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RWF ROTARY SCREW COMPRESSOR UNITS

MAINTENANCE

S70-600 IOM
Page 26

MAINTENANCE SCHEDULE

OPERATING LOG

The use of an operating log as included in this manual (see Table of Contents) permits thorough analysis of the operation of a
refrigeration system by those 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 the operation of the
system and to recognize immediately any deviations from normal operating conditions. It is recommended that readings be taken
at least every four hours.

This schedule should be followed to ensure trouble-free operation of the compressor unit.

CLEAN OIL STRAINERS

CLEAN LIQUID
STRAINERS

REPLACE FILTER

REPLACE COALESCER

CHECK AND CLEAN
SUCTION STRAINER

95000

90000

85000

80000

75000

70000

65000

60000

55000

50000

45000

40000

35000

30000

25000

20000

15000

10000

8000

5000

1000

200

MAINTENANCE

FREQUENCY OR HOURS OF OPERATION (MAXIMUM)

CHANGE OIL

As directed by oil analysis

OIL ANALYSIS

Then every 6 months

VIBRATION ANALYSIS

Every 6 months, more frequently if levels increase

REPLACE SEAL

When leak rate exceeds 7 - 8 drops per minute

CHECK COUPLING

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Summary of Contents for RWF

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 OF THE UNIT S70 600 IOM MAY 2001 File SERVICE MANUAL Section 70 Replaces S70 600 IOM MAR 2000 Dist 3 3a 3b 3c RWF ...

Page 2: ...UAL 19 STRAINER DEMAND OIL PUMP 19 STRAINER LIQUID INJECTION 20 COALESCER FILTER ELEMENT S 20 CHANGING OIL 20 DEMAND PUMP DISASSEMBLY 21 DEMAND PUMP ASSEMBLY 22 TROUBLESHOOTING THE DEMAND PUMP 23 PREVENTATIVE MAINTENANCE 24 RECOMMENDED MAINTENANCE PROGRAM 25 VIBRATION ANALYSIS 25 MOTOR BEARINGS 25 OIL QUALITY and ANALYSIS 25 OPERATING LOG 26 MAINTENANCE SCHEDULE 26 TROUBLESHOOTING GUIDE 27 ABNORMA...

Page 3: ...ges 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 compres sor design limits It is recommended that the entering vapor temperature to the compressor be superheated to 10 F above the refriger ant saturation temperature This assures that all refrigerant at the compressor suction is in the vap...

Page 4: ...nly under the I beams that support the compressor 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 to use rubber or spring isolators or a combi nation of both to prevent the transmission of compressor vibration directly to the structure However this m...

Page 5: ... 720C0045H0_ Power hp 424 740 Speed rpm 3 000 3 000 Torque in lb 13 356 23 310 Includes 1 5 service factor COUPLING TORQUE RATINGS COUPLING PART NO TORQUE 720C0044H0_ 720C0045H0_ Max continuous 17 500 in lb 24 300 in lb Peak overload 35 000 in lb 48 600 in lb OIL PUMP COUPLING Compressor units with direct motor pump coupled pumps need no pump motor coupling alignment since this is main tained by t...

Page 6: ...shell vessel cooling the oil to within 15 F of that temperature The vapor at con densing pressure is vented to the condenser inlet and reliquified This method is the most cost effective of all cur rently applied cooling systems since no compressor ca pacity is lost or compressor power penalties incurred The vapor from the cooler need only be condensed not com pressed Refrigerant flow to the cooler...

Page 7: ...om a high side source high stage compressor discharge This should be a 3 8 line connected into the solenoid valve provided This gas is required by the expansion valve external port to control oil temperature It is IMPERATIVE that an uninterrupted supply 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 receiv...

Page 8: ...xchanger It is im portant to establish regular cleaning schedules Cleaning A 3 solution of Phosphoric or Oxalic Acid is recommended Other cleaning solutions can be obtained from your local distributor but they must be suitable for stain less 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 exchan...

Page 9: ...t 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 compres sor Also piston type check valves are recommended for...

Page 10: ...supplied with a QUANTUM 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 NOTE All customer connections are made in the single box control mounted on the oil separator This is the ONLY electrical enclosure and it sho...

Page 11: ...0 5 100 5 500 1000 5 800 5 600 5 200 5 100 5 600 1200 5 1000 5 800 5 200 5 100 5 700 1200 5 1000 5 200 5 200 5 800 1000 5 300 5 200 5 900 1200 5 300 5 200 5 1000 300 5 200 5 1250 400 5 200 5 1500 500 5 300 5 MINIMUM BURDEN RATINGS The following table gives the minimum CT burden ratings This is a function of the distance between the motor starting package and the compressor unit BURDEN MAXIMUM DIST...

Page 12: ... from superheating suction gas 9 Shaft seal design to maintain operating pressure on seal well below discharge pressure for increased seal life 10 Oil injected into the rotors to maintain good volumetric and adiabatic efficiency even at very high compression ratios 11 Shaft rotation clockwise facing compressor suitable for all types of drives SEE FOLLOWING CAUTION Compressor rotation is clockwise ...

Page 13: ... more tightly See the SUCTION CHECK VALVE BYPASS section for operation NOTE For alarm descriptions and shutdown or cutout parameters see publication S90 010 O 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 D...

Page 14: ...Close valve at BP bypass Booster Compressor Loading The compressor loads when MSV solenoid YY2 is energized and oil flows from the oil manifold through valve ports P and B to cylinder port SC2 and enters the load side of the cylinder Simultaneously oil contained in the unload side of the cylinder flows out cylinder port SC1 through valve ports A andT to compressor suction Booster Compressor Unload...

Page 15: ...swing duty applications 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 refriger ant into one of two ports optimally located on the compressor This minimizes the performance penalty incurred with liquid injection oil cooling The dual port system cont...

Page 16: ... option utilized on multiple compressor plants On high stage systems check valve CK 1 should be installed with a 40 psi spring to avoid the possibility of back feeding to a shut down compressor from a common economizer ves sel On booster systems check valve CK 1 should be installed with a 15 psi spring to avoid the possibility of air ingress into the system if the system suction pressure is below ...

Page 17: ...or compressors with Liquid Injection Oil Cooling Because the discharge temperature is controlled by the Liquid Injection Thermal Expansion Valve you will not be able adjust for the correct oil flow by using the discharge temperature Before the initial startup of the compressor close the hand expansion valve completely Open the valve back up and count the turns that it takes to fully open the valve...

Page 18: ...witches 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 MAINTENANCE Proper maintenance is important in order to assure long and trouble free service from your screw compressor unit Some areas critical to good compressor operation are 1 Keep refrigerant and oil clean and dry avoid moisture contamin...

Page 19: ...if ferential alarm 2 Close outlet then inlet service valves of filter being ser viced 3 Open bleed valve and purge pressure from the oil filter cartridge NOTE Recover or transfer all refrigerant va por in accordance with local ordinances before open ing to atmosphere 4 Remove the plug from the bottom of the filter canister and drain the oil Remove the canister cover and discard the gasket Remove t...

Page 20: ...etainer and nut Torque nut to 21 ft lb DO NOT OVERTIGHTEN NUT 7 Install a new manway gasket and replace manway cover 8 Tighten manway bolts NOTE RETIGHTEN AFTERTHE COMPRESSOR UNIT IS REPRESSURIZED SINCE MANWAY BOLTS WILL LOOSEN 9 Refer to CHANGING OIL Steps 9 through 14 CHANGING OIL DO NOT MIX OILS of different brands manufacturers or types Mixing of oils may cause excessive oil foaming nuisance o...

Page 21: ...knut counterclockwise and remove locknut See Fig ure 18 or 19 6 Loosen two setscrews in face of bearing housing and turn thrust bearing assembly counterclockwise and remove from casing See Figure 18 or 19 7 GG HJ HL Remove snap ring from shaft See Figure 1 AS AK AL Remove bearing spacer from shaft See Figure 2 8 Remove brass bar or piece of hardwood from port opening 9 The rotor and shaft can now ...

Page 22: ...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 re frigeration oil 3 Start seal seat in seal housing bore If force is neces sary protect seal face with a clean cardboard disc and gen tly tap it in place with a piece of wood Be sure seal seat is completely seated in the bore 4 Place tapered installation sleeve on s...

Page 23: ...ional end clear ance 0 004 for GG HJ and HL size 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 When installing carbon graphite bushings extreme care must be taken to prevent breaking Carbon graphite is a brittle material and easily cracked If cracked t...

Page 24: ... 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 ...

Page 25: ...Only use Frick refrigeration oil or high quality refrigera tion oils approved by Frick for your application 2 Only use Frick filter elements Substitutions must be approved in writing by Frick engineering or warranty claim may be denied 3 Participate in a regular periodic oil analysis program to maintain oil and system integrity THE FACTORY INSTALLED RECOMMENDED LUBRICANT IS LISTED ON THE MOTOR DAT...

Page 26: ...ely any deviations from normal operating conditions It is recommended that readings be taken at least every four hours This schedule should be followed to ensure trouble free operation of the compressor unit CLEAN OIL STRAINERS CLEAN LIQUID STRAINERS REPLACE FILTER REPLACE COALESCER CHECK AND CLEAN SUCTION STRAINER 95000 90000 85000 80000 75000 70000 65000 60000 55000 50000 45000 40000 35000 30000...

Page 27: ...stment increasing the liquid feed could lead to other problems Under low load conditions the liquid in jection system may have a tendency to overfeed The high suction superheat condition moreover may only be tempo rary When system conditions return to normal the units liq uid injection will overfeed and oil temperature will drop In solving the wrong problem a new problem was created When an operat...

Page 28: ... section External Trans ducers for Board 1 to identify the wiring harness connectors 4 Loosen screw and disconnect wiring harness connector from transducer 5 Unscrew the transducer using a wrench on the metal hex at the base of the transducer DO NOT ATTEMPT TO LOOSEN OR TIGHTEN TRANSDUCERS BY THEIR TOP CASING 6 Install new transducer 7 Reconnect the wiring harness to the transducer 8 Reopen the tr...

Page 29: ...e with the slide valve fully unloaded and the compressor running The Operating dis play at this time should indicate a slide valve position of 0 If the display is greater than 0 adjust potentiometer POT 4 on the SBC until 0 is indicated If 0 is not attainable get as close as possible and then proceed to the next step The adjustments of POT 4 and POT 3 are interactive and POT 3 may require adjustme...

Page 30: ... ESD proce dures when handling 1 Shut off control power 2 Remove DIN connector plug from transmitter See Figure 27 3 Unscrew knurled ring and remove transmitter unit 4 Apply thermal compound to new sensor assembly insert into thermal well and tighten knurled ring 5 Apply DIN connector plug to transmitter 6 Turn on control power NOTE The temperature sensor is factory set If calibra tion is required...

Page 31: ...ause If a mechanical problem is suspected contact the Service Department Frick DO NOT ATTEMPT TO DISASSEMBLE COMPRESSOR TROUBLESHOOTING THE OIL SEPARATION SYSTEM SYMPTOM PROBABLE CAUSES and CORRECTIONS GRADUAL OIL LOSS WITH AN OIL Maintaining too high an oil level lower level LEVEL IN THE COALESCER SECTION SIGHT GLASS Refrigerant carryover or liquid injection overfeeding correct operation Loss of ...

Page 32: ...valve from operating both ways Clean Check LED on coil If lit valve is functioning mechanically Problem is electrical Solenoid may be actuated mechanically by inserting a piece of 3 16 rod against armature pin and pushing spool to opposite end Push A side to confirm unload capability If valve works problem is electrical SLIDE STOP WILL NOT FUNCTION Solenoid coils may be burned out Replace EITHER D...

Page 33: ...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 Liquid refrigerant overfeed Adjust liquid injection Pump worn out Repair or replace GREASE LEAKS FROM VENT PORT Normal leakage which will cease after initial operation Black oil leaking IN THE SIDE OF THE ...

Page 34: ...HE VALVE S PERFORMANCE THIS ADJUSTMENT IS PRESET ATTHE FACTORY ONLY AD JUST 1 4 BLEED VALVE ON EQUALIZING LINE Figure 28 TYPE D 1 15 TONS R 717 Figure 29 TYPE A 20 100 TONS R 717 Figure 30 TYPE H 2 1 2 TO 16 TONS R 22 TX VALVE MODE PORT SIZE DISCHARGE TUBE SIZE DAE 1 1 16 1 32 DAE 2 1 16 1 16 DAE 5 7 64 5 64 DAE 10 3 16 7 64 DAE 15 3 16 5 32 AAE 20 5 16 1 8 AAE 30 5 16 5 32 AAE 50 3 8 3 16 AAE 75 ...

Page 35: ... 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 to the left and the slot in the valve disc is on the top this valve is set for Direct Acting see figure 34 To change the action of the valve to Reverse Acting simply rotate the valve plate and the val...

Page 36: ...r with the crane install and hand tighten the eight bolts to connect the motor to the tunnel Then torque the bolts in a star pattern to 250 ft lb 7 Then install the two bolts in the in the motor feet and torque them to 250 ft lb Remove the crane from motor 8 Reattach coupling to the motor BARE COMPRESSOR REPLACEMENT The following procedure is required only when a bare com pressor is replaced in th...

Page 37: ...RWF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE S70 600 IOM Page 37 P I DIAGRAM ...

Page 38: ... PRESSURE 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 CONTROLLER TCV THERMAL CONTROL VALVE TE TEMPERATURE ELEMENT TI TEMPERATURE INDICATOR TS TEMPERATURE SWITCH TSH TEMPERATURESWITCHHIGHALARM TW THERMOWELL VI VI CONTROL SB 2 INLET BEARING BALANCE PISTON SB 3 DI...

Page 39: ...RWF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE S70 600 IOM Page 39 P I DIAGRAM LIQUID INJECTION SINGLE PORT P I DIAGRAM LIQUID INJECTION DUAL PORT ...

Page 40: ...RWF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE S70 600 IOM Page 40 P I DIAGRAM LIQUID INJECTION BOOSTER ...

Page 41: ...RWF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE S70 600 IOM Page 41 WIRING HARNESS External Transducers for Board 1 ...

Page 42: ...RWF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE S70 600 IOM Page 42 WIRING HARNESS External AC to Heaters and Valves ...

Page 43: ... NO 1 1 1 1 2 1 1 2 3 G 1 4 1 1 4 5 1 1 5 6 1 2 1 7 1 2 2 8 G 2 9 1 2 4 10 1 2 5 11 1 3 4 12 1 3 5 13 1 3 6 14 1 4 1 15 1 4 2 16 1 4 3 17 1 4 4 18 1 4 5 19 1 4 6 20 1 5 1 21 1 5 2 22 1 5 3 23 1 7 4 24 1 7 5 25 1 7 6 26 G 3 27 1 8 1 28 1 8 3 29 1 8 2 30 1001 31 1000 32 1002 33 SEAL PLUG WIRING HARNESS Internal Analog Board 1 WIRING HARNESS AC Conduit Quantum to DBS Panel WIRING HARNESS Internal AC ...

Page 44: ...e 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 contactors and solenoids These sudden dips in voltage can cause the processor whether it be a microprocessor a computer or a PLC to malfunction momentarily or cause a complete reset of the control syste...

Page 45: ... the same conduit with 120 volt wires Figure 3 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 inter fere with the operation of the control An extreme example of this would be to run the 480 volts from a motor starter throug...

Page 46: ...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 interfere with the electronics if run too close to the cir cuitry Never daisy chain or parallel connect power or ground wires to electronic control panels Each electronic con trol panel must have its own su...

Page 47: ...RWF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE S70 600 IOM Page 47 OPERATING LOG SHEET ...

Page 48: ...ol 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 sizing and instal lation __ Check all point to point wiring between the micro and motor starter __ Confirm all interconnections between micro motor starter and the system are made and are correct After the ab...

Page 49: ...ard 1 Serial _____________ Rev _____ U13 Analog Ver _________ and Date ______________ Analog Board 2 Serial _____________ Rev _____ U13 Analog Ver _________ and Date ______________ Compressor Motor Information Manufacturer _________________________________ Frame Size _____________ H P ___________ RPM _________ Serial ___________________________Service Factor ______________Voltage __________ Hz ___...

Page 50: ...nt Ambient Temperature at Time of Alignment _______ Oil Separator Temperature at Time of Alignment ________ Motor Coupling Type __________ Size ___________ Distance Between Coupling Hub Faces _________ Soft Foot Check OK as Found Shimming Required Amount of Shims used to Correct _________ Indicator Readings in in 1000 mm Indicator Clamped to Motor Compressor Indicator Readings Facing Compressor Mo...

Page 51: ..._______________________ Installing Contractor ____________________________ Address ______________________________________ Service Technician ______________________________ Equipment ID As in Microlog _____________________ Compressor Serial Number ______________________ Unit Serial Number _____________________________ National Board Number _________________________ Running Hours ___________________...

Page 52: ...alve 2 ALL 951A0092H05 Coil 240V 50Hz Solenoid Valve 2 ALL 951A0092H06 Seal Kit Solenoid Valve 1 ALL 951A0056H34 Transmitter Linear Slide Valve less well 1 ALL 534D1251H03 Transmitter Linear Slide Stop less well 1 ALL 534C1478H02 Heater Oil 500W 120V 1 ALL 913A0092G01 Heater Oil 1000W 120V 1 ALL 913A0092G02 Heater Oil 500W 240V 1 ALL 913A0092G03 Heater Oil 1000W 240V 1 ALL 913A0092G04 Filter Coale...

Page 53: ...RWF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE S70 600 IOM Page 53 ...

Page 54: ...RWF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE S70 600 IOM Page 54 ...

Page 55: ...RWF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE S70 600 IOM Page 55 ...

Page 56: ... 2003 YORK Refrigeration Systems YORK Refrigeration Systems 100 CV Avenue P O Box 997 Waynesboro Pennsylvania USA 17268 0997 Phone 717 762 2121 FAX 717 762 8624 www frickcold com ...

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