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Installation - Operation - Maintenance

ROTARY SCREW COMPRESSOR UNITS

ALL REFRIGERANTS

MODELS

60 through 480

THIS MANUAL CONTAINS RIGGING, ASSEMBLY, START-UP, AND
MAINTENANCE INSTRUCTIONS. READ THOROUGHLY BE FORE BE-
GINNING INSTALLATION. FAILURE TO FOLLOW THESE IN STRUC -
TIONS COULD RESULT IN DAMAGE OR IM PROP ER OP ER A TION
OF THE UNIT.

S70-200 IOM/OCT 2004

File:

SERVICE MANUAL - Section 70

Replaces:

S70-200 IOM/AUG 2001

Dist:

3, 3a, 3b, 3c

Содержание RWB II

Страница 1: ...MANUAL CONTAINS RIGGING ASSEMBLY START UP AND MAINTENANCE INSTRUCTIONS READTHOROUGHLY BEFORE BE GINNING INSTALLATION FAILURE TO FOLLOW THESE INSTRUC TIONS COULD RESULT IN DAMAGE OR IMPROPER OPERATION...

Страница 2: ...t 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 h...

Страница 3: ...lator or slugging protection that load surges are known and provisions made for control operating cycles and defrosting periods are reasonable and that high side condensers are sized within system and...

Страница 4: ...essor 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 necessa...

Страница 5: ...make sure that they are free of burrs dirt and grit CH COUPLING DATA TABLE 3 Check that the keys fit the hubs and shafts properly CH COUPLING The T B Woods Elastomeric CH Coupling is used in most app...

Страница 6: ...ocated Injury may occur if loose clothing etc becomes entangled on the spinning motor shaft If the motor is coupled to the compressor using a fixed end play coupling such as the Series 52 coupling and...

Страница 7: ...lignment compensates for thermal growth when the unit is at operating temperature The following procedure is applicable to both the CH and DBZ B couplings Dial indicators are to be used to measu re th...

Страница 8: ...isalignment 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 Fi...

Страница 9: ...charge checked periodically COMPRESSOR UNIT OIL DO NOT MIX OILS of different brands manufacturers or types Mixing of oils may cause excessive oil foaming nuisance oil level cutouts oil pressure loss g...

Страница 10: ...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 imbal...

Страница 11: ...pply 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 li...

Страница 12: ...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 PER VOLUME MODEL PIPE TUBING 5 MIN CU FT R 717 HIGH STAGE 100...

Страница 13: ...ect Expansion Economizer System Figure 11 Shell and Coil Economizer System Figure 14 Multiple Compressor Economizer System Figure 13 Flash Economizer System For refrigeration plants employing multiple...

Страница 14: ...the use of UPS power systems in front of the Quantum panel With a UPS power system providing shutdown protection for the Quantum the panel may not see the loss of the 3 phase voltage on the motor bec...

Страница 15: ...each normally open compressor motor and oil pump motor starter auxiliary contact should be supplied In addition to the compressor and oil pump motor starter coils the CT and CPT secondaries should be...

Страница 16: ...VE FERRITE TUBE WHEN SOLA IS ADDED 6B 6 H NOTE AT SOLA ASSEMBLY MAKE WIRES 6 2 GND 6B 2B 10 FT LONG CUT WIRESTO LENGTH AT INSTALLATION H5 REGULATOR H3 H4 OUTPUT INPUT X1 120 240 V IN 120 V OUT SOLA 63...

Страница 17: ...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 c...

Страница 18: ...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 across the compresso...

Страница 19: ...rough valve ports P and A to cylinder 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 p...

Страница 20: ...system contains all the components of the single port system with the addition of a double acting so lenoid valve SV7 and operates as outlined Solenoid valve SV5 is energized by the microprocessor whe...

Страница 21: ...injection valve look at the power head of the Thermal Expansion Valve If the unit is using Ammonia as a refrigerant and is for low temperature the Sporlan number on the power head should be Y764 or Y8...

Страница 22: ...diagram in S90 010 M Quantum or S70 200 OM Plus shows the wiring included when required Introduction of high discharge pressure gas is made to the check valve A timer limits the high pressure gas to o...

Страница 23: ...ressor s economizer port If an electric shut off is not installed in the economizer vapor line valve HV 2 must remain closed to avoid a gas bypass from the economizer line through the suction check va...

Страница 24: ...hut down on Comp Differential 4 After running the unit for approximately three hours adjust liquid injection oil cooling if applicable If unit has thermosy phon or water cooled oil cooling adjust wate...

Страница 25: ...pplicable 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...

Страница 26: ...vice valves of the standby filter Open inlet service valve slowly to prevent a sudden pressure drop which could cause an oil filter dif ferential alarm 2 Close outlet then inlet service valves of fil...

Страница 27: ...alescer filter retainer 4 Remove retainer coalescer 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 b...

Страница 28: ...GRAPHITE BUSHINGS fFigure 26 Thrust Bearing assembly GG HJ HL Figure 27 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 keep...

Страница 29: ...sure both are free from dirt and grit Coat outer diameter of seal seat and inner diameter of seal housing bore with refrigeration oil 3 Start seal seat in seal housing bore If force is nec essary pro...

Страница 30: ...ditional 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...

Страница 31: ...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 spee...

Страница 32: ...rom 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 rea...

Страница 33: ...and servicing Continual recording of gauge pressures temperatures and other pertinent information enables the observer and serviceman to be constantly familiar with the operation of the system and to...

Страница 34: ...perheat 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 slugging...

Страница 35: ...cer 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 measured in inches of mercury P...

Страница 36: ...TE The total travel on theVOLUMIZER potentiometer is 394 inch SV POSITION POTENTIOMETER REPLACEMENT AND ADJUSTMENT The Slide Valve Position potentiometer is located on the end of the compressor unload...

Страница 37: ...crews 7 Apply DIN connector plug to transmitter 8 Turn on control power Figure 34 TROUBLESHOOTING THE RWB II COMPRESSOR SYMPTOM PROBABLE CAUSES and CORRECTIONS EXCESSIVE NOISE and VIBRATION Main oil i...

Страница 38: ...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 end If valve works problem is electrical SLIDE STOP...

Страница 39: ...ervice valves are open Filter cartridges may be blocked Check PSID across filters Strainer may be blocked Clean Oil pressure regulator set too low or stuck open Readjust or repair Pump worn out Repair...

Страница 40: ...hieved by increasing or decreasing discharge tube size NOTE DO NOT ATTEMPT TO ADJUST SUPERHEAT ADJUSTMENT STEM ON BOTTOM OF VALVE IN AN EF FORT TO CHANGE THE VALVE S PERFORMANCE THIS ADJUSTMENT IS PRE...

Страница 41: ...t seems to be a total absence 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...

Страница 42: ...e 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 conditi...

Страница 43: ...RWB II ROTARY SCREW COMPRESSOR UNITS MAINTENANCE S70 200 IOM Page 43 P I DIAGRAM...

Страница 44: ...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 CONTROLL...

Страница 45: ...RWB II ROTARY SCREW COMPRESSOR UNITS MAINTENANCE S70 200 IOM Page 45 P I DIAGRAM LIQUID INJECTION SINGLE PORT P I DIAGRAM LIQUID INJECTION DUAL PORT...

Страница 46: ...RWB II ROTARY SCREW COMPRESSOR UNITS MAINTENANCE S70 200 IOM Page 46 P I DIAGRAM LIQUID INJECTION BOOSTER...

Страница 47: ...erride any rules by the NEC but are to be used in conjunction with the NEC code WIRE SIZING Size supply wires one size larger than required for amperage draw to reduce instantaneous voltage dips cause...

Страница 48: ...the same conduit with 120 volt wires Figure 46 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...

Страница 49: ...y destroy 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 int...

Страница 50: ...RWB II PLUS ROTARY SCREW COMPRESSOR UNITS FORMS S70 200 IOM Page 50 OPERATING LOG SHEET...

Страница 51: ...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...

Страница 52: ...and Date _________ Analog Board 1 Serial ______________Rev _____ U13 Analog Ver _________ and Date ______________ Analog Board 2 Serial ______________Rev _____ U13 Analog Ver _________ and Date _____...

Страница 53: ...nment Ambient Temperature at Time of Alignment _______ Oil Separator Temperature at Time of Alignment ________ Motor Coupling Type ___________ Size ___________ Distance Between Coupling Hub Faces ____...

Страница 54: ...___________________ Installing Contractor _____________________________ Address ______________________________________ Service Technician ______________________________ Equipment ID As in Microlog ___...

Страница 55: ...0 200 PSIA Quantum only 1 ALL 913A0110H01 Transducer Pressure 0 500 PSIA Quantum only 1 ALL 913A0110H02 Potentiometer Slide Stop 1 ALL 111Q0041148 Kit Potentiometer Slide Valve 1 ALL 534D0523G02 Valve...

Страница 56: ...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 delivers increased operating efficiency and lowe...

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