOWLY vent separator to low side system pressure using the suction check valve bypass 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 transfer and recovery procedure if necessary 5 Make replacement or repair 6 Isolate the low pressure transducer PE 4 to prevent dam age during pressurization and leak test 7 Pressurize unit and leak test 8 Evacuate unit to 29 88 Hg 1000 microns 9 Open all valves previously closed and reset solenoid valves to automatic position Remove tags 10 Close disconnect switches for compressor motor starter and oil pump motor starter if applicable 11 Unit is ready to put into operation OIL FILTER SPIN ON RXF 12 50 To change the filter proceed
52. HINGS 5 Insert a brass bar or piece of hardwood in the port opening and between the rotor teeth to keep the shaft from turning Turn the locknut counterclockwise and remove locknut See Figure 29 or 30 6 Loosen the two setscrews in the face of bearing housing and turn the thrust bearing assembly counterclockwise and remove from casing See Figure 29 or 30 7 GG HJ HL Remove the snap ring from the shaft See Figure 29 AS AK AL Remove the bearing spacer from the shaft See Figure 30 8 Remove the brass bar or piece of hardwood from the port opening 9 The rotor and shaft can now be removed by tapping on the end of the shaft with a lead hammer or If using a regular INNER BALL BEARING BALL BEARING INNER SNAP RING SNAP RING SHAFT SNAP RING iat SEI BEARING 222 s a HOUSING 22222 SETSCREWS Figure 29 Thrust Bearing assembly GG HJ HL 070 410 IOM NOV 14 RXF ROTARY SCREVV COMPRESSOR UNITS n n xu s Frick Page 28 MAI NTENANCE BY JOHNSON CONTROLS BALL BEARING BEARING RETAINER WASHER SETSCREW INNER BALL BEARING NYLON INSERT Z 322 END CAP 2220 Lp SEAL Z EMI 1 Cas tone o Tl 2 xa LOCKNUT BEARING HOUSING SETSCREVV Figure 30 Thrust Bearing assembly AS AK AL hammer use a piece of hardwood between the shaft and hammer The rotary member of the seal will come out with the rotor and shaft 10 AS AK AL R
53. JOHNSON CONTROLS Symbols 3 phase ground 53 3 phase supply 53 Back Flushing 9 Bleed Valve 25 Booster Applications 15 Brownouts 13 C Cable Trays 53 Carbon Graphite Bushings 27 28 29 Chemical Cleaning Process 9 CH Coupling Data Table 6 Clamping Bolts 7 Closed Loop Fluids 9 Closed Loop System 9 Coalescer 15 Coalescer Filter Element 8 Codes 53 Cold Start Valve 14 Comm Port 55 Comm Port Protection 55 Communications 55 Compressor Discharge 15 Motor 11 Compressor Motor Starter 12 Compressor Port Locations RXF 12 19 38 RXF 24 50 39 RXF 58 101 41 Compressor Prestart Checklist 57 Compressor Shaft 6 14 Compressor Unloading 15 Compressor Volume Ratio 15 16 Conduit 53 Cone Button 8 Constant Speed Starters 53 Constant Voltage Cv Transformer 55 Control Power Regulator 13 Cooling Tower Water 9 Cooling Water 9 CoolWare 21 coupling 11 Current Transformer 12 Cutout Parameters 15 D Daisy Chaining 55 Demand Pump Bearing Retainer Washer 28 Bearings 28 Bearing Spacer 27 Carbon Graphite Bushings 29 Casing 27 29 End Clearance 29 Head 27 Idler 27 RXF ROTARY SCREW COMPRESSOR UNITS INDEX Index Idler Pin 27 Locknut 27 O Ring Gasket 29 Pump 28 Pump Head 27 29 Refrigeration Oil 28 Rotor 28 29 Rotor Hub 28 Rotor Shaft 29 Rotor Teeth 29 Seal 28 Seal Housing Bore 28 Seal Seat 28 Seal Spring 29 Snap Ring 27 Spring
54. NFOSS LIQUID INJECTION VALVE 18 THERMOSYPHON OIL COOLING 21 INITIAL START UP 21 NORMAL SIART UPDRROCEDURE 22 VED SKIF FREQUENCIES sxc ig oot ACE 22 NORMAL MAINTENANCE OPERATIONS 23 GENERAL MAINTENANCE 23 COMPRESSOR SHUTDOWN and START UP 23 COMPRESSOR MOTOR SERVICING 24 GENERAL INSTRUCTIONS FOR REPLACING COMPRESSOR UNIT COMPONENTS 1 24 OIL FILTER SPIN ON 12 50 24 OIL FILTER OF 1 CARTRIDGE STYLE 58 101 24 COALESCER OIL RETURN SIRAINER 25 LIQUID INJECTION STRAINER 52 25 OIL PUMP STRAINER Optional 25 SUCTION CHECK VALVE BYPASS 26 COALESCER FILTER ELEMENT 26 CHANGING OE 26 SUCTION STRAINER CLEANING PROCEDURE 27 DEMAND PUMP DISASSEMBLY 5222 27 DEMAND PUMP ASSEMBLY 28 THRUST BEARING ADJUSTMENT ees 29 INSTALLATION OF CARBON GRAPHITE BUSHINGS 29 TROUBLESHOOTING THE DEMAND PUMP 30 RECOMMENDED MAINTENANCE PROGRAM 31 MAINTENANCE SCHEDULE 31 VIBRATION ANALYSIS o Gio AL O W A L RAA 32 OIL QUALITY and 515
55. NOTES MAIN OIL SUPPLY 1 PRESSURE TRANSDUCERS INDICATE SLIDE VALVE PISTON SUCTION PRESSURE DISCHARGE PRESSURE LIQ INJ BLEED LINE COALESCER BLEED LINE THERMOWELL MAIN OIL INJECTION CAPACITY VALVE VENT TO SUCTION Not all ports are shown See COMPRESSOR PORT LOCATIONS for all ports PE 1 OIL PRESSURE PE 3 DISCHARGE PRESSURE PE 4 SUCTION PRESSURE TEMPRERATURE PROBES INDICATE TE 1 SUCTION GAS TEMPERATURE TE 2 DISCHARGE GAS TEMPERATURE TE 3 LUBE OIL TEMPERATURE TE 4 SEPARATOR OIL TEMPERATURE TERMINATIONS A THROUGH C REFER TO CONNECTION POINTS FOR VARIOUS OPTIONS Frick BY JOHNSON CONTROLS RXF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE 070 410 IOM NOV 14 Page 45 RXF MODELS 24 throughy 50 without OIL PUMP See OIL COOLING ADDITIONS SUCTION GAS TO THE COMPR PIC PALA PAL F 1 4 x 4 x 4 4 CM b H UL gt a 161 1 gt d EE
56. ONTROLS TROUBLESHOOTING THE HYDRAULIC SYSTEM SYMPTOM PROBABLE CAUSES and CORRECTIONS SLIDE VALVE WILL NOT LOAD Solenoid coil burned out Replace coil OR UNLOAD HV2 needle valve closed Open valve Solenoid spool may be stuck or centering spring broken Free spool or replace spring Solenoid may be mechanically actuated by inserting a piece of 3 16 rod against armature pin and pushing spool to opposite end Push A side to confirm unload capability If valve works problem is electrical Solenoid valve piston hung in bore or bolt loose Check piston or tighten bolt SLIDE VALVE WILL LOAD BUT YY1 solenoid coil burned out Replace coil WILL NOT UNLOAD Check valve in solenoid valve piston bad Replace or repair Dirt inside solenoid valve preventing valve from operating both ways Clean valve Solenoid may be mechanically actuated by inserting a piece of 3 16 rod against armature pin and pushing spool to opposite end Push YY1 valve to confirm unload capability If valve works problem is electrical Slipper seals worn out or damaged Replace Check valve in slide valve piston sticking Remove and clean check valve SLIDE VALVE WILL UNLOAD YY2 solenoid coil burned out Replace coil BUT WILL NOT LOAD NE Dirt inside solenoid valve preventing valve from operating both ways Clean valve Solenoid may be mechanically actuated by inserting a piece of 3 16 rod against armature pin and pushing spool to opposite end If valve
57. ORRECT e e ELECTRONIC ELECTRONIC ELECTRONIC CONTROL CONTROL CONTROL Figure 42 Frick BY JOHNSON CONTROLS COMMUNICATIONS The use of communications such as serial and ethernet in industrial environments are commonplace he 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 cable 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
58. OUNT NG 8 THERMOSYPHON OIL COOL ING 8 WATER COOLED OIL COOLING 9 LIQUID INJECTION OIL COOLING 9 DUAL DIP TUBE METHOD 10 ECONOMIZER HIGH STAGE OPTIONAL 10 EEECTRICA BEEN 11 VOLTAGE PROTECT ON 11 MOTOR STARTER PACKA GEF 12 MINIMUM BURDEN RATINGS 13 CONTROL POWER REGULATOR 13 OPERATION OPERATION and START UP INSTRUCTIONS 14 RAF COMPRESSOR Kadet 14 COMPRESSOR LUBRICATION SYSTEM 14 NO PUMP OIL SYSTEM 14 COLD TARI TEM 14 DEMAND PUMP OIE S ZSTEM iuee e 15 COMPRESSOR OIL SEPARATION SYSTEM 15 COMPRESSOR HYDRAULIC SYSTEM 15 CAPACIYCONTROE z zanika KSC EE 15 VOLUMIZER II Vi CONTROL 16 SLIDE VALVE 16 COMPRESSOR OIL COOLING SYSTEM 17 SINGLE PORT 4 1 5222 17 DUAL PORT UOUIDINIECTION 17 QUANTUM HD EZ COOL LIQUID INJECTION ADJUST MENT PROCEDURE eege 17 OPERATION OF DA
59. Open drain valve on oil filter head and drain the oil Remove the canister cover Discard the cartridge and gasket 6 Flush the filter body with clean Frick refrigeration oil wipe dry with a clean lint free cloth and close drain valve 7 Place a new cartridge in the filter canister Replace the gasket and spring and reinstall the canister cover Torque cover bolts in sequence to a Finger tight b 17 ft lb c 35 ft lb 8 Isolate the low pressure transducer PE 4 to prevent damage during pressurization and leak test 9 Pressurize and leak test 10 Evacuate the unit to 29 88 Hg 1000 microns 11 Add 2 gallons of oil by attaching a suitable pressure type hose to the oil charging valve located on top of the separator Use a pressure type oil pump and recommended Frick oil 12 Open the suction and discharge service valves oil filter isolation valves and the low pressure transducer Readjust suction check valve bypass Close disconnect switches for the compressor and if applicable the oil pump motor start ers Start the unit COALESCER OIL RETURN STRAINER 1 Push STOP key to shut down the unit Open disconnect switches for the compressor 2 Isolate the package by closing all package valves to the system Tag all closed valves Open any solenoid valves or other valves that may trap liquid between the isolation valves and other package valves to prevent injury or damage to components SLOWLY vent separator to lo
60. QUID 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 QUANTUM HD EZ COOL LIQUID INJECTION ADJUSTMENT PROCEDURE Contre Suction Pressure Setpoint 6 6 PSRs Actual 19 7 PSK Package Pere ilea Liquid injection LOCH DA Chimi Fueren Cone prone G h Liqi d injectar CHI Coming Figure 22 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 RXF ROTARY SCREW COMPRESSOR UNITS OPERATION Page 17 tetpo ni Waar lgh Lim Lora Limia h Baart IQ Channel Par 070 410 IOM NOV 14 liquid refrigerant is then supplied to the motorized expansion valve Refer to P 8 I DIAGRAMS section for piping and instrumentation drawings DUAL PORT LIQUID INJECTION The dual port liquid injection system is designed to obtain the most efficient compressor performance at high and low compression ratios by permitting injection of liquid refrigerant into one of two ports optimally located on the compress
61. RFI 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 RFI 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 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
62. S M L 24 30 39 50 XJF 120S M L 250 58 68 85 101 XJF 151A M L N 300 1 Based on metal to metal contact 2 Based on Gaskets Garlock Blue Gard 3300 Bolts class 8 8 or stronger hex head bolts lightly oiled and clean 070 410 IOM NOV 14 RXF ROTARY SCREVV COMPRESSOR UNITS Page 32 MAINTENANCE n n xu s Frick BY JOHNSON CONTROLS LUBRICATION SCHEDULE INSTRUCTIONS SYNC FRAME SERVICE CYCLE BALL BEARING SERIES me OPERATION 3600_ LUBRICATE BEARINGS WITH POWER IN THE OFF CONDITION CLEAR AND CLEAN THE GREASE FITTINGS AND SURROUNDING AREA REMOVE THE PIPE PLUG FROM THE VENTING PORT OPPOSITE THE GREASE FITTING w 390 DAYS 3120 HRS 130 DAYS 3120 HRS USING A LOW PRESSURE GREASE GUN APPLY 1 OZ 30 GRAMS OF GREASE 1800 LUBRICATION SCHEDULE FOR SEVERE SERVICE VIBRATION SHOCK AND OR ENVIRONMENTAL EXTREME 1 3 OF THE ABOVE INTERVALS AT EACH FITTING DO NOT OVERGREASE WITH THE VENT PORTS OPEN OPERATE THE MOTOR FOR A MINIMUM OF 15 MINUTES AND UNTIL ANY GREASE FLOW HAS CEASED AT THE VENTING PORTS REMOVE POWER REPLACE THE VENT PIPE PLUGS e 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 IS LISTED ON THE MOTOR DATA PLATE THIS IS A POLYUREA GREASE AS ARE THE PRODUCTS LISTED BELOW THE INTRODUCTION
63. SDUCERS INDICATE SLIDE VALVE PISTON PE 1 OIL PRESSURE SUCTION PRESSURE PE 3 DISCHARGE PRESSURE DISCHARGE PRESSURE PE 4 SUCTION PRESSURE LIQ INJ BLEED LINE TEMPRERATURE PROBES INDICATE COALESCER BLEED LINE TE 1 SUCTION GAS TEMPERATURE THERMOWELL TE 2 DISCHARGE GAS TEMPERATURE SUCTION PRESSURE TE 3 LUBE OIL TEMPERATURE CAPACITY VALVE VENT TO SUCTION TE 4 SEPARATOR OIL TEMPERATURE TERMINATIONS A THROUGH C REFER TO Not all ports are shown See COMPRESSOR CONNECTION POINTS FOR VARIOUS OPTIONS PORT LOCATIONS for all ports RXF ROTARY SCREW COMPRESSOR UNITS 070 410 1OM NOV 14 BY JOHNSON CONTROLS MAINTENANCE Page 47 RXF MODELS 58 68 85 amp 101 without OIL PUMP See OIL COOLING ADDITIONS 1 1 CV 4 y SUCTION GAS HHH TO COMPR SUCTION_BYPASS T CV 1 J 43 SUCTION VALVE LAH e so LOOSE D s 1 4 NV 3 8 NV 1 U T Lo rL 1 n Ze Z NV 2 M 1 C 1 PE __7PAH PAH m OR i u A B AA A 2 2 2 4 DISCHARGE GAS FROM UNIT R 1 4 VENT gt 3 4 69 GO
64. SS LIQUID REFRIGERANT 1 STRAINER TUBING LINE COMPRESSOR LOW VI COMPRESSOR HIGH VI S FROM RECEIVER A LIQUID LINE SOLENOID VALVE MOTORIZED EXPANSION VALVE d SIGHT GLASS N TUBING LINE TO SEPARATOR RXF COOLING OPTIONS See P amp I Diagrams PLATE OIL COOLER TO OIL FILTER A OIL TEMPERATURE S REGULATING VALVE FROM OIL C SEPARATOR h REFRIGERANT OUT REFRIGERANT IN VVATER IN VVATER OUT p RXF ROTARY SCREW COMPRESSOR UNITS 070 410 IOM NOV 14 Ey so EY
65. T PIN 2 WHT PIN 2 WHT L RXF ROTARY SCREW COMPRESSOR UNITS Frick BY JOHNSON CONTROLS WIRING HARNESS AC to Heaters and Valves External 1 HOT 2 NEUTRAL HTR 107 17 3 NOT USED PIN 1 BLK GRND NOT USED PIN 2 WHT 28 VIEW B B 106 YY 3 PIN 41 BLK WIRING HARNESS AC Conduit Quantum to DBS Panel Frick BY JOHNSON CONTROLS RXF ROTARY SCREW COMPRESSOR UNITS PROPER INSTALLATION OF ELECTRICAL EQUIPMENT Page 51 070 410 IOM NOV 14 PROPER INSTALLATION OF ELECTRONIC EQUIPMENT IN AN INDUSTRIAL ENVIRONMENT In today s refrigeration plants electronic controls have found their way into almost every aspect of refrigeration control Electronic controls have brought to the industry more precise control improved energy savings and operator conveniences Electronic control devices have revolutionized the way refrigeration plants operate today The earlier relay systems were virtually immune to radio frequency interference
66. TENANCE Ba RXF MODELS 24 through 50 with OIL PUMP See OIL COOLING ADDITIONS SUCTION GAS TO THE COMPR P PE NV 3 1 CV 4 C mH HS CV 1 19 a 47 12 o s U 11 22 5 NV 1 N rd SUCTION VALVE IS veri SHIPPED M 1 C1 om 1 O YY4 GER HTR 3 m 1 Ta Leg PAL PALN_ PE supu 08 an VALVE TAHN ae HA CH Fa Heo d 1 NPT OUTLET U 1 2 NPT INLET Z DISCHARGE GAS 1 4 VENT 4 300 PSIG 1 4 FROM UNIT OMU iy i Saou ORIFICE dh jej b b a 8 41 SEPARATOR y a HTR 1 44 1 SCH CJ s Va CH R U TP 1 1 eat D d I TSOC OUTLET 8 MR WCOC me O 2 8 GCOC INLET x lma Tov SET 120 F SHIP LOOSE STRAINER PLATE OIL COOLER WCOC amp GCOC ot OUTLET m TSOC INLET ES HiT mn CONNECTIONS NOTES MAIN OIL SUPPLY 1 PRESSURE TRAN
67. TION OF ELECTRICAL EQUIPMENT Page 53 070 410 IOM NOV 14 electrical ducts carrying 3 phase power to starters vfd or motors Control povver communicat ons analog or signal vviring 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 metallic dividers must be used for separation of conductors of unlike voltages and types AC or DC NOTICE 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 applies to both the line side and load side of the drive When VFD rated cable is
68. UANTUM LX FIELD SAFETY TOUTSA ENCLOSURE dee CHECK MOTOR STARTER OIL MANUFACTURER S INSTRUCTIONS PUMP AND QUANTUM LX MANUAL MOTOR 890 020 M NOTES 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 be per latest edition of the NEC and local codes Figure 14 Point to Point Wiring Diagram 5 The compressor motor Current Transformer CT can be installed on any one phase of the compressor leads NOTICE The CT must see all the current on any one phase therefore in wye delta applications BOTH leads of any one phase must pass through the CT Frick BY JOHNSON CONTROLS CURRENT TRANSFORMER SIZE Calculate CT size using the following formula where SF is Service Factor and FLA is Full Load Amps of the Motor FLA x SF x 1 1 round up to the next hundred Example FLA 379 Service Factor 1 15 379 x 1 15 x 1 1 479 Use a 500 5 CT DO NOT use undersized current transformers since the panel will not be capable of reading potential current If the CT is higher than calculated enter it s value for CT Factor on the panel The unit can operate with a CT one size larger than calculated however replace with the proper size ASAP NOTICE DO NOT operate unit with a CT more than one size larger than recommended MINIMUM BURDEN RATINGS The following table gives
69. al 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 particularly on new systems 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 oll and lead to premature bearing failure 4 Avoid slugging compressor with liquid refrigerant While screw compressors are probable the most tolerant to in gestion 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 com pressor suction RXF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE Page 23 070 410 IOM NOV 14 Keep liquid injection valves properly adjusted and in good condition to avoid flooding compressor w
70. alarms that have been active but have physi cally disappeared again can be found in parameter i11 Typically motorized valves are factory set If adjustments are needed the following procedure can be used RXF ROTARY SCREW COMPRESSOR UNITS OPERATION Page 19 070 410 IOM NOV 14 1 Ensure that there is povver to the valve 24 VDC and all wiring is complete prior to configuring the motorized valve The ICAD 600 requires 1 2 amps for operation and the ICAD 900 requires 2 0 amps 2 Identify which actuator is being used ICAD 600 or 900 and which motorized valve is being used ICM 20 25 32 40 50 or 65 Ensure that the correct actuator is being used with the ICM valve as follows ICM20 with ICAD 600 ICM25 with ICAD 600 ICM32 with ICAD 600 ICM40 with ICAD 900 ICM50 with ICAD 900 ICM65 with ICAD 900 3 When the valve is initially powered A1 and CA will be flashing on the LED display Hold the enter button down for two seconds until these values stop flashing 4 Push the down arrow button and scroll until j10 is displayed and push the enter button Using the up arrow scroll until 11 is displayed and push the enter button This step must be completed within 20 seconds or the valve will reset 5 Push the down arrow button again and scroll until j26 is displayed and push the enter button Identify the ICM valve being used and push the up arrow until the correct number is displayed for the ICM valve and then push the enter
71. an easier start and the dis charge check valve will seat more tightly See the SUCTION CHECK VALVE BYPASS section for operation P3 TO SUCTION d m CLOSED 2020020000000000 4 P2 TO CONDENSER N T P1 FROM OIL SEPARATOR Figure 16 Cold Start Discharge Check Valve DEMAND PUMP OIL SYSTEM This system is designed to provide adequate compressor lubrication for some high stage applications that operate with low differential pressure across the compressor suction and discharge and all booster applications On start up Quantum HD will calculate the pressure dif ferential between the compressor discharge and the main oll 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 RXF is an oil flooded screw compressor Most of the oil discharged by the compressor separates from the gas flow in the oil charge reser
72. and even then sound attenuation or noise curtains may be required to reduce noise to desired levels For more detailed information on Screw Compressor Founda tions please request Frick publication 070 210 IB HANDLING and MOVING This screw compressor package may be top heavy Use caution in rigging and handling RXF 12 50 units can be moved with a forklift or with rigging and a crane The recommended method is to insert lengths of 2 pipe through the base tubing see Figure 1 below Spreader bars should be used on both the length and width of the package to prevent bending oil lines and damage to the package CAUTION must also be used in locating the lifting ring Appropriate adjustment in the lifting point should be made to compensate for motor weight Adjustment of the lifting point must also be made for any additions to the standard package such as an external oil cooler etc as the center of balance will be affected Figure 1 RXF 12 50 070 410 IOM NOV 14 The unit can be moved vvith a forklift by forking through the base tubing NEVER MOVE THE UNIT BY PUSHING OR FORKING AGAINST THE SEPARATOR SHELL OR ITS MOUNTING SUPPORTS RXF 58 101 units can be moved with rigging using a crane or forklift by hooking into three lifting points on the oil sepa rator See Figure 2 Spreader bars may be required on both the length and width of the package to prevent bending oil lines and damage to the package CAUTION m
73. ary screw compressor serial numbers are defined by the following information EXAMPLE 10240A90000015Z GLOBAL ADDITIONAL PLANT DECADE MONTH YEAR SEQ NO REMARKS 1024 9 0000015 Month A JAN B FEB C MAR D APR E MAY F JUN G JUL H AUG K SEP L OCT M NOV N DEC Additional Remarks R Remanufactured Z Deviation from Standard Configuration GEOMETRICAL SWEPT VOLUME TABLE Geometrical Rotor Swept Volume Compressor Diameter Drive Shaft End CFM M3 H Model mm Ft3 Rev M3 Rev 3550 RPM 2950 RPM XJF 1511 JF 151N 180 XJS XJF 1201 0 06272 0 001775 223 292 1 1 3 4 15 0 0 14075 0 003983 5 XJF I5IN 151 E 0 16833 0 004764 598 843 95 95 10 95 145 20 80 20 223 20 292 151 42 151 03 151 00 151 598 Frick BY JOHNSON CONTROLS Installation FOUNDATION NOTICE 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 mass is required to effectively dampen these relatively high frequency vibrations Firmly anchoring the compressor package to a suitable foundation by proper application of grout and elimination
74. as follows 1 Push STOP key to shut down the unit Open disconnect switches for the compressor RXF ROTARY SCREW COMPRESSOR UNITS Page 24 MAINTENANCE n n SS Frick BY JOHNSON CONTROLS 2 Isolate the package by closing all package valves to the system Tag all closed valves Open any solenoid valves or other valves that may trap liquid between the isolation valves and other package valves to prevent injury or damage to components SLOWLY vent separator to low side system pressure using the suction check valve bypass 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 transfer and recovery procedure if necessary 3 Remove spin on oil filter element and discard NOTICE Use of oil filters other than Frick may cause warranty claim to be denied 4 Replace with new oil filter element Make finger tight plus an additional half turn 5 Isolate the low pressure transducer PE 4 to prevent dam age during pressurization and leak test 6 Pressurize and leak test 7 Evacuate unit to 29 88 Hg 1000 microns 8 Open the suction and discharge service valves and the low pressure transducer Close disconnect switches for the compressor Start the unit OIL FILTER OF 1 CARTRIDGE STYL
75. ation 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 drive 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 wirin
76. ation of gaskets and location of solenoids PRESSURE COMMON PRESSURE At YY4 GASKET INSTALLATION Figure 19 RXF 12 19 Vi Control SIDE VIEW COMMON NEE ves 1624 Takase PRESSURE Heed COMMON VENT O GASKET INSTALLATION i common d GASKET INSTALLATION Figure 21 RXF 58 101 Vi Control SLIDE VALVE CALIBRATION Slide valve calibration is performed on the Quantum HD control panel in automatic mode If further problems occur or persist contact Johnson Controls Frick service Frick BY JOHNSON CONTROLS COMPRESSOR OIL COOLING SYSTEMS The RXF unit can be equipped with one of several systems for controlling the compressor oil temperature They are single or dual port liquid injection thermosyphon or water cooled oil coolers Each system is automatically controlled independent of compressor loading or unloading Oil cooling systems maintain oil temperature within the fol lowing ranges for R 717 Liquid Injection Oil Cooling 130 to 150 F External Oil Cooling 120 to 140 F Thermosyphon Oil Cooling TSOC or Water Cooled Oil Cooling VVCOC SINGLE PORT LI
77. be cooled with forced air to reduce the temperature of the fitting to 350 F or lower prior to welding the second segment The maximum connection static forces and moments for Alfa Nova heat exchangers are listed in the following table Keep these values in mind when designing your system It is also recommended to minimize connection loads when designing piping systems Also see Figure 7 RXF ROTARY SCREW COMPRESSOR UNITS INSTALLATION Page 9 070 410 IOM NOV 14 Figure 6 Application of heat sink paste before vvelding Figure 7 Maximum static forces and moments LIQUID INJECTION OIL COOLING The liquid injection system provided on the unit is self con tained but requires the connection of the liquid line Liquid line sizes and the additional receiver volume quantity of refrigerant required for 5 minutes of liquid injection oil cool ing are given in the following table ave LIQ LINE SIZE 5 MIN LIQUID MODEL PIPE TUBING SUPPLY VOLUME SC OD POUNDS CU FT 5 8 R 17 1219 88 0 HIGH 2450 12 A8 3 STAGE 58 101 6 2 STAGE 58 101 12 58 1219 38 24 50 3 8 58 101 38 14 04 12 19 R 507 220 No oil heat of rejection rv at this condition 100 ft liquid line For longer runs increase line size accordingly CONDITIONS High Stage at O F Evap and 95 F Cond 10 F suction superheat Booster at 40 F Evap 95 F Cond 20 F 12 03
78. 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 return If the panel was In Auto Compressor motor will return to running as pro grammed Remote The external controller would reinitialize the panel and proceed to run as required Manual The compressor will have to be restarted manually after the 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 unexplainabl
79. ck RXF ROTARY SCREW COMPRESSOR UNITS 070 410 IOM NOV 14 BY JOHNSON CONTROLS MAI NTENANCE Page 27 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 See Oil Charge section 12 Open discharge and liquid injection service valves 13 Close disconnect switch for compressor motor starter 14 Start the unit SUCTION STRAINER CLEANING PROCEDURE 1 Open disconnect switch 2 Isolate the package by closing all package valves to the system Tag all closed valves Open any solenoid valves or other valves that may trap liquid between the isolation valves and other package valves to prevent injury or damage to components 3 With liquid injection close the manual hand valve upstream of YY7 and manually open YY7 by turning in the manual Opening stem clockwise viewed from below valve Failure to follow this procedure will damage valve YY7 4 SLOWLY vent the separator to low side system pressure using the suction check valve bypass 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 transfer and recovery procedure if necessary 5 Remove cover plate 6 Remove strainer
80. d valve controlled via Digital Input See also j09 Type of Analog input signal from external controller 1 0 20mA Analog Input signal 1 2 4 20mA 3 0 10V 4 2 10V Speed can be decreased Max speed is 100 Not active when j01 2 If j02 2 the display will indicate speed in display Low Med and 1 High also means ON OFF operation If j04 lt 33 Low is displayed 33 lt If j04 66 Med is displayed If j04 gt 67 High is displayed Automatic calibration 1 Always auto reset to O CA will flash in the display during calibration Type of AO signal for ICM valve position O No signal Analog Output signal 2 2 1 0 20mA 2 4 20mA Define condition at power cut when fail safe is installed 1 Close valve Fail safe j07 1 4 1 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 j02 2 Digital Input function 1 Open ICM valve OE OFF gt Close ICM 2 2 Close ICM valve DI OFF gt Open ICM valve Enter number to access password protected parameters ex e lm Eo Old alarms will be listed with the latest shown first Alarm list can be Old Alarms A1 A99 reset by means of activating down arrow and up arrow at the same time for 2 seconds Only active if j07 4 OD at powercut 100 50 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 i
81. e a Strainer and a check valve between the economizer vessel and the economizer port on the compressor The strainer prevents dirt from passing into the compressor and the check valve prevents oil from flowing from the compressor unit to the economizer vessel during shutdown Other than the isolation valve needed for strainer cleaning it is essential that the strainer be the last device in the economizer line before the compressor The strainer must be strong enough to handle the gas pulsations from the compressor Johnson Controls Frick recommends an R S or Hansen strainer Also piston type check valves are recommended for installation in the economizer line as opposed to disc type check valves The latter are more prone to 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 SUCTION INTERMEDIATE PRESSURE GAS TO COMPRESSOR gt STR VCK ECONOMIZER HIGH PRESSURE SUBCOOLED LIQUID HIGH PRESSURE LIQUID TO EVAPORATOR lt Figure 9 Shell And Coil Economizer System For refrigeration plants employing multiple compressors on a common economizing vessel regardless of economizer type each compressor must have a back pressure regulat ing valve in order to balance the economizer load or gas flow between compressors The problem of balancing load
82. e entire compressor package Follow General Instructions For Replacing Com pressor Unit Components section before going to step 3 5 Unscrew the transducer using a wrench on the metal hex at the base of the transducer DO NOT ATTEMPT TO LOOSEN OR TIGHTEN TRANSDUCERS BY THEIR TOP CASING 6 Install new transducer reconnect DIN connector and PIN 1 retighten DIN connector screw 7 Recalibrate 274 10 281 60 289 10 296 60 1 346 V 0 968 V 1 268 V TRANSDUCER CONNECTION Suction Pressure PE 4 Discharge Pressure PE 3 Oil Pressure PE 1 A PE 2 NOTICE If replacing older hard wired transducer cut cable at back of old transducer and rewire to the Danfoss unit 8 Reopen the transducer isolation valve or compressor package Isolation valves Figure 34 Pressure Transducer Color Key 3 Refer to Figure 34 to identify wiring harness connectors 4 Remove DIN connector screw then remove DIN connector ET EE STEE 9 Turn on control power Frick BY JOHNSON CONTROLS SLIDE VALVE TRANSMITTER REPLACEMENT SLIDE STOP The Slide Valve Transmitter Figure 35 is located on the right side of the compressor facing shaft at the inlet end 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 c
83. e problems 070 410 IOM NOV 14 RXF ROTARY SCREW COMPRESSOR UNITS Frick Page 12 INSTALLATION BY JOHNSON CONTROLS MOTOR STARTER PACKAGE GROUND SCH LINE NOTE CUSTOMER GROUND REQUIRED SEE THE WIRING DIAGRAM IN S90 020 M LA M aa CIRCUIT BREAKER SIE DISCONNECT USED WITH ACROSS THE LINE ONLY When starting at full voltage or across the line a shunting device must be installed or the Analog I O board in the Quantum HD panel may be severely dam i COMPRESSOR COMPR aged at start up See Figure 13 STARTER 8 MOTOR e ATL SS AT YD OR PW Motor starter and interlock wiring requirements are shown YD or PW ONLY in the diagram Figure 12 All ofthe equipment shown is sup TRANSFORMER plied by the installer unless a starter package is purchased 2 a separately from Frick Starter packages should consist of MONITOR 7 MOTOR 1 The compressor motor starter of the specified horse WHEN COMPRESSOR MOTOR VOLTAGE IS power and voltage for the starting method specified VOLTAGE SUPPLY CIRCUIT BREAKER across the line autotransformer wye delta or solid state LAW INLIEUOFFUSES O SED ADD TIMER FOR ACROSS 120 VOLT L a THE LINE STARTERS ONLY TR STARTING CURRENT VOLTAGE MONITOR 10 SEC SHUNT TIMER CONTACT 1M OL ON DELAY 1 Ox
84. e 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 RXF ROTARY SCREW COMPRESSOR UNITS Page 30 MAINTENANCE n n SS Frick BY JOHNSON CONTROLS 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 50 RO Oo O 2 Pump starts then loses its prime 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 pump is above the liquid raise
85. e 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 Units which will be stored for more than two months must have the nitrogen charge checked periodically Contact Johnson Controls Frick for long term storage procedure COMPRESSOR 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 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 publication 160 802 SPC for guidance OIL CHARGE The normal charging level is midway in the top sight glass located midway along the oil separator shell Normal operating level is between the top sight glass and bottom sight glass Oil charge quantities are as follows RXF ROTARY SCREW COMPRESSOR UNITS 070 410 IOM NOV 14 INSTALLATION Page 7 BASIC ADDITIONAL FOR RXF CHARGE OIL COOLER MODEL gallon gallon
86. e vertical position If the hinge pin is not in a vertical position then failure of the check valve may occur Figure 4 Suction Isolation Valve Mounting THERMOSYPHON OIL COOLING EQUIPMENT The basic equipment required for a thermo syphon system consists of 1 A source of liquid refrigerant at condensing pressure and temperature located in close proximity to the unit to minimize piping pressure drop RXF ROTARY SCREW COMPRESSOR UNITS Page 8 INSTALLATION n n SS Frick BY JOHNSON CONTROLS The liquid level in the refrigerant source must be 6 to 8 feet above the center of the oil cooler 2 A shell and tube or plate type oil cooler with a minimum 300 psi design working pressure on both the oil and refrig erant sides Due to the many variations in refrigeration system design and physical layout several systems for assuring the above two criteria are possible INSTALLATION The plate type thermosyphon oil cooler with oil side piping and a thermostatically controlled mixing valve are factory mounted and piped See Figure 5 SYSTEM CONDENSER VAPOR STATIC HEAD SAFETY TO OVERCOME VALVE aa CONDENSER THERMOSYPHON PRESSURE DROP Z 7 S LIQUID LIQUID OVERFLOW LEVEL DRAIN TO RECEIVER CONTROL VALVE R HOT ZS COOL gt lt COOL OIL OUT TO SYSTEM 3 EVAPORATOR gt REFRIGERANT OUT 5 HOT OIL IN
87. ed between the solenoid and the service valve 4 Close the service valve located between the compressor and the liquid injection thermal expansion valve 5 Carefully loosen capscrews securing the strainer cover to the strainer Allow pressure to relieve slowly 6 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 7 Wash the strainer basket and cover in solvent and blow clean with air 8 Reassemble the strainer 9 Open the service valve between the compressor and the liquid injection thermal expansion valve purge entrained air and check for leakage 10 Screw out the manual solenoid valve stem 11 Carefully open the liquid supply service valve 12 Leak test 13 Close disconnect switches for compressor starter 14 Start the unit OIL PUMP STRAINER Optional To clean the full lube oil pump strainer the unit must be shut down The procedure is as follows 1 Push STOP key to shut down the unit then open the disconnect switches for the compressor and if applicable the oil pump motor starters 070 410 IOM NOV 14 2 Close strainer service valves 3 Open the drain valve located in the strainer cover and drain the oil into a container 4 Remove the capscrews securing the strainer cover strainer cover gasket and element Retain the gasket 5 Wash the element in solvent a
88. ed for direct motor drive and include a flexible drive coupling to connect the compressor to the motor CH COUPLING The T B Woods Elastomeric Type CH Coupling is used in most applica tions This coupling consists of tvvo drive hubs and a gear 1 type Hytrel EDPM or neo prene drive spacer The split hub is clamped to the shaft by tightening the clamp screws Torque is transmitted from the motor through the elastomeric 2 gear which floats freely between the hubs Because of the use of the motor compressor adapter housing on the RXF no field alignment is necessary It is mandatory that the coupling center be removed and the direction of motor rotation be confirmed before run ning the compressor Proper rotation of the compressor shaft is clockwise looking at the end of the compressor shaft Failure to follow this step could result in backward compressor rotation which can cause compressor failure or explosion of the suction housing 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 necessary to use a screwdriver as a wedge in the slot to open the bore before the hubs will slide on the shafts 5 Hold the elastomeric gear
89. egulator Installation 070 410 IOM NOV 14 OPERATION and START UP INSTRUCTIONS The Frick RXF Rotary Screw Compressor Unit is an integrated system consisting of six major subsystems Control Panel See publications 090 040 0 M amp CS for QUANTUM HD Compressor Compressor Lubrication System Compressor Oil Separation System Compressor Hydraulic System Compressor Oil Cooling System The information in this section of the manual provides the logical step by step instructions to properly start up and operate the RXF Rotary Screw Compressor Unit NOTICE For alarm descriptions and shutdown or cutout param eters see publication 090 040 0 THE FOLLOWING SUBSECTIONS MUST BE READ AND UNDERSTOOD BEFORE ATTEMPTING TO START OR OPERATE THE UNIT RXF COMPRESSOR The Frick RXF rotary screw compressor utilizes mating asym metrical profile helical rotors to provide a continuous flow of refrigerant vapor and is designed for high pressure applica tions 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 angular contact ball bearings to carry axial loads are mounted at the discharge end of compressor 3 Moveable slide valve to provide infinite step capacity control from 100 to 25 of full load capacity 4 VOLUMIZER II adjusts to the most efficient of three volume ratios 2 2 3 5 or 5 0 depending upon s
90. emove the bearing retainer washer The washer may have stayed with rotor and shaft when removed or is against ball bearing See Figure 30 11 Remove the mechanical seal rotary member and spring from the rotor and shaft assembly 12 GG HJ HL Remove inner snap ring and single row ball bearing from the casing AS AK AL Remove single row ball bearing from casing 13 Remove seal seat or stationary part of seal from casing 14 Disassemble the thrust bearing assembly GG HJ HL Remove outer snap ring from the bearing housing and remove the ball bearing See Figure 29 AS AK AL Loosen the two set screws in flange outside diameter Rotate end cap and lip seal counterclockwise and remove Remove the 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 the pump Is put together When making major repalrs 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 MECHANICAL SEAL ROTARY MEMBER TAPERED SLEEVE COAT WITH LIGHT OIL BEFORE ASSEMBLY Figure 31 Wash bearings in clean so
91. enance 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 MAINTENANCE SCHEDULE Recommended schedule for Frick screw compressor package preventive maintenance operations FREQUENCY OR HOURS OF OPERATION MAXIMUM ololololololololololololo o ole VAN TERANG 3 N O La s uo Change Oil As Directed By Oil Analysis Oil Analysis CEJ Every 6 Months Replace Oil Filters 8 C As Directed By Oil Analysis As Directed By Oil Analysis 8 Clean Oil 5 m mi im m m m Im imi im m Clean Liquid Strainers m mi m m m m m im imi im m Replace Coalescers f oflm _ jm fm Check and Clean Suction Strainer N mi mi mi mi mi imi imi imi imi imi Check Coupling Annually Regardless of Operating Hours Suction 8 Disch Flange Bolts H T mimimimimimimimimimimimimimimimimimimimimim VFD Units Check Skip Freq 9 Check Annually Check Electrical Connections m mi mimimimimimimimimimimimimimimimimim Check Sensor Calibration Every 6 Months More Frequently If Levels Increase When Leak Rate Exceeds 7 8 Drops Per Minute Check bolts shim packs center inserts keys and all bolt torques Verify tightn
92. erally be ignored but in extreme cases may be compensated for by adding sub tracting 0 002 VDC for each 0 1 inch of barometric pressure adjusted to sea level above below O PSIG Therefore if PE 4 is measured at 5000 feet elevation under relatively normal weather conditions the output voltage should differ by 0 10 VDC to read between 1 38 VDC and 1 62 VDC 5 Subtract 1 from the voltage 6 Multiply by 25 7 This result is the absolute suction pressure PSIA Subtract 14 7 to obtain PSIG which the Operating display will indicate 8 Isolate the oil pressure transducers PE 1 amp 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 1 amp PE 2 on connector P5A terminals 5 and 6 on the analog board 10 The voltage reading should be between 1 1 VDC and 1 29 VDC at standard atmospheric pressure PE 1 amp PE 2 and PE 3 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 de viation 11 Subtract 1 2 from the voltage 12 Multiply by 75 the result will be PSIG 13 Since the discharge pressure PE 3 cannot be closed off from its sensing point code requirements remove all transducers from atmosphere and ope
93. ess of bolts on suction and discharge flanges See table below for torque requirements Units with variable speed drives check for excess vibration and skip frequencies any time unit operating conditions change 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 Baseline vibration analysis is required during initial commissioning 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 above g The filter may need to be changed more frequently based on differential pressure or as directed by oil analysis Motor Flange to Compressor Discharge Flange Compressor Compressor Tunnel 1 to Separator Flange 2 RXF Model Model Bolt Size in Torque ft lb Bolt Size mm Torque ft lb 8 60 60 80 145 80 M20 X 2 5 M20 X 2 5 M22 X 2 5 1 2 or 5 8 1 2 or 5 8 5 8 or 3 4 12 15 19 XJF 95S M L 24 30 39 50 XJF 120S M L 58 68 85 101 XJF 151A M L N Gempressor Compressor Suction Flange RXF Model Model Torque 2 ft lb Bolt Size mm Torque 2 ft lb 180 180 M20 X 2 5 M22 X 2 5 250 M24 X 3 0 470 12 15 19 XJF 95
94. feed could lead to other problems Under low load conditions the liquid injection system may have a tendency to overfeed The high suction superheat condition moreover may only be temporary When system conditions return to normal the unit s liquid injection will overfeed and oil temperature will drop In solv ing the wrong problem a new problem was created The following list of abnormal system conditions can cause abnormal operation of the RXF compressor unit 1 Insufficient or excessive refrigeration load 2 Excessively high suction pressure 3 Excessively high suction superheat 4 Excessively high discharge pressure 5 Inadequate refrigerant charge or low receiver level 6 Excessively high or low temperature coolant to the oil cooler 7 Liquid return from system carryover 8 Refrigerant underfeed or overfeed to evaporators 9 Blocked tubes or plates in water cooled oil cooler from high mineral 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 The second step
95. g connections 7 Calibrate slide valve and slide stop 3 Verify compressor motor rotation 8 Calibrate temperature and pressure readings 4 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 IOM 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 070 410 IOM NOV 14 RXF ROTARY SCREW COMPRESSOR UNITS Erick Page 58 FORMS v oxusu oxun Sta rt up Report Frick Order 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
96. he top sight glass and bottom sight glass located midway along the oil separator shell COMPRESSOR HYDRAULIC SYSTEM The hydraulic system of the RXF compressor utilizes oll pressure from internally drilled passages in the compres sor casing to selectively load and unload the compressor by applying this pressure to the actuating hydraulic piston of the movable slide valve MSV It also uses oil pressure to actuate a hydraulic piston that moves the movable slide stop Volumizer Il This allows adjustment of the compressor volume ratio Vi while the compressor is running CAPACITY CONTROL COMPRESSOR LOADING The compressor loads when MSV solenoid coil YY2 is energized and oil flows from the solenoid valve through the needle valve HV2 to compressor port 2 where it enters the load side of the slide valve piston This equalizes the force on the slide valve piston and discharge pressure on the slide valve area loads the compressor See Figure 18 COMPRESSOR UNLOADING The compressor unloads when MSV solenoid YY1 Is energized and oil is allowed to flow from compressor port 2 thru the needle valve to the MSV solenoid This allows discharge pressure on the slide valve piston to unload the slide valve as the piston moves outward ADJUSTMENT Capacity Control A needle valve HV2 is provided to adjust slide valve travel time preventing excessive slide valve hunting HV2 should be adjusted to restrict oil flow to the compressor por
97. ically 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 drawings 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 p UE JO gt 0 Frick BY JOHNSON CONTROLS RXF ROTARY SCREW COMPRESSOR UNITS 070 410 IOM NOV 14 FORMS Page 56 OPERATING LOG SHEET p lp lpul ssojun A An ds l O Sd PUL 4 U SHUN inss ld pue 41ON 9 8 jane 4003 pinbr Bunea INdd TEH MOJ 40 dolq 1 95 S ONO T o sInielsdwej Io B a amdu HOW gt 2 UC JIV INd 9IEH MOL W dq dolq 8INSSSId SINIEJSdWGJ 1 1914 peppy IO a 6 ae oo
98. in cold ambi ent temperatures with all pressures equalized See Figure 16 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 DO NOT ATTEMPT TO SERVICE THE COLD START VALVE PLEASE CONTACT THE FRICK SERVICE DEPARTMENT Once the compressor is running it will begin to force gas to the condenser at connection P2 See Figure 16 As the condenser heats up it will begin to rise in pressure as the compressor suction pulls down in pressure As soon as dif ferential pressure is developed 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 Frick BY JOHNSON CONTROLS For booster applications the valve is equipped with a lighter spring which produces 1 2 bar 7 psig oil pressure above suc tion pressure before it fully powers open The heavier spring is not required because booster compressors are equipped with a demand oil pump The RXF package is also equipped with a suction check valve bypass The oil separator will slowly bleed down to system suction pressure when the unit is stopped This allows the compressor drive motor to have
99. 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 tempera ture readings may both be symptoms of a problem and not casually related High suction superheat or a low receiver level however could cause both symptoms The third step is to identify the most likely cause and take action to correct the problem If the symptoms are not relieved move to the next item on the list and repeat the procedure until you have identified the cause of the problem Once the cause has been identified and confirmed make the necessary corrections RXF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE Page 33 070 410 IOM NOV 14 PRESSURE TRANSDUCERS TESTING Test Procedure 1 Shut compressor down and allow pressures to equalize 2 Isolate suction transducer PE 4 from unit and depres surize NOTICE Recover or transfer all refrigerant vapor in accordance with local ordinances before opening to atmosphere 3 Measure the DC voltage of PE 4 on connector P6A ter minals 2 and 3 on the analog board with a digital voltmeter 4 The voltage reading should be between 1 48 VDC and 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 Barometric pressure can gen
100. 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 RXF ROTARY SCREW COMPRESSOR UNITS Page 54 PROPER INSTALLATION OF ELECTRICAL EQUIPMENT n n SS 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 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 42 PLANT SUPPLY 1 00 3 PHASE TRANS BUS 0 42 ert tt GROUND BUS Le Le Le ELECTRONIC ELECTRONIC ELECTRONIC CONTROL CONTROL CONTROL CORRECT PLANT SUPPLY 3 PHASE TRANS BUS a GROUND BUS INC
101. ing spacer collar in the lip seal and install in the bearing housing and tighten the set screws securely See Figure 30 16 Insert a brass bar or piece of hardwood through the port opening between the rotor teeth to keep the shaft from turning 17 Start the thrust bearing assembly into casing Turn by hand until tight This forces the rotor against the head Replace and tighten the locknut or shaft 18 Remove the brass bar or hardwood from port opening 19 Adjust pump end clearance refer to Thrust Bearing Adjustment 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 Loosen two screws in face of thrust bearing assembly See Figures 29 or 30 If shaft cannot be rotated freely turn thrust bearing assembly counterclockwise until shaft can be turned easily 1 While turning rotor shaft rotate thrust bearing assembly 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 position For viscosities above 2500 SSU add additional end clearance 0 004 for GG HJ and HL size pumps
102. ith liquid Liquid can 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 setting for long periods without run ning it is advisable to evacuate to low pressure and charge with dry nitrogen or oil particularly on systems known to contain water vapor 6 Preventive maintenance inspection is recommended any time a compressor exhibits a noticeable change in vibration level noise or performance COMPRESSOR SHUTDOWN and START UP For seasonal or prolonged six months shutdown use the following procedure 1 Push STOP key to shut down unit 2 Open disconnect switch for compressor motor starter 3 Turn off power 4 Isolate the package by closing all package valves to the system Tag all closed valves Open any solenoid valves orother valves that may trap liquid between the isolation valves and other package valves to prevent injury or damage to components 5 With liquid injection close the manual hand valve up stream of the solenoid and manually open the solenoid by turning in the manual opening stem clockwise viewed from below valve 6 Shut off the cooling water supply valve to the oil cooler Drain water if applicable Attach CLOSED tags 7 Protect oil cooler from ambient temperatures below freezing NOTICE The unit should be inspected monthly during shutdown Check for leaks or abnor
103. l 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 RXF ROTARY SCREW COMPRESSOR UNITS 070 410 IOM NOV 14 070 410 IOM NOV 14 Page 60 FORMS Frick Page 3 Unit Serial Frick Order No Compressor Motor Setpoints and Information Motor Name Plate VFD Manufacturer Motor Amps Maximum Drive Output 90 Frame Size Volts Minimum Drive Output 90 H P Service Factor Remote Control RPM Horsepower Rate Of Increase Delay Serial CT Factor Rate Of Decrease Delay Sec Service Factor Recycle Delay Min Capacity Control Voltage High Motor Amps VVhen Slide Valve Reaches Hz Load Inhibit Drive Speed Reaches Design Force Unload Variable Speed Min Slide Valve Position Code Warning Delay Sec Skip Frequency Bands Bearing Type Shutdown Delay 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 VVarning gF Sec Module A High Shutdovn gF Sec High Shutdown ____ gF Sec Module B Module C Motor Bearing Module D Shaft Side Delay Opposite Shaft Side Delay Step
104. low Warning Delay Sec Shutdown 50 PSI Shutdown PSIG Shutdown Delay Sec Shutdown Delay Sec High Discharge Pressure Dual Mode Economizer Regulation Modes 1 amp 3 Modes 2 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 90 Stopping Period For Cap Unload Of Compressor Auto Mode Min Cap Ignore Delay Min Capacity Unload Assist Rate Yo 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 Temperature 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 Leve
105. lvent Blow out bearings with compressed air Do not allow bearings to spin turn them slowly by hand Spinning bearings will damage the 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 the bearings if they have roughness Be sure shaft is free from nicks 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 a 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 the rotary portion of the mechanical seal prepare and organize the rotor shaft head and idler assem blies and appropriate gaskets for quick assembly Once the rotary portion of the mechanical seal is installed on the rotor shaft it is necessary to assemble parts as quickly as possible to ensure that the seal does not stick to the shaft in the wrong axial position The seal will stick to
106. mal pressure Use the main tenance log to record readings to verify the pressure stability of the unit To prevent the seals and bearing from drying out run oil pump if available and manually rotate the compressor shaft Consult motor manufac turer for motor recommendations TO START UP AFTER SEASONAL OR PROLONGED SHUT DOWN USE THE FOLLOWING PROCEDURE 1 Perform routine maintenance Change oil and replace filters Check strainers 2 Any water necessary for the operation of the system that may have been drained or shut off should be restored or turned on 3 Reset solenoid valves to automatic position then open all valves previously closed Remove tags 4 Compressor unit is ready for prestart checks Refer to PRESTART CHECKLIST 070 410 IOM NOV 14 COMPRESSOR MOTOR SERVICING Before removing the motor from an RXF unit it is criti cal that proper support be provided for the compressor to prevent damage to the oil separator Insert blocks or a Jack between the separator shell and compressor casting Make sure the weight is held safely by the separator shell Loosen the compressor discharge flange bolts to relax any flange and pipe stress then carefully remove the motor Similarly before removing the compressor for servicing the back end of the motor must be supported to prevent damage Again insert either blocks or a jack between the rear of the motor and the separator shell GENERAL INSTRUCTIONS FOR REPLACIN
107. 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 environment 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 in
108. me all oil filter cartridges must be changed and all oil strainer ele ments removed and cleaned The procedure is as follows 1 Push STOP key to shut down the unit 2 Open disconnect switch for the compressor motor starter 3 Close liquid injection service valves if applicable 4 Close discharge service valve SLOWLY vent the separator to low side system pressure using the suction check valve bypass Close suction valve 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 separa tor pressure increase Repeat transfer and recovery procedure if necessary 5 Open drain valve s located on the underside of the sepa rator and drain the oil 6 Drain oil filter strainers and oil cooler if applicable 7 Remove and install new oil filter element 8 Remove clean and reinstall strainer elements in strainers 9 Evacuate unit to 29 88 Hg 1000 microns 10 Open 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 on top of the separator Using a pressure type oil pump and recommended Frick oil open the drain valve and fill the separator until oil level is midway in the top sight glass Fri
109. mmended that readings be taken at least every four hours 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 problems combine to provide a set of symptoms that can mislead the troubleshooter Be aware of this possibility and avoid solving the wrong problem Frick BY JOHNSON CONTROLS 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
110. n bearing Install the inner snap ring AS AK AL Install the bearing retainer washer over the shaft before installing the ball bearing Install the ball bearing in the casing with sealed side towards head end of the pump Drive the bearing into the bore Tap the inner race with a brass bar and lead hammer to position the bearing 13 GG HJ HL Install the shaft snap ring in groove in the shaft See Figure 29 AS AK AL Install the bearing spacer over the shaft and against the single row ball bearing See Figure 30 14 Pack the lubrication chamber between the inner ball bearing and double row ball bearing in the thrust bearing as sembly approximately one half full of multi purpose grease NLGI 2 The thrust bearing assembly will take the remaining Space See Figures 29 or 30 15 Pack the double row ball bearing with multipurpose grease NLGI 2 GG HJ HL Install the ball bearing into the bearing housing with shield side toward the coupling end of the shaft See Figure 29 Install the 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 the ball bearing RXF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE Page 29 070 410 IOM NOV 14 AS AK AL Install the ball bearing into the bearing housing Install the lip seal in the bearing housing end cap The lip should face tovvards the end of the shaft Put the bear
111. n display Enter valve type O No valve selected Alarm AT will become active 1 ICM20 with ICAD 600 ICM configuration 2 ICM25 with ICAD 600 3 ICM32 with ICAD 600 4 ICM40 with ICAD 900 5 ICM50 with ICAD 900 6 ICM65 with ICAD 900 009000 50 100 ICM valve Opening Degree Cis Alma ga o 20 mA O AM 52 o 10 V fAnaloglnputsgnl 6 00 AO mAl 53 20 mA Analog Output signal 0 40 osa J Digitalinput signal DO Close 5 1 Digital Output Closed status ON when OD lt 3 000 DOOpen j6 O 1 Digital Output Open status ON when OD gt 97 DOAlam 557 1 Digital Output alarm status ON when an alarm isdetected MAS mP SW ver 568 100 Software version for MASTER Microprocessor SLA mP SW ver 59 100 Software version for SLAVE Microprocessor 6000 Speed at ON OFF and Modulating Mode Frick BY JOHNSON CONTROLS 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 which is partially vaporized at the condenser temperature in a shell and tube or plate type vessel cooling the oil The vapor at condensing pressure is vented to the condenser inlet and reliquified This method
112. n them to their sensing points so all transducers can equalize to separator pressure 14 Measure the voltage of PE 3 on connector P5B ter minals 5 and 6 on the analog board 15 Test complete PRESSURE TRANSDUCERS REPLACEMENT 1 Shut off control power 2 Close the applicable transducer isolation valve 070 410 IOM NOV 14 RXF ROTARY SCREW COMPRESSOR UNITS Erick Page 34 MAINTENANCE BY JOHNSON CONTROLS Sensor Range PSIG Voltage 29 92 19 74 29 02 14 65 20902 55 24 83 4 48 19 74 0 30 10 KL E ABT 14 1 5 14 65 2 80 16 TRA 515 WNE EE PRESSURE TRANSDUCER CONVERSION DATA 500pi 2 Range PSIG low _ 29 92 29 92 Range PSIG 7 0 4 10 29 92 11 60 151 0 30 5 30 10 30 15 30 20 30 25 30 30 30 35 30 40 30 45 30 50 30 55 30 60 30 65 30 70 30 75 30 80 30 85 30 90 30 95 30 100 30 105 30 110 30 115 30 120 30 125 30 130 30 135 30 140 30 145 30 150 30 155 30 160 30 165 30 170 30 175 30 180 30 185 30 190 30 195 30 1 494 V 29 92 29 92 29 32 19 74 9 57 0 30 5 30 10 30 15 30 20 30 25 30 30 30 35 30 40 30 45 30 50 30 55 30 60 30 65 30 70 30 75 30 80 30 85 30 90 30 95 30 100 30 105 30 110 30 115 30 120 30 125 30 130 30 135 30 140 30 145 30 150 30 155 30 160 30 165 30 170 30 175 30 1 094 V 29 92 29 22 22 3 pis 4 10 11 60 19 10 26 60 34 10 41 60 49 10 56 6
113. nal Calibrated LJ Oil pump motor rotation L14 20 CT Channel 16 Setup LJ Cold alignment 1 Motor rotation LJ 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 Frick FORMS Page 59 Page 2 Unit Serial Frick Order No Capacity Control Setpoints 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 Warning Delay Sec Cycle Time _ Sec Warning Sec VFD Prop Band Shutdown VFD Prop Band Shutdown VFD Integ Time Sec Sec Shutdown Delay Sec VFD Integ Time 5 5 ShutdownDelay Sec Channel Channel Auto Cycle Low Suction Auto Cycle Low Suction Start Load Inhibit Start Load Inhibit Start Delay Force Unload Start Delay Min 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 Be
114. nd blow it clean with air 6 Wipe the strainer body cavity clean with a lint free clean cloth 7 Replace the cleaned element and gasket then reattach the cover using the retained capscrews 8 Reinstall the drain plug and open the strainer service valves 9 Check for leakage 10 Close the disconnect switches for the compressor and if applicable the oil pump motor starters 11 Start the unit SUCTION CHECK VALVE BYPASS A 1 4 angle valve is installed between the compressor and suction flange that can be used as a suction valve bypass This feature has several uses including reducing starting torque Improving oil quality and relieving the refrigerant to low side for servicing In most cases the valve should be left open approximately 1 to 2 turns at all times If the compressor back spins or too much oil foaming is experienced while venting partially close valve to slow speed of equalization If system is on AUTO CYCLE and short cycling occurs the valve must be closed To relieve refrigerant to low side close separator discharge service valve Slowly open bypass valve if closed and wait for pressure to equalize Close bypass and suction service valves before evacuating the unit COALESCER FILTER ELEMENT Use of coalescer filter elements other than Frick may cause warranty claim to be denied When changing the coalescer filter element it is recom mended that the oil and oil filter be changed Applicable straine
115. ng 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 ASSEMBLY TORQUE TABLE Straight and Adjustable Fittings or Plugs steel H Assembly Torque 130 10 170 10 260 15 320 20 500 25 720 30 960 50 1380 75 2700 150 3000 160 NOTE Compressor port locations for RXF 58 101 are located on the following page Frick BY JOHNSON CONTROLS RXF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE 17 Dedicated Closed Thread 16 Oil Pressure 11 Thermowell Su ction Temp 1 Mam Oil Supply 070 410 IOM NOV 14 COMPRESSOR PORT LOCATIONS RXF 58 101 4 High Vi Liquid Z M H 16 Oil Pressure 18 Dedicated Capacity Valve Vent to Suction Pressure 10 Coalescer 3 Low Vi Liquid Injection 6 Suction Pressure 5 DRIVE SHAFT 7 Closed Thread Discharge 7 COMPRESSOR
116. nical 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 OIL SEPARATOR COVER BOLTS at con denser design pressure while system is running to 90 ft lb for models 12 50 RETIGHTEN MANWAY BOLTS at condenser design pressure while system is running to 150 ft lb for models 58 101 11 x 15 manway 180 ft lb on 12 x 16 manway for oversized separator on 85 101 models RESTARTING COMPRESSOR UNIT AFTER CONTROL POWER INTERRUPTION PLANT POWER FAILURE 1 Check ADJUSTABLE setpoints 2 Follow normal start up procedure VFD SKIP FREQUENCIES Criteria for Identifying Elevated Energy on VFD Packages and Establishing Skip Frequencies With the RXF running loaded at full speed the entire package must be physically checked for elevated energy including any corresponding extremities such as valves liquid injec tion 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 microproce
117. o 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 070 410 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 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
118. o illustrate the operating principles of thermo syphon oil cooling Other component layouts may be better suited to a specific installation Refer to publication 070 900 E for additional information on Thermosyphon Oil Cooling Frick BY JOHNSON CONTROLS WATER COOLED OIL COOLING The plate type water cooled oil cooler is mounted on the unit complete with all oil piping The customer must supply adequate water to the oil cooler Johnson Controls Frick recommends a closed loop system 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 con dition 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 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 type oil cooler may be sub jected to severe water conditions including high temperature and or hard water conditions This causes accelerated scal ing rates which will penalize the performance of the heat exchanger A chemical cleaning process will extend the life of the heat exchanger It is important to establish regular cleaning schedules Cleaning A 3 solution of Phosphoric or Oxalic Acid is rec
119. 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 Fricke 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 shall 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 HANDLING and MOVING the feet must then be shimmed in order to level the unit The shims should be placed to position the feet roughly one inch above the housekeeping pad to allow room for grouting An expansion type epoxy grout must be worked under all areas of the base with no voids and be allowed to settle with a slight outward slope so oil and water can run off of the base When installing on a steel base the following guidelines should be implemented to properly design the system base 1 Use l beams in the skid where the screw compressor will be attached to the system base They shall run parallel to the package feet and support the feet for their full length 2 The compressor unit feet shall be continuously welded to the system base at all points of contact 3 The compressor unit shall not be mounted on vibration isolators in
120. 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 FIELD WELDING INSTRUCTIONS FOR TSOC AND WCOC The heat exchanger body is constructed in stainless steel while the stub connections are carbon steel The highly polished stub connections can give the appearance of stain less steel The following are requirements for welding to the socket weld fittings on Plate heat exchangers 1 Use a heat sink paste around the base of the connection These are available from a number of suppliers of welding materials Heat sink paste must be applied around the base of the connection prior to welding See Figure 6 2 Two pass welding is required stagger start stop region welding procedure in accordance with ASME Section 9 3 If possible use gas protection when welding to avoid oxidation of the surface As it is rarely possible to clean the root side of the weld by grinding or brushing to remove the root oxide it is optimal to use root gas 4 Welding should occur in two segments from 6 00 to 12 00 The maximum intersegment temperature should be 350 F Temperature should be verified with temperature indicating crayon or equivalent 5 The fitting may
121. on See Liquid Injec tion On Page 65 Thermosyphon See Thermosy phon Oil Cooling On Page 67 a dr EES Frick Oil Distillers 7 Oil Filter 8 Oil Heaters 7 Operating Volume Ratio 17 Optical Isolation 55 O Ring Compression 40 p pH 9 Power Feed 53 Power Fluctuations 13 Pressure Differential 15 Proper Installation of Electronic Equip ment 51 PVC Coated Metallic 53 PVC conduit 53 Q Quantum HD 11 15 55 R Reboot 55 Recovery Procedure 27 RXF Rotary Screw Compressor 14 Moveable Slide Valve 14 Shaft Seal 14 S Scaling 9 Self Lubricating 14 Separator 6 Severe Water Conditions 9 Shell And Coil Economizer System 10 Shipping Gauges 7 Shutdown 23 Liquid Injection 23 Package Valves 23 Solenoid Valves 23 Strainers 23 Sight Glass 7 15 27 Signal Wiring 53 Single Port Liquid Injection 17 Skip Frequencies 22 Slide Stop 22 Slide Valve 22 Slide Valve Piston 15 Sola Constant Voltage Cv Trans former 11 Solenoid Valve 17 Star Networks 55 Start Up Suction Strainer 21 Start Up CoolvvareTM 21 Discharge Temperature 21 Hand Expansion Valve 21 Initial Start Up 21 Prestart Checklist 21 Theoretical Discharge Temperature 21 Water Control Valve 21 Erick RXF ROTARY a e e UNITS BY JOHNSON CONTROLS Starter Package Wiring Diagram 12 Static Forces 9 Strainer 9 27 Stub Connections 9 Suction Check Valve 8 Suction Check Valve Bypass 15 27 Sucti
122. on Housing 6 14 Suction Isolation Valve 8 Suction Strainer 21 Surge Suppression 55 T Temperature Sensor 17 Thermosyphon Oil Cooling 8 17 21 Condensing Pressure 21 Drain Valve 8 Liquid Refrigerant 8 Refrigerant Side Safety Valve 8 Thermostatically Controlled Mixing Valve 8 Vapor Mixture 21 Welding 9 Threaded Metallic 53 Threaded Pvc Coated Metallic 53 TROUBLESHOOTING 36 37 Excessive Noise And Vibration 36 High Oil Temperature 36 Low Oil Temperature 36 Oil Temperature Fluctuates 36 Rapid Oil Loss 36 Slide Valve 37 U Uninterrupted Power Supply 55 Unit Data Plate 3 Unshielded 53 UN UNF Straight Threads 40 UPS 11 55 UPS Power 55 UPS Power System 11 V Variable Frequency Drives 53 Vessel 21 VFD 22 VFD Applications 52 VFD Output 52 Vibration Analysis 21 Vibration Data Sheet 62 Voltage Isolation 55 W Water Control Valve 21 Water Cooled Oil Cooling 17 Water Treatment 9 Welding 9 070 410 IOM NOV 14 Page 67 November 2014 Form Revisions p 17 Replaced double acting solenoid valve with 3 way motorized valve text p 31 Added PhD vibration analysis requirement text p 65 Revised multiple index entries Form 070 410 IOM 2014 11 JOHNSON CONTROLS Supersedes 070 410 IOM 2014 08 K 100 CV Avenue Subject without notice Johnson 5277077 E 17777 ublished in USA PDF Phone 717 762 2121 FAX 717 762 8624 2014 Johnson Controls Inc ALL
123. ontrol and has no user adjustments 1 Shut off control power 2 Remove DIN connector plug from transmitter 3 Loosen set screws 4 Remove transmitter unit 5 Install new transmitter unit 6 Tighten set screws 7 Apply DIN connector plug to transmitter 8 Turn on control power NOTICE For calibration of the Slide Valve unit refer to the Ana log Calibration instructions in publication 090 040 0 M DIN CONNECTOR 43650 A PRINTED CIRCUIT BOARD STAINLESS STEEL SENSOR WELL CAST ALUMINUM HOUSING Figure 35 Slide Valve Transmitter TEMPERATURE SENSOR REPLACEMENT DIN CONNECTOR W M3 SCREW SILICONE GASKET e SENSOR WELL HHH TRANSMITTER UNIT Figure 36 Temperature Transmitter This device is static sensitive Please follow proper ESD procedures when handling 1 Shut off control power 2 Remove DIN connector plug from transmitter See Figure 36 3 Unscrew knurled ring and remove transmitter unit RXF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE Page 35 070 410 IOM NOV 14 4 Apply thermal compound to new sensor assembly insert into thermal well and tighten knurled ring 5 Apply DIN connector plug to
124. oper operation of the Volumizer l control can be checked as follows 1 Set the compressor Vi to 2 2 then record the voltage that is shown on the Slide Valve calibration screen for the cur rent Slide Valve and 0 Slide Valve positions The difference between these voltages must be in the 1 35 1 65 Vdc range 2 Set the compressor Vi to 3 5 then record the voltage that is shown on the Slide Valve calibration screen for the cur rent Slide Valve and 0 Slide Valve positions The difference between these voltages must be in the 0 95 1 15 Vdc range 3 Set the compressor Vi to 5 0 then record the voltage that is shown on the Slide Valve calibration screen for the cur rent Slide Valve and 0 Slide Valve positions The difference between these voltages must be in the 0 73 0 93 Vdc range 4 If the above voltage measurements are all in range the Volumizer l is working properly If any of the voltages are out of range go to the troubleshooting section Proper installation of the Vi control valves and gaskets Is essential to the operation of this equipment Incorrectly installed parts may cause the compressor to operate at the RXF ROTARY SCREW COMPRESSOR UNITS Page 16 OPERATION n n SS Frick BY JOHNSON CONTROLS wrong Vi or to load or unload improperly Operation at the wrong compressor Vi can cause excessive power consump tion noise vibration or excessive oil foaming See Figures 19 21 for correct install
125. or 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 micro processor when the temperature sensor installed in the compressor discharge exceeds the setpoint Liquid refriger ant is then passed through the motorized expansion valve to the 3 way motorized valve Depending on the compressor s operating volume ratio Vi the microprocessor will select the flow of the liquid refrigerant to the optimum compressor port Dachkrga Copal urip Wahe Positiot fe Package Liquid Injection LIOC Configuration 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 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 070 410 IOM NOV 14 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 090 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 belo
126. order to hold down package vibration levels 4 The customer s foundation for the system base shall fully support the system base under all areas but most certainly under the l 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 shall be supported in pipe hangers preferably within 2 feet of vertical pipe run so that the lines won t move if RXF ROTARY SCREW COMPRESSOR UNITS INSTALLATION Page 5 070 410 IOM NOV 14 disconnected from the compressor See table for Allovvable Flange Loads ALLOVVABLE FLANGE LOADS MOMENTS ft lbf LOAD lbf AXIAL VERT AXIAL VERT Proper foundations and proper installation methods are vital
127. 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 tt 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 RXF ROTARY SCREW COMPRESSOR UNITS PROPER INSTALLATION OF ELECTRICAL EQUIPMENT Page 55 070 410 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
128. r 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 ts 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 unexplained 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 NOTICE RXF ROTARY SCREW COMPRESSOR UNITS PROPER INSTALLA
129. r elements should be removed and cleaned 1 Refer to CHANGING OIL Steps 1 thru 8 2 Remove coalescer head and gasket Discard the gasket 3 Remove and retain nut securing coalescer filter retainer 4 Remove retainer coalescer filter element s and two O rings Discard the filter element s 5 Install new coalescer filter element s NOTICE Frick SuperCoalescer element with drain feature on Models 24 101 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 RXF ROTARY SCREW COMPRESSOR UNITS Page 26 MAINTENANCE n n SS Frick BY JOHNSON CONTROLS 6 Replace coalescer filter retainer and nut Tighten the nut to 21 ft lb torque DO NOT OVERTIGHTEN NUT Excessive torque can damage the element and result in oil carryover Install jam nut and tighten 7 Install a new head gasket and replace the coalescer head 8 Tighten the head bolts first to finger tight then 65 ft lb NOTICE then 130 ft lb WHEN THE COMPRESSOR UNIT IS REPRESSURIZED RETIGHTEN SINCE HEAD BOLTS WILL LOOSEN 9 Refer to CHANGING OIL Steps 9 thru 14 CHANGING OIL DO NOT MIX OILS of different brands manufacturers or types Mixing of oils may cause excessive oil foaming nuisance oil level cutouts oil pressure loss gas or oil leakage and catastrophic compressor failure Shut down the unit when changing oil At the same ti
130. rers 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 for guidance 1 Only use Fricke oil filter elements or warranty claim may be denied 2 Participate in a regular periodic oil analysis program to maintain oil and system integrity Oil Analysis Kit part num ber 333Q0001853 3 Oil samples for analysis should be taken after the oil filter A 14 purge valve is provided between the filter and compressor MOTOR BEARINGS Lubricate motor bearings properly before start up Maintain subsequent lubrication as recommended by the motor manufacturer See Figure 33 OPERATING LOG The use of an operating log as shown in this manual see Table of Contents FORMS permits thorough analysis of the operation of a refrigeration system by those responsible for its maintenance and servicing Continual recording of gauge pressures temperatures and other pertinent informa tion enables the observer and serviceman to be constantly familiar with the operation of the system and to recognize immediately any deviations from normal operating condi tions It is reco
131. rges are known and provisions made for control operating cycles and defrosting periods are reasonable oil return is controlled and that high side condenser units control head pressures and temperatures are within system and compres sor design limits It is recommended that the entering vapor temperature to the compressor be superheated to 10 F above the refrigerant saturation temperature to ensure 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 070 410 SED SAFETY PRECAUTION DEFINITIONS RXF ROTARY SCREW COMPRESSOR UNITS GENERAL INFORMATION Page 3 070 410 IOM NOV 14 JOB INSPECTION Immediately upon arrival examine all crates boxes and exposed compressor and component surfaces for damage Unpack all items and check against shipping lists for any possible shortage Examine all items for damage in transit TRANSIT DAMAGE CLAIMS All claims must be made by consignee This is an ICC re quirement Request immediate inspection by the agent of the carrier and be sure the proper claim forms are executed Contact Johnson Controls Frick Sales Administration Department in Waynesboro PA to report damage or short age claims UNIT IDENTIFICATION Each compressor unit has two identification data plates The unit data plate containing unit model serial number and F
132. rick sales order number is mounted on the control panel support bracket The compressor data plate containing compressor model and serial number is mounted on the compressor body NOTICE When inquiring about the compressor or unit or order ing repair parts provide the MODEL SERIAL and FRICK SALES ORDER NUMBERS from these data plates Frick BY JOHNSON CONTROLS ROTARY SCREW COMPRESSOR UNIT SALES ORDER NUMBER MODEL NO TT SERIAL NO TT VAESES PRESSURE kPa HENNA 100 CV AVENUE WAYNESBORO PA 17268 PHONE 717 762 2121 UNIT DATA PLATE A DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury serious injury 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 to equipment and or minor injury NOTICE Indicates an operating procedure practice etc or portion thereof which is essential to highlight 070 410 1 NOV 14 RXF ROTARY SCREW COMPRESSOR UNITS Erick Page 4 GENERAL INFORMATION BY JOHNSON CONTROLS COMPRESSOR IDENTIFICATION 2 Frick BY JOHNSON CONTROLS ROTARY SCREW COMPRESSOR MODEL NO Pp SERIAL NO Pp MAX ALLOWABLE MAX DRIVER PRESSURE PSIG SPEED RPM Po WAYNESBORO PA 17268 COMPRESSOR DATA PLATE Rot
133. roblems 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 running 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 z 3 PHASE PLANT SUPPLY TRANSFORMER COPPER COPPER ELECTRONIC CONTROL Figure 39 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 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 us
134. s heavy grooving galling twisting breaking or similar severe signs of trouble Frick BY JOHNSON CONTROLS RECOMMENDED MAINTENANCE PROGRAM In order to obtain maximum compressor unit performance and ensure reliable operation a regular maintenance program should be followed see Maintenance Schedule 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 schedule 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 RXF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE Page 31 070 410 IOM NOV 14 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 maint
135. ssor 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 IB for acceptable package vibration readings Skip frequencies should be reviewed and verified annually Frick BY JOHNSON CONTROLS Maintenance This section provides instructions for normal maintenance a recommended maintenance program troubleshooting and correction guides typical wiring diagrams and typical P and diagrams This section must be read and understood before at tempting to perform any maintenance or service to the unit NORMAL MAINTENANCE OPERATIONS When performing maintenance you must take several pre cautions to ensure your Safety IF UNIT IS RUNNING PUSH STOP KEY TO SHUT DOWN THE UNIT DISCONNECT POWER FROM UNIT BEFORE PER FORMING ANY MAINTENANCE WEAR PROPER SAFETY EQUIPMENT WHEN COM PRESSOR UNIT IS OPENED TO ATMOSPHERE 4 ENSURE ADEQUATE VENTILATION TAKE NECESSARY SAFETY PRECAUTIONS RE QUIRED FOR THE REFRIGERANT BEING USED CLOSE ALL COMPRESSOR 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 critic
136. supply of flashing liquid on a shell and coil or DX economizer when the capacity falls below approximately 60 70 85 90 slide valve position This is done to improve compressor operating efficiency Please note however that shell and coil and DX economizers can be used at low compressor capacities in cases where efficien cy is not as important as ensuring 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 de creasing compressor capacity a back pressure regulator valve BPR is generally required on a Flash Economizer System Figure 11 in order to maintain some preset pressure difference between the subcooled liquid in the flash vessel and the evaporators If the back pressure regulator valve is not used on a flash economizer it is possible that no pressure difference will exist to drive liquid from the flash vessel to the evaporators since the flash vessel will be at suction pressure In cases where wide swings in pressure are 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 system feeding liquid to the flash vessel in batches The recommended economizer systems are shown in Figures 9 12 Notice that in all systems there must b
137. t so that slide valve travel time from full load to full unload or vice versa is a minimum of 30 seconds 070 410 IOM NOV 14 NOTICE A change in operating conditions such as vvinter to summer operation may require readjustment of slide valve travel time CIE o w gt 4 s SA Z L CONTROL VALVE PORT LABELS ENERGIZE b COIL YY2 TO LOAD VOLZCONT ENERGIZE a COIL YY1 TO UNLOAD Figure 18 VOLUMIZER II Vi CONTROL The RXF compressor is equipped with a special internal control that automatically adjusts the compressor volume ratio to the most efficient of three available steps 2 2 3 5 or 5 0 volume ratio This gives the compressor the ability to operate at varying operating conditions while minimizing power consumption by avoiding over or undercompression Solenoid valves 3 and 4 See Figures 19 21 and location on P 8 diagram represented by YY3 and YY4 control the Volumizer Il volume ratio control Oil is internally ported to apply hydraulic pressure to two stepping pistons in order to move the moveable slide stop to the optimum position The following chart shows the logic of solenoid operation to adjust the volume ratio SOLENOID 3 YY3 SOLENOID 4 YY4 Energized Energized Energized Deenergized Deenergized Deenergized Pr
138. ter when there is no oil in the unit otherwise the heater will burn out The oil heater will be energized whenever 120 volt control power is applied to the unit and the compressor is not running unless the 16 amp circuit breaker in micro enclosure is turned off or 15 amp fuse 1FU in the Plus panel is removed 070 410 IOM NOV 14 OIL FILTER S NOTICE Use of filter elements other than Frick may cause war ranty claim to be denied The oil filter s and coalescer filter element s shipped with the unit are best suited to ensure proper filtration and op eration of the system SUCTION ISOLATION 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 4 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 the cone button see Figure 4 BOTTOM Please design your system piping accordingly After removing the suction sealing disc confirm that the check valve hinge pin is in th
139. terference 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 38 CONTROL LJ TRANSFORMER ISOLATED CIRCUIT ELECTRONIC CONTROL CORRECT CONTROL TRANSFORMER NONISOLATED CIRCUIT INCORRECT Figure 38 070 410 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 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 Figure 39 Driving a ground stake at the electronic control may also cause additional p
140. the liquid level closer to the pump If the liquid is above the pump Increase the head of liquid Check alignment 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 an 4 Pump not up to capacity a Starving or cavitating increase suction pipe size or reduce length b Strainer partially clogged clean c Air leak in suction piping or along pump shaft d Running too slowly is motor the correct speed and is it wired up correctly e Relief valve set too low or stuck open f Pump worn out g Tighten end clearance h Head position incorrect 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 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 e 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 Examination of a pump that has gradually lost its ability to deliver capacity or pressure would show a smooth wear pat tern on all parts Rapid wear shows up a
141. 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 1 Coat the idler pin with refrigeration oil and place idler and bushing on idler pin in the head If replacing a carbon graphite bushing refer to INSTALLATION OF CARBON GRAPHITE BUSHINGS 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 ROTOR HUB SPRING MECHANICAL SEAL ROTARY MEMBER Figure 32 Frick BY JOHNSON CONTROLS 4 Place tapered installation sleeve on shaft Refer to Figure 32 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 5 Place seal spring on the shaft against the rotor hub Refer to Figure 32 6 Slide rotary member with lapped contact surface facing away from the spring over installation sleeve on shaft until just contacting the spring Do
142. transmitter 6 Turn on control power NOTICE For calibration instructions refer to Quantum HD Op erator s Manual 090 040 OIL LEVEL TRANSMITTER REPLACEMENT The Oil Level Transmitter is located on the front of the sepa rator near the bottom center See Figure 37 DIN PLUG FRONT STATUS LED s 4 PLUG SET SCREW 2 gt gt bu SENSOR VVELL DIN PLUG NN TRANSMITTER UNIT 43650 Figure 37 Oil Level Transmitter 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 If it is necessary to replace the well the separator must be purged and the oil drained Refer to the section CHANGING OIL 1 Shut off control power 2 Remove DIN connector plug from transmitter 3 Loosen set screws 4 Remove transmitter unit 5 Install new transmitter unit 6 Tighten set screws 7 Apply DIN connector plug to transmitter 8 Turn on control power TEMPERATURE and or PRESSURE ADJUSTMENT All temperature and pressure sensors are factory set If cali bration Is required refer to Analog Calibration for tempera ture or pressure in QUANTUM HD publication
143. ually missing is not insulated or improperly sized RXF ROTARY SCREW COMPRESSOR UNITS Page 52 PROPER INSTALLATION OF ELECTRICAL EQUIPMENT n n SS 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 nolse Frick requirements for the ground conductor are 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 For Direct Coupled Package Mounted Starters the ground between the motor and the starter may need to be made externally Figure 40 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 connec tion at each end will maximize metal to metal contact MOTOR STARTER Figure 40 VFD APPLICATIONS The primary ground conductor that accompanies the three phase supply must be stranded coppe
144. ulic System 15 Initial Start Up 21 Inlet Service Valve 24 J Jack 6 L Liquid Carryover 7 Liquid Injection 9 17 Analog Input Signal 19 Danfossliquid Injection Valve 18 Digital Input Signal 19 Dual Dip Tube Method 10 Enter Push Button 18 High Stage Units 10 ICAD Industrial Control Actuator with Display 18 ICM Valve 19 Low Condensing Pressures 10 Mod 19 Motorized Industrial Control Valve 18 070 410 IOM NOV 14 Page 66 Opening Degree 19 Parameters 18 Parameter List 20 Analog Output Signal 20 Automatic Calibration 20 Digital Input Function 20 Fail Safe 20 ICM Configuration 20 Main Switch 20 Mode 20 Modulating Mode 20 Old Alarms 20 Password 20 Solenoid Valve 19 Liquid Injection Oil Cooling 21 Liquid Injection Thermal Expansion Valve 21 Liquid Loading 21 Liquid Refrigerant 17 Liquid Starvation 21 Low Voltage 11 Lubrication System 14 M Magnetic Field 53 Main Oil Injection Port 15 Maintenance 23 Abnormal Vibration 31 Bare Compressor Mounting 35 Bearing Failure 23 Coalescer Filter Element 26 DIN Connector Plug 35 Discharge Service Valve 26 Disconnect Power 23 Disconnect Switches 24 Drain Valve 26 Dry Nitrogen 23 Filter Elements 32 Isolation Valves 23 Leaks 31 Linear Transmitter 35 Liquid Injection Strainer 25 Liquid Injection Valves 23 Liquid Refrigerant 23 Low Pressure Transducer 24 Moisture 32 Motor Bearings 32 Lubrication 32 Noise 31
145. ust also be used in locating the lifting ring Appropriate adjustment in the lifting point should be made to compensate for motor weight Adjustment of the lifting point must also be made for any additions to the standard package such as an external oil cooler etc as the center of balance will be affected Figure 2 RXF 58 101 The unit can be moved with a forklift by forking under the wooden skid if provided or it can be skidded into place with pinch bars by pushing against the skid NEVER MOVE THE UNIT BY PUSHING OR FORKING AGAINST THE SEPARATOR SHELL OR ITS MOUNTING SUPPORTS SKID REMOVAL This screw compressor package may be top heavy Use caution to prevent unit from turning over If the unit is rigged into place the wooden skid can be re moved by taking off the nuts and bolts that are fastening the RXF ROTARY SCREW COMPRESSOR UNITS Page 6 INSTALLATION n n SS Frick BY JOHNSON CONTROLS 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 COMPRESSOR MOTOR COUPLINGS RXF units are arrang
146. ute supply of refrigerant for oil cooling The evaporator supply must be secondary to this consideration Failure to follow these requirements causes wire draw which can result in damage to the expansion valve loss of oil cooling and intermittant oil cooling One method of accomplishing this is described below DUAL DIP TUBE METHOD The dual dip tube method uses two dip tubes in the receiv er The liquid injection tube is below the evaporator tube to assure continued oil cooling when the receiver level is low See Figure 8 2 TO EVAPORATOR TO COMPRESSOR p s O L COOLING FROM CONDENSER SYSTEM RECEIVER LOCATE TO PROVIDE 5 MIN LIQUID SUPPLY Figure 8 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 screw compressor unloads the economizer port will drop in pressure level eventually being fully open to suc RXF ROTARY SCREW COMPRESSOR UNITS Page 10 INSTALLATION n n SS Frick BY JOHNSON CONTROLS tion Because of this an output from the microprocessor is generally used to turn off the
147. ve 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 stralner plugged 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 the suction pipe c Vibrating from cavitation misalignment or damaged parts Pressure Gauge Discharge Port 1 High reading would indicate High viscosity and small and or long discharge line Gate valve partially closed Filter plugged 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 h Oo has solidified Relief valve set too high 2 Low reading would indicate a Relief valv
148. voir Some oil however is discharged as a mist which does not separate readily from the gas flow and is carried past the oil charge reservoir The coalescer filter element then coalesces the oil mist into droplets the droplets of oil fall to the bottom of the coalescer section of the oil separator The return of this oil to the compressor Is controlled by a hand expansion valve HV1 See Figure 17 NOTICE Open HV1 only enough to keep the coalescer end of the separator free of oil RXF ROTARY SCREW COMPRESSOR UNITS OPERATION Page 15 070 410 IOM NOV 14 COMPRESSOR SUCTION V 1 5 2 COMPR DISCHARGE I SEPARATOR gt DISCHARGE FROM OIL OUTLET Se OIL RESERVOIR OIL OUTLET Figure 17 The sight glass located near the bottom of the coalescer section of the oil separator should remain empty during normal operation If an oil level develops and remains in the sight glass a problem in the oil return separation system or compressor operation has developed Refer to Maintenance for information on how to correct the problem NOTICE Normal operating level is between t
149. w side system pressure using the suction check valve bypass NOTICE Recover or transfer all refrigerant vapor in accordance with local ordinances before opening to atmosphere The separator MUST be equalized to atmospheric pressure RXF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE Page 25 070 410 IOM NOV 14 Oil entrained refrigerant may vaporize causing a separa tor pressure increase Repeat transfer and recovery procedure if necessary 3 Close strainer isolation valves Remove the large plug from the bottom of the strainer and remove the element from the strainer 4 Wash the element in solvent and blow clean with air 5 Replace the cleaned element and removed plug Open strainer isolation valves 6 Isolate the low pressure transducer PE 4 to prevent dam age during pressurization and leak test 7 Pressurize and leak test Evacuate unit to 29 88 Hg 1000 microns 8 Open the suction and discharge service valves and the low pressure transducer Close disconnect switches for the compressor Start the unit LIQUID INJECTION STRAINER To clean the liquid injection strainer the unit must be shut down The procedure is as follows 1 Push STOP key to shut down the unit then open discon nect switches for the compressor 2 Close the liquid supply service valve located before the liquid solenoid 3 Immediately screw in the manual solenoid valve stem to relieve liquid refrigerant pressure trapp
150. w the Control Setpoint Integration Time This setpoint controls the influence that the Integral component exerts on the PI 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 I O Board One of the following will be shown e None e Analog Board 1 e Analog Board 2 I O 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 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
151. works the problem is electrical SLIDE STOP WILL NOT FUNC Solenoid coil burned out Replace coils TION IN EITHER DIRECTION Solenoid valve sticking Replace valve SLIDE VALVE and or SLIDE Slipper seals worn out or damaged STOP WILL NOT MOVE Unloader spindle or slide valve jammed Slide stop indicator rod jammed 070 410 IOM NOV 14 RXF ROTARY SCREVV COMPRESSOR UNITS MAINTENANCE dr SS Frick BY JOHNSON CONTROLS COMPRESSOR PORT LOCATIONS RXF 12 19 16 Thermowell Suction Temp 3 Low Vi Liquid Injection d 4 High Vi Liquid Injection Page 38 a SN m m O 3 f TA D 21 Evacuation Port na G fel 8 a 5 0 Eh 4 20 Oil Pressure LI J LI J 1 Main Oil Supply gp Lo m O 6 Qj A BS E m ZE A O O H 18 Main Oil Injection ZZ CPNS Q l mi Q Q z2 8 Closed 11
152. ystem requirements 5 Hydraulic cylinders to operate the slide valve 6 Compressor housing suitable for 350 PSI pressure 7 Most bearing and control oil is vented to closed threads in the compressor instead of suction port to avoid performance penalties from superheating suction gas 8 The shaft seal is designed to maintain operating pressure on the seal well below discharge pressure for increased seal life 9 Oil is injected into the rotors to maintain good volumetric and adiabatic efficiency even at very high compression ratios It is mandatory that the coupling center be removed and the direction of motor rotation be confirmed before run ning the compressor Proper rotation of the compressor shaft is clockwise looking at the end of the compressor shaft Failure to follow this step could result in backward compressor rotation which can cause compressor failure or explosion of the suction housing RXF ROTARY SCREW COMPRESSOR UNITS Page 14 OPERATION n n SS Frick BY JOHNSON CONTROLS COMPRESSOR LUBRICATION SYSTEM The RXF compressor is designed specifically for operation without an oil pump for high stage service Boosters and some low differential pressure applications will require the demand pump option The lubrication system on an RXF screw compressor unit performs several functions 1 Lubricates the rotor contact area allowing the male rotor to drive the female rotor on a cushioning film of oil

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