Johnson Controls Frick 101 Installation, Operation And Maintenance Manual Download Page 13

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RXF ROTARY SCREW COMPRESSOR UNITS

OPERATION

070.410-IOM (JAN 12)

Page 13

Operation

OPERATION and START-UP INSTRUCTIONS

The Frick RXF Rotary Screw Compressor Unit is an integrat ed

system consisting of six major subsystems:

Control Panel – See publications 090-020 O, M, & CS (also

090-021 & -022 O) for

QUANTUM

™

; Compressor; Com-

pressor Lubrication System; Compressor Oil Separation Sys-

tem; 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.

NOTE: For alarm descriptions and shutdown or cutout

parameters, see publication 090-020, -021, -022 O.

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

refriger ant vapor and is designed for high pressure applica-

tions. The compres sor 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 system 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 rota tion be confirmed

before

running 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.

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 appli cations 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.
2. Provides lubrication of the bear ings and shaft seal.
3. Serves to remove the heat of compression from the gas,

keeping discharge temperatures low and minimizing refriger-

ant or oil break down.
4. Fills gas leakage paths between or around the rotors with

oil, thus greatly reducing gas leakage and main tain ing good

compressor per formance even at high compres sion 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 compres sor from the oil

separator is at system head pressure. Within the compressor,

oil porting to all parts of the compressor is vented back to

a point in the compres sor’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 oil

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 in cold ambi-

ent temperatures with all pressures equalized. See Figure 15.

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 CON-

TA C T T H E F R I C K S E R V I C E

DEPARTMENT.

Once the compressor is running it will begin to force gas

to the condenser at connection P2. See Figure 15. 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.

For booster applications, the valve is equipped with a lighter

spring which produces 1/2 bar (7 psig) oil pressure above suc-

Summary of Contents for Frick 101

Page 1: ...10 IOM JUL 2011 Dist 3 3a 3b 3c Please check www johnsoncontrols com frick for the latest version of this publication 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 ...

Page 2: ...DURE 21 VFD SKIP FREQUENCIES 21 MAINTENANCE NORMAL MAINTENANCE OPERATIONS 22 GENERAL MAINTENANCE 22 COMPRESSOR SHUTDOWN and START UP 22 COMPRESSOR MOTOR SERVICING 22 GENERAL INSTRUCTIONS FOR REPLACING COMPRESSOR UNIT COMPONENTS 23 OIL FILTER SPIN ON RXF 12 50 23 OIL FILTER SINGLE ELEMENT 58 101 23 COALESCER OIL RETURN STRAINER 24 LI Q UID INJECTION STRAINER 24 OIL PUMP STRAINER Optional 24 SUCTION...

Page 3: ...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 JOB INSPECTION Immediately upon arrival examine all crates boxes and exposed compressor a...

Page 4: ...otor Max Swept Volume Compressor Diameter Rotor Speed Drive Shaft End Cfm M H Model mm L D Rpm Ft Rev M Rev 3550 Rpm 2950 Rpm XJS XJF 95M 95 1 4 5 772 0 02513 0 000711 89 126 XJS XJF 95L 95 1 4 4 661 0 03112 0 000881 110 156 XJS XJF 95S 95 1 4 3 600 0 04086 0 001156 145 205 XJS XJF 120M 120 1 4 5 772 0 05065 0 001433 180 254 XJS XJF 120L 120 1 4 4 661 0 06272 0 001775 223 314 XJS XJF 120S 120 1 4 ...

Page 5: ...uildings 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 ...

Page 6: ...vacuated and charged with dry nitrogen to ensure the integrity of the unit during shipping and short term storage prior to installation 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 pa...

Page 7: ... 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...

Page 8: ...r suited to a specific installation Refer to publication E70 900E for additional information on Thermosyphon Oil Cooling 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 Frick recommends a closed loop system for the waterside of the oil cooler Careful attention to water trea...

Page 9: ...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 compres sor is operating at higher compression ratios 3 5 Vi and above for best efficiency Where low compres sion ratios low condensing pressures are anticipated thermo sypho...

Page 10: ...t suction pressure In cases where wide swings in pressure are anticipated in the flash econo mizer 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 8 11 Noti...

Page 11: ...stem providing shutdown protection for the Quantum LX 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 con tinue 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 So...

Page 12: ...Figure 12 Figure 13 Point to Point Wiring Diagram 5 The compressor motor Current Transformer CT can be installed on any one phase of the compressor leads NOTE the CT must see all the current on any one phase there fore in wye delta applications BOTH leads of any one phase must pass through the CT CURRENT TRANSFORMER SIZE Calculate CT size using the following formula where SF is Service Factor and ...

Page 13: ...ure appli cations 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 2 Provides lubrication of the bear ings and shaft seal 3 Serves to remove the heat of compression from the gas keeping discharge temperatures low and ...

Page 14: ...lter 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 16 NOTE Open HV1 only enough to keep the coalescer end of the separator free of oil The sight glass located near the bottom of the coales cer section of the oil sep...

Page 15: ...presented by YY3 and YY4 control the Volumizer II 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 Vi SOLENOID 3 YY3 SOLENOID 4 YY4 2 2 Energized Energized 3 5 Deenergized Energized 5 0 Deenergized Dee...

Page 16: ...the single port system with the addition of a double acting solenoid valve and operates as outlined The liquid injection solenoid valve is energized by the micro processor when the temperature sensor in stalled in the compressor discharge exceeds the setpoint Liquid refrigerant is then passed through the motorized expansion valve to the doub le acting solenoid valve Depending on the compressor s o...

Page 17: ...he influence the Integral component exerts on the PID Output value The Integral component works to push the Control Input toward the Control Setpoint by tracking the difference between the Control Input and the Control Setpoint over time Derivative Gain This setpoint controls the influence the Derivative component exerts on the PID Output value The Derivative component reacts to rapid changes in t...

Page 18: ...utton activated for 2 seconds A Parameter list example is shown below parameter i08 Figure 25 Figure 25 Gives access to change a value once the Parameter list has been accessed Acknowledge and save change of value of a parameter To exit from the Parameter list and return to the display of Opening Degree OD keep the push button activated for 2 seconds Display Figure 26 Normally the Opening Degree O...

Page 19: ... 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 j11 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 ...

Page 20: ...1 4 1 Define condition at power cut when fail safe is installed 1 Close valve 2 Open valve 3 Maintain valve position 4 Go to OD given by j12 Digital Input function j09 1 2 1 Define function when Dl is ON short circuited Dl terminals when j02 2 1 Open ICM valve Dl OFF Close ICM valve 2 Close ICM valve Dl OFF Open ICM valve Password j10 0 199 0 Enter number to access password protected parameters j2...

Page 21: ...licable If unit has water cooled oil cooling adjust water control valve to cooler if applicable 2 The compressor slide valve should be calibrated 3 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 NORMAL START UP PROCEDURE 1 Confir...

Page 22: ...dumping liquid refrigerant into com pressor suction Keep liquid injection valves properly adjusted and in good condition to avoid flooding compressor with 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 ...

Page 23: ... separator to low side system pressure using the suction check valve bypass NOTE Recover or transfer all refrigerant vapor in accor dance with local ordinances before opening to atmo sphere The separa tor MUST be equal ized to atmo spher ic pres sure Oil entrained refriger ant may vapor ize causing a separa tor pressure increase Repeat transfer and recov ery procedure if neces sary 3 Remove spin o...

Page 24: ...pped refrigerant has been relieved carefully remove loosened capscrews as liquid refrigerant is some times caught in the strainer strain er cover and strainer basket 7 Wash the strainer basket and cover in sol vent 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 leak...

Page 25: ...edure if neces sary 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 ele ments 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 suc...

Page 26: ...me out with the rotor and shaft 10 AS AK AL Remove 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...

Page 27: ... contact surface facing away from the spring over installation sleeve on shaft until just con tacting the spring Do not compress the spring Re move the installa tion 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 ...

Page 28: ...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 the bushing will quickly disinte grate Using a lub...

Page 29: ...ect 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...

Page 30: ... pressures and temperatures Calibration should be conducted with NIST certified devices d Verify tightness of bolts on suction and discharge flanges See table below for torque requirements e Vibration measurement must be carried out continuously to obtain optimum preventative control on bearings If not continuously controlled then every 6 months more frequently if levels increase f Units with vari...

Page 31: ...gh or low temperature coolant to the oil cooler 7 Liquid return from system carryover 8 Refrigerant underfeed or overfeed to evapor ators 9 Blocked tubes or plates in water cooled oil cooler from high mineral content of water 10 Insufficient evaporator or condenser siz ing MOTOR BEARINGS Lubricate motor bearings properly before start up Maintain subse quent lubrication as recommended by the motor ...

Page 32: ...24 83 4 48 19 74 10 30 7 0 19 10 4 10 41 60 1 4 19 74 0 30 9 57 15 30 4 10 26 60 16 60 54 10 1 5 14 65 2 80 0 30 20 30 11 60 34 10 29 10 66 60 1 6 9 57 5 30 5 30 25 30 19 10 41 60 41 60 79 10 1 7 4 48 7 8 10 3 30 30 26 60 49 10 54 10 91 60 1 8 0 30 10 30 15 30 35 30 34 10 56 60 66 60 104 10 1 9 2 80 12 80 20 30 40 30 41 60 64 10 79 10 116 60 2 0 5 30 15 30 25 30 45 30 49 10 71 60 91 60 129 10 2 1 ...

Page 33: ...hange the discharge pressure transducer PE 3 it will be necessary to depressurize the entire compressor package Follow General Instructions For Replacing Compressor Unit Components section before going to step 3 3 Remove DIN connector screw then remove DIN connector from the transducer TRANSDUCER CONNECTION Suction Pressure PE 4 Discharge Pressure PE 3 Oil Pressure PE 1 PE 2 4 Unscrew the transduc...

Page 34: ...ate 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 scr...

Page 35: ...ents not seated properly Replace oil charge and coalescers Oil viscosity too low Verify correct 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 IN...

Page 36: ... valve preventing valve from operating both ways Clean valve Solenoid may be mechanical ly 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 ...

Page 37: ...age 37 COMPRESSOR PORT LOCATIONS RXF 12 19 PORT CONNECTION SIZE 1 3 4 14 NPTF 3 3 8 18 NPTF 4 3 8 18 NPTF 5 3 4 14 NPTF 7 1 4 18 NPTF 8 3 8 18 NPTF 10 1 4 18 NPTF 11 1 4 18 NPTF 12 1 4 18 NPTF 16 3 4 14 NPTF 18 1 2 14 NPTF 20 1 4 18 NPTF 21 3 4 14 NPTF 22 1 4 18 NPTF ...

Page 38: ...TIONS RXF 24 50 PORT CONNECTION SIZE 1 1 11 NPTF 2 1 4 18 NPTF 3 3 8 18 NPTF 4 3 8 18 NPTF 5 1 11 NPTF 6 1 2 14 NPTF 7 1 4 18 NPTF 8 1 4 18 NPTF 10 1 4 18 NPTF 11 1 4 18 NPTF 12 1 4 18 NPTF 15 3 8 18 NPTF 16 3 4 14 NPTF 18 1 8 27 NPTF 19 1 4 18 NPTF 20 1 8 27 NPTF 21 3 8 18 NPTF 22 1 4 18 NPTF ...

Page 39: ...170 10 14 1 0 5 1 2 20 260 15 22 1 0 6 9 16 18 320 20 27 2 0 8 3 4 16 500 25 42 2 0 10 7 8 14 720 30 60 2 5 12 1Z zn 12 960 50 80 5 0 16 1B zn 12 1380 75 115 6 0 20 1B 12 2700 150 225 12 0 24 1M 12 3000 160 250 12 0 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 st...

Page 40: ...01 PORT CONNECTION SIZE 1 1Z zn 12UN 2B 2 7 16 20UNF 2B 3 1Z zn 12UN 2B 4 1Z zn 12UN 2B 5 1M 12UN 2B 6 9 16 18UNF 2B 7 1Z zn 12UN 2B 8 7 16 20UNF 2B 9 9 16 18UNF 2B 10 9 16 18UNF 2B 11 3 4 14 NPTF 12 1Z zn 12UN 2B 13 1 4 18 NPTF 14 1 8 27 NPTF 15 1 2 14 NPTF 16 9 16 18UNF 2B 17 1Z zn 12UN 2B 18 9 16 18UNF 2B ...

Page 41: ...ID VALVE MOTORIZED EXPANSION VALVE SIGHT GLASS LIQUID LINE TUBING LINE COMPRESSOR LOW VI ECONOMIZER OR CLOSED THREAD COMPRESSOR HIGH VI BOOSTER ONLY TUBING LINE LIQUID LINE SIGHT GLASS MOTORIZED EXPANSION VALVE SOLENOID VALVE STRAINER S 9 YY COMPRESSOR LOW VI COMPRESSOR HIGH VI TO SEPARATOR COMPRESSOR SUCTION PRESS LIQUID REFRIGERANT FROM RECEIVER S RXF COOLING OPTIONS See P I Diagrams PLATE OIL C...

Page 42: ...PAH HIGH PRESSURE ALARM PAHH HIGH PRESSURE SHUTDOWN PAL LOW PRESSURE ALARM PALL LOW PRESSURE SHUTDOWN PCV PRESSURE CONTROL VALVE PDSLL LOW DIFFERENTIAL PRESS SHUTDOWN PE PRESSURE ELEMENT PI PRESSURE INDICATOR PIC TIC PRESS TEMP INDICATING CONTROLLER PM PUMP MOTOR PS AUTO CYCLE PRESSURE SWITCH PSV PRESSURE SAFETY VALVE SP SUCTION PRESSURE STR STRAINER TAH HIGH TEMPERATURE ALARM TAHH HIGH TEMP SHUTD...

Page 43: ...RESSURE 8 CLOSED THREAD 10 DISCHARGE PRESSURE 11 LIQ INJ BLEED LINE 12 COALESCER BLEED LINE 15 VENT UNLOADING 16 THERMOWELL 19 SUCTION PRESSURE NOTES 1 PRESSURE TRANSDUCERS INDICATE PE 1 OIL PRESSURE PE 3 DISCHARGE PRESSURE PE 4 SUCTION PRESSURE 2 TEMPRERATURE PROBES INDICATE TE 1 SUCTION GAS TEMPERATURE TE 2 DISCHARGE GAS TEMPERATURE TE 3 LUBE OIL TEMPERATURE TE 4 SEPARATOR OIL TEMPERATURE 3 TERM...

Page 44: ...AH HIGH PRESSURE ALARM PAHH HIGH PRESSURE SHUTDOWN PAL LOW PRESSURE ALARM PALL LOW PRESSURE SHUTDOWN PCV PRESSURE CONTROL VALVE PDSLL LOW DIFFERENTIAL PRESS SHUTDOWN PE PRESSURE ELEMENT PI PRESSURE INDICATOR PIC TIC PRESS TEMP INDICATING CONTROLLER PM PUMP MOTOR PS AUTO CYCLE PRESSURE SWITCH PSV PRESSURE SAFETY VALVE SP SUCTION PRESSURE STR STRAINER TAH HIGH TEMPERATURE ALARM TAHH HIGH TEMP SHUTDO...

Page 45: ...READ 8 DISCHARGE PRESSURE 9 LIQ INJ BLEED LINE 10 COALESCER BLEED LINE 11 THERMOWELL SUCT TEMP NOTES 1 PRESSURE TRANSDUCERS INDICATE PE 1 OIL PRESSURE PE 3 DISCHARGE PRESSURE PE 4 SUCTION PRESSURE 2 TEMPRERATURE PROBES INDICATE TE 1 SUCTION GAS TEMPERATURE TE 2 DISCHARGE GAS TEMPERATURE TE 3 LUBE OIL TEMPERATURE TE 4 SEPARATOR OIL TEMPERATURE 3 TERMINATIONS A THROUGH C REFER TO CONNEC TION POINTS ...

Page 46: ...RXF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE 070 410 IOM JAN 12 Page 46 WIRING HARNESS External for Analog Devices ...

Page 47: ...RXF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE 070 410 IOM JAN 12 Page 47 WIRING HARNESS AC to Heaters and Valves External WIRING HARNESS AC Conduit Quantum to DBS Panel ...

Page 48: ...ry important to read the installation instruc tions thoroughly before beginning the project Make sure you have drawings and instructions with your equipment If not call the manufacturer and request the proper in structions and drawings Every manufacturer of electronic equipment should have a knowledgeable staff willing to answer your questions or provide additional information Following correct wi...

Page 49: ...rcuits This conduc tor must also be insulated to avoid inadvertent contact at multiple points to ground which could create Ground Loops In many installations that are having electronic control prob lems this essential wire is usually missing is not insulated or improperly sized NEC size ratings are for safety purposes and not necessarily for adequate relaying of noise EMI to earth ground to avoid ...

Page 50: ...equirements 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 electrical ducts carrying 3 phase power to starters vfd or motors Control power communications analog or signal wiring should be run overhead preferred or in a separate ...

Page 51: ...he enclosure This is extremely important in outdoor applications Note 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 electr...

Page 52: ...roviding shutdown protection for a 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 compres sor auxiliary will continue to feed an okay signal to the Quantum LX panel This may allow the motor to be subjected to the fault condition on the 3 phase b...

Page 53: ...RXF ROTARY SCREW COMPRESSOR UNITS FORMS 070 410 IOM JAN 12 Page 53 ROTARY SCREW COMPRESSOR OPERATING LOG SHEET FORMS ...

Page 54: ...iring __ 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 __ Ensure all electrical panels are free from installation debris METAL PARTICLES and m...

Page 55: ...e_______________ 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 Pr...

Page 56: ...w _______ 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 _______________...

Page 57: ... Temp Alarm______ Delay_ ______ Shutdown_______ Delay_________ High Temp Alarm______ Delay_ ______ Shutdown_______ Delay_________ PHD Monitoring Setpoints Condenser Control Compressor Bearing _ ____________ Condenser Control Setpoint ______________ Suction End Delay Discharge End Delay Digital Controls Step Order High Warning_ ______ gF_ _____ Sec High Warning______ gF_ _____ Sec Module A ________...

Page 58: ..._________ ____________ Integral Gain ____________ ____________ ____________ ____________ Communications Compressor ID_______ Comm 1 Comm 2 Comm 3 Baud Rate_ _________ Baud Rate ___________ Baud Rate_ ___________ Data Bits __________ Data Bits_ ____________ Data Bits_ ____________ Stop Bits __________ Stop Bits ____________ Stop Bits_ ____________ Parity _____________ Parity _______________ Parity_...

Page 59: ...Coupling _ ____________________ Motor Manufacturer RAM_ ____________________________ Motor Serial Number _ ________________________________ RPM _________ Frame Size ____________ H P ___________ Refrigerant Ambient Room Temperature _ ____________ F Operating Conditions VIBRATION DATA SHEET SUCTION DISCHARGE OIL SEPARATOR Slide Valve Position Press Press Press Temp F V I Ratio Temp F Temp F Temp F F...

Page 60: ... Troubleshooting 28 Air leak 28 29 alignment 29 cavitation 28 Cavitation 29 discharge port 28 Discharge Port 29 Discharge pressure 29 end clearance 29 Filter 29 foot valve 28 gate valve 28 Gate valve 29 head 28 misalignment 28 29 Motor 29 motor speed 29 pressure gauge 28 Pressure Gauge 29 Pump 29 Pump 28 Relief valve 29 sheave size 29 Strainer 29 Suction 28 Suction line 28 suction pipe 29 suction ...

Page 61: ...e Transducers 32 Conversion Data 32 Replacement 33 Testing 32 P I Diagram 41 refrigerant vapor 23 25 Safety Equipment 22 service valves 23 sole noid valves 23 spin on oil filter element 23 starting torque 24 strainer ele ments 25 strainer service valves 24 suction check valve bypass 23 25 suction service valve 25 suction strainer 22 suction valve bypass 24 superheat 22 Troubleshooting See Index Tr...

Page 62: ... safety valve 8 vapor mixture 21 Thermosyphon Oil Cooling 16 Thermosyphon oil cooling 8 drain valve 8 liquid refrigerant 8 thermo statical ly controlled mixing valve 8 Welding 8 threaded metallic 50 threaded PVC coated metallic 50 Troubleshooting 35 Excessive Noise And Vibration 35 High Oil Temperature 35 Low Oil Temperature 35 Oil Temperature Fluctuates 35 Rapid Oil Loss 35 Slide Valve 36 U unint...

Page 63: ...RXF ROTARY SCREW COMPRESSOR UNITS NOTES 070 410 IOM JAN 12 Page 63 ...

Page 64: ...ge 64 Johnson Controls 100 CV Avenue Waynesboro PA 17268 1206 USA Phone 717 762 2121 FAX 717 762 8624 www johnsoncontrols com frick Form 070 410 IOM 2012 01 Supersedes 070 410 IOM 2011 07 Subject to change without notice Published in USA 0312 PDF 2012 Johnson Controls Inc ALL RIGHTS RESERVED ...

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