Frick RWB II 480 Installation Operation & Maintenance Download Page 2

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RWB II ROTARY SCREW COMPRESSOR UNITS

INSTALLATION - OPERATION - MAINTENANCE

S70-200 IOM
Page 2

Contents

Maintenance

GENERAL INFORMATION ............................................. 22
NORMAL MAINTENANCE OPERATIONS ...................... 22
GENERAL MAINTENANCE ............................................ 22
COMPRESSOR SHUTDOWN and START-UP ............... 22
GENERAL INSTRUCTIONS FOR REPLACING

COMPRESSOR UNIT COMPONENTS. .................. 23

ANALYSIS and CORRECTION ................................ 31

SERVICING THE COLD-START VALVE ......................... 31
PRESSURE TRANSDUCERS - TESTING ...................... 31
PRESSURE TRANSDUCERS - REPLACEMENT .......... 32
SV POSITION POTENTIOMETER

REPLACEMENT AND ADJUSTMENT .................... 33

VOLUMIZER® POTENTIOMETER

REPLACEMENT AND ADJUSTMENT .................... 33

TEMPERATURE and/or PRESSURE ADJUSTMENT .... 34
OIL LEVEL TRANSMITTER ............................................ 34
REPLACEMENT ............................................................. 34
TROUBLESHOOTING

RWB II COMPRESSOR ........................................... 35
OIL SEPARATION SYSTEM .................................... 35
HYDRAULIC SYSTEM ............................................. 36
LIQUID INJECTION OIL COOLING SYSTEM ......... 37
DEMAND PUMP SYSTEM ...................................... 38

THERMAL EXPANSION VALVES ................................... 39
JORDAN TEMPERATURE REGULATOR VALVE ........... 40
BARE COMPRESSOR MOUNTING ............................... 41
GREASE COMPATIBILITY .............................................. 41
NLGI Grease Compatibility Chart .................................... 41

P & I DIAGRAM .............................................................. 42

PROPER INSTALLATION OF ELECTRONIC EQUIPMENT

IN AN INDUSTRIAL ENVIRONMENT ...................... 46

FORMS

OPERATING LOG SHEET ....................................... 49
COMPRESSOR PRESTART CHECKLIST .............. 50
START-UP REPORT ................................................ 51
VIBRATION DATA SHEET ........................................ 53

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.

Indicates a potentially hazardous situation or practice which, if not avoided, will result in death
or serious injury.

SAFETY PRECAUTION DEFINITIONS

Indicates a potentially hazardous situation or practice which, if not avoided, will result in damage
to equipment and/or minor injury.

NOTE:

Indicates an operating procedure, practice, etc., or portion thereof which is essential to highlight.

PREFACE ......................................................................... 3
DESIGN LIMITATIONS ...................................................... 3
JOB INSPECTION ............................................................ 3
TRANSIT DAMAGE CLAIMS ............................................ 3
COMPRESSOR and UNIT IDENTIFICATION ................... 3

Installation

FOUNDATION ................................................................... 4
RIGGING and HANDLING ................................................ 4
SKID REMOVAL ................................................................ 4
MOTOR MOUNTING ......................................................... 5
CHECKING MOTOR/COMPRESSOR ROTATION ............ 5
COMPRESSOR/MOTOR COUPLINGS

INSTALLATION .......................................................... 5

Operation

Summary of Contents for RWB II 480

Page 1: ...ANUAL CONTAINS RIGGING ASSEMBLY START UP AND MAINTENANCE INSTRUCTIONS READ THOROUGHLY BEFORE BEGINNING INSTALLATION FAILURE TO FOLLOW THESE IN STRUCTIONS COULD RESULT IN DAMAGE OR IMPROPER OPERA TION...

Page 2: ...in death or serious injury Indicates a potentially hazardous situation or practice which if not avoided will result in death or serious injury SAFETY PRECAUTION DEFINITIONS Indicates a potentially ha...

Page 3: ...r slugging protection that load surges are known and provisions made for control operat ing cycles and defrosting periods are reasonable and that high side condensers are sized within system and compr...

Page 4: ...r package When installing on the upper floors of buildings extra pre cautions should be taken to prevent normal package vibra tion from being transferred to the building structure It may be necessary...

Page 5: ...the shaft by tightening the clamp screws Torque is transmitted from the motor through the elas tomeric gear which floats freely between the hubs Install as follows 1 Slide one hub onto each shaft as...

Page 6: ...HE SAME OR DER Mark the adjoining bolt holes of each part the two hubs the two disc packs and the center spool so they are put back together in the same position 2 Mount the coupling hubs on their res...

Page 7: ...arings it is necessary to secure the two cou pling hubs with a bolt to prevent them from drifting apart when rotating 2 Rotate both coupling hubs several revolutions until they seek their normal axial...

Page 8: ...salignment is within specified tolerance 10 Check parallel lateral misalignment by positioning dial indicator so the stem is in contact with the rim of the com pressor hub at 3 o clock as shown in Fig...

Page 9: ...turers or types Mixing of oils may cause excessive oil foaming nuisance oil level cutouts oil pressure loss gas or oil leakage and catastrophic compressor failure Use of oils other than Frick Oil in F...

Page 10: ...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 s...

Page 11: ...upply of high pres sure 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 l...

Page 12: ...r volume quanti ty of refrigerant required for 5 minutes of liquid injection oil cooling are given in the following table LIQUID LINE SIZE and RECEIVER VOLUME LINE SIZE POUND LIQUID RWB II SCH 80 OD P...

Page 13: ...2 HIGH PRESSURE LIQUID INTERMEDIATE PRESSURE GAS TO COMPRESSOR SUCTION STR VCK SUBCOOLED HIGH PRESSURE LIQUID TO EVAPORATOR ECONOMIZER COOLER WIRING ECON2 HV 2 HIGH PRESSURE LIQUID INTERMEDIATE PRESS...

Page 14: ...rter Wiring Diagram Figure 15 All Frick motor starter pack ages have the timer relay as standard Motor starter and interlock wiring requirements are shown in the Starter Wiring Diagram All of the equi...

Page 15: ...5 300 5 300 5 100 5 50 5 250 800 5 800 5 500 5 400 5 300 5 100 5 50 5 300 1000 5 1000 5 600 5 500 5 400 5 100 5 50 5 350 1000 5 800 5 500 5 500 5 100 5 100 5 400 800 5 600 5 500 5 200 5 100 5 450 1000...

Page 16: ...pressure for increased seal life 10 Oil injected into the rotors to maintain good volumetric and adiabatic efficiency even at very high compression ra tios 11 Shaft rotation clockwise facing compresso...

Page 17: ...n S90 010 O COLD START 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 acro...

Page 18: ...inder port SC 1 and enters the unload side of the cylinder Simultaneously oil contained in the load side of the cylinder flows out com pressor port SC 2 through valve ports B andT to compressor closed...

Page 19: ...NJECTION 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 refriger ant into on...

Page 20: ...leakage into the system during shut down However on high stage or booster systems with check valve HV 2 can remain open HV 2 also should be closed on systems that utilize autocycle to restart the comp...

Page 21: ...gnment and adjust as necessary NORMAL START UP PROCEDURE 1 Confirm system conditions permit starting the compressor 2 Press the RUN key 3 Allow the compressor to start up and stabilize Press the AUTO...

Page 22: ...cable Re move tags 3 Close disconnect switches for compressor motor and oil pump starters 4 Turn off oil heater circuit breaker 5 Perform checkpoints on prestart check list then start unit GENERAL MAI...

Page 23: ...disconnect switches for compressor and oil pump motor starters If dual oil filters are installed open the outlet then inlet ser vice valves of the standby filter Open inlet service valve slowly to pr...

Page 24: ...er filter element and 2 O rings Discard filter elements 5 Install new coalescer filter element s Seat element in center of locating tabs on separator bulk head 6 Replace coalescer filter retainer and...

Page 25: ...RBON GRAPHITE BUSHINGS fFigure 22 Thrust Bearing assembly GG HJ HL Figure 23 Thrust Bearing assembly AS AK AL 5 Insert a brass bar or piece of hardwood in the port open ing and between rotor teeth to...

Page 26: ...ousing 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...

Page 27: ...ize pumps and 0 005 for AS AK and AL size pumps Pump Distance in on O D End Clearance Size of Bearing Housing in GG 7 16 003 HJ HL 9 16 003 AS AK AL 1 2 003 INSTALLATION OF CARBON GRAPHITE BUSHINGS Wh...

Page 28: ...ck alignment d May have a bent shaft or rotor tooth Straighten or replace e May be a foreign object trying to get into the pump through the suction port 4 Pump not up to capacity a Starving or cavitat...

Page 29: ...NTENANCE PROGRAM In order to obtain maximum compressor unit performance and ensure reliable operation a regular maintenance pro gram should be followed The compressor unit should be checked daily for...

Page 30: ...se responsible for its maintenance and servicing Continual recording of gauge pressures tempera tures and other pertinent information enables the observer and serviceman to be constantly familiar with...

Page 31: ...ssively 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 retu...

Page 32: ...ler 5 Disconnect transducer leads by loosening the terminal screws for the transducer to be changed 6 Tape a 3 ft length of pull wire to the leads of the transdu cer to be removed Below 0 PSIG measure...

Page 33: ...next step Adjustment of POT 2 and POT 1 are interactive and POT 1 may require adjustment to allow POT 2 to come into range Now completely increase the slide stop The display at this time should indica...

Page 34: ...front of the sepa rator near the bottom center See Figure 30 The linear transmitter with hermetic enclosure is based on the capacitive measuring principle It features removable elec tronics from the...

Page 35: ...Frick Factor or Frick for assistance NOTE Troubleshooting the compressor is limited to identifying the probable cause If a mechanical problem is suspected contact the Frick Service Department DO NOT A...

Page 36: ...OAD Dirt inside solenoid valve preventing valve from operating both ways clean Solenoid may be mechanically actuated by inserting a piece of 3 16 rod against armature pin and pushing spool to opposite...

Page 37: ...roblem Thermal valve power head lost charge replace Liquid strainer blocked clean Liquid solenoid coil failed replace Excessive load Thermovalve undersized Reduce load or install larger thermovalve LO...

Page 38: ...RENTIAL ALARM OIL PRESSURE FLUCTUATES Liquid injection overfeeding or refrigerant flood back from system Make necessary adjustments or corrections NOISE and VIBRATION Pump strainer blocked Clean Liqui...

Page 39: ...achieved by increasing or decreasing discharge tube size NOTE DO NOT ATTEMPT TO ADJUST SUPERHEAT ADJUSTMENT STEM ON BOTTOM OF VALVE IN AN EF FORTTO CHANGETHEVALVE S PERFORMANCE THIS ADJUSTMENT IS PRE...

Page 40: ...seems to be a total ab sence of oil cooling you will need to check the action of the valve To check the action you will need to remove the cap flange and disc guide If the hole in the valve plate is...

Page 41: ...closed the oil pressure should be 1 1 times suction pressure 15 psi Differential pressure is defined as de fined as discharge pressure minus suction pressure The shutdown should occur if the conditio...

Page 42: ...RWB II ROTARY SCREW COMPRESSOR UNITS MAINTENANCE S70 200 IOM Page 42 P I DIAGRAM...

Page 43: ...RESSURE SAFETY VALVE SP SUCTION PRESSURE STR STRAINER TAH HIGH TEMPERATURE ALARM TAHH HIGH TEMPERATURE SHUTDOWN TAL LOW OIL TEMPERATURE ALARM TALL LOW OIL TEMPERATURE SHUTDOWN TC TEMPERATURE CONTROLLE...

Page 44: ...RWB II ROTARY SCREW COMPRESSOR UNITS MAINTENANCE S70 200 IOM Page 44 P I DIAGRAM LIQUID INJECTION SINGLE PORT P I DIAGRAM LIQUID INJECTION DUAL PORT...

Page 45: ...RWB II ROTARY SCREW COMPRESSOR UNITS MAINTENANCE S70 200 IOM Page 45 P I DIAGRAM LIQUID INJECTION BOOSTER...

Page 46: ...be used in conjunction with the NEC code WIRE SIZING Size supply wires one size larger than required for am perage draw to reduce instantaneous voltage dips caused by large loads such as heaters and c...

Page 47: ...the same conduit with 120 volt wires Fig ure 42 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...

Page 48: ...estroy the electronics If the electronic control panel has a starter built into the same panel be sure to run the higher voltage wires where indicated by the manufacturer EMI from the wires can in ter...

Page 49: ...RWB II PLUS ROTARY SCREW COMPRESSOR UNITS FORMS S70 200 IOM Page 49 OPERATING LOG SHEET...

Page 50: ...ontrol wiring is run in a separate conduit from oil pump and compressor motor wiring __ Confirm no high voltage wiring enters the micro panel at any point __ Check current transformer for correct sizi...

Page 51: ...rd 1 Serial _____________ Rev _____ U13 Analog Ver _________ and Date ______________ Analog Board 2 Serial _____________ Rev _____ U13 Analog Ver _________ and Date ______________ Compressor Motor Inf...

Page 52: ...nment Ambient Temperature at Time of Alignment _______ Oil Separator Temperature at Time of Alignment ________ Motor Coupling Type ___________ Size ___________ Distance Between Coupling Hub Faces ____...

Page 53: ...____________________ Installing Contractor _____________________________ Address ______________________________________ Service Technician ______________________________ Equipment ID As in Microlog __...

Page 54: ...333Q0001326 Relay 3PDT 115V 1 ALL 333Q0000206 UNIT Temperature Probe TE 1 4 1 ALL 640A0035H01 Transducer Pressure 0 200 PSIA PE 4 Quantum only 1 ALL 111Q0280887 Transducer Pressure 0 500 PSIA PE 1 3 Q...

Page 55: ...RWB II ROTARY SCREW COMPRESSOR UNITS NOTES S70 200 IOM Page 55...

Page 56: ...Q NET can be applied to both new and existing systems Q NET means precise control 24 hours a day seven days a week Q NET distributed architecture means faster easier economical installations Q NET del...

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