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070.550-IOM (JUN 2016)

Page 2

NGC GAS ROTARY SCREW COMPRESSOR

INSTALLATION - OPERATION - MAINTENANCE

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.

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

Contents

GENERAL INFORMATION

PREFACE .......................................................................... 3

COMPRESSOR BASICS ................................................. 3

DESCRIPTION .................................................................... 3

NGC COMPRESSOR ...................................................... 3
COMPRESSOR LUBRICATION SYSTEM ......................... 3
OIL PUMP ...................................................................... 4

COMPRESSOR DELIVERY ................................................. 4

JOB INSPECTION .......................................................... 4
TRANSIT DAMAGE CLAIMS .......................................... 4

COMPRESSOR AND UNIT IDENTIFICATION ....................... 4
LONG TERM STORAGE ...................................................... 5
PREPARING COMPRESSOR FOR STORAGE ........................ 5
MAINTAINING COMPRESSOR ............................................. 5
CONSTRUCTION DETAILS .................................................. 6
TABLE 1. COMPRESSOR VOLUME & CAPACITY RATIO ..... 6

INSTALLATION

DESIGN LIMITS .................................................................. 7
CONNECTION TYPES & SPECIFICATIONS ........................... 7

PIPING REQUIREMENTS................................................. 7
TABLE 2 - GENERAL SPECIFICATIONS ........................... 7
FIGURE 3. PORT LOCATIONS, NGC 100/150. .................. 8
FIGURE 4. PORT LOCATIONS, NGC 200/250. ................. 9
FIGURE 5. PORT LOCATIONS, NGC 300. ...................... 10
FIGURE 6. PORT LOCATIONS, NGC 400/450. ................11

COMPRESSOR/MOTOR COUPLING REQUIREMENTS .....13

ELECTRICAL INSTALLATION ............................................. 14

SLIDE STOP TRANSMITTER ......................................... 14
CAPACITY SLIDE VALVE TRANSMITTER ...................... 14
DIRECTIONAL CONTROL VALVES ................................ 14

OPERATION

OPERATION AND START-UP INSTRUCTIONS ...................15
COMPRESSOR HYDRAULIC SYSTEM ...............................15

FIGURE 12 - HYDRAULIC SCHEMATIC ...........................15

VOLUMIZER VOLUME RATIO CONTROL  ...........................16
LOW AMBIENT OPERATION  .............................................16
INITIAL STARTUP  .............................................................16

INITIAL STARTUP PROCEDURE ....................................16
NORMAL STARTUP PROCEDURE .................................16

MAINTENANCE

GENERAL INFORMATION .................................................17
NORMAL MAINTENANCE OPERATIONS ...........................17

GENERAL MAINTENANCE ............................................17
CHANGING OIL .............................................................17
OIL PUMP .....................................................................17

TORSIONAL ANALYSIS .....................................................19

FIGURE 14. NGC/NGCH 400/450 DRIVELINE & GEAR
DIMENSIONS. ...............................................................19

VIBRATION ANALYSIS  ..................................................... 20
OIL QUALITY AND ANALYSIS  ......................................... 20
TROUBLESHOOTING GUIDE  ............................................ 20

ABNORMAL OPERATION ANALYSIS & CORRECTION  .. 20
TROUBLESHOOTING THE NGC COMPRESSOR  .............21
TROUBLESHOOTING THE OIL PUMP AND SYSTEM  .....21
TROUBLESHOOTING THE HYDRAULIC SYSTEM ............21
CAPACITY LINEAR TRANSMITTER REPLACEMENT -
SLIDE VALVE  ...............................................................22
FIGURE 15 - CAPACITY LINEAR TRANSMITTER ............22
VOLUMIZER

TRANSMITTER REPLACEMENT -

SLIDE STOP ..................................................................22
FIGURE 16 - VOLUMIZER

TRANSMITTER ....................22

BARE COMPRESSOR REPLACEMENT ...............................22
SHUTDOWN DUE TO IMPROPER OIL PRESSURE ..............22
DRIVE TRAIN ALIGNMENT ............................................... 24
VIBRATION DATA SHEET ...................................................25

INDEX

WARNING

CAUTION

DANGER

NOTICE

Содержание Frick 100

Страница 1: ...or MODELS 100 150 200 250 300 400 and 450 ALL GEAR RATIOS 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 johnsoncontrols com frick for the latest version of this publication ...

Страница 2: ... AND STORAGE 12 RIGGING AND HANDLING 12 DEHYDRATION EVACUATION TEST 12 FOUNDATION 12 COMPRESSOR OIL 12 OIL FILTER S 12 OIL PUMP 13 OIL HEATER S 13 OIL COOLING REQUIREMENTS 13 COUPLING 13 COMPRESSOR MOTOR COUPLING REQUIREMENTS 13 ELECTRICAL INSTALLATION 14 SLIDE STOP TRANSMITTER 14 CAPACITY SLIDE VALVE TRANSMITTER 14 DIRECTIONAL CONTROL VALVES 14 OPERATION OPERATION AND START UP INSTRUCTIONS 15 COM...

Страница 3: ...ring life 4 Moveable slide valve to provide fully modulating capacity control from 100 to minimum capacity See Table 1 5 VOLUMIZER volume ratio control to allow infinitely variable volume ratio from 2 2 to 5 0 for all NGC models except the NGC 300 2 0 4 1 and the NGC 450 2 4 4 5 during compressor operation 6 A hydraulic cylinder to operate the slide stop and slide valve 7 Housings designed for dis...

Страница 4: ...ack all items and check against shipping lists for any discrepancy 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 execut ed Report damage or shortage claims immediately to Johnson Controls Frick Sales Administration Departme...

Страница 5: ...on of components over the period of time Synthetic components in the compressor may deteriorate over time even if they are kept flooded with oil A warm and dry environment is essential to minimize environmental and corrosion damage Long term storage of the affected equipment at a customer s site may involve additional requirements and interested parties should refer to the Johnson Controls Frick I...

Страница 6: ...age up to 400 psig but is vented to low pressure to provide extended life VOLUMIZER VARIABLE VOLUME RATIO CONTROL The Johnson Controls Frick compressor includes a patented method of varying the internal volume ratio to match the system pressure ratio Control of the internal volume ratio eliminates the power penalty associated with over compression or under compression Volume ratio control is achie...

Страница 7: ... compressors are primarily designed for direct engine drive The NGC 100 300 models can be delivered with 4 different gear ratios The NGC 400 and 450 models are available with 6 gear ratios The rotor gear and bearing design limitations must not be exceeded See CoolWare The table below lists some of the design limits Other design limits are identical to standard non gear driven compressors Refer to ...

Страница 8: ...ight Thread O ring 1 4 18 NPTF Discharge Pressure SC 7 1 8 27 NPTF Seal Weepage SC 8 1 1 16 12UN 2B Straight Thread O ring Closed Thread Drain SC 9 9 16 18UNF 2B Straight Thread O ring Inlet Housing Drain SC 13 9 16 18UNF 2B Straight Thread O ring Cylinder Oil Drain SC 15 1 5 8 12UN 2B Straight Thread O ring 1 11 1 2 NPTF Gear Box Oil Drain SC 16 9 16 18UN 2B Straight Thread O ring Discharge Housi...

Страница 9: ... Thread O ring Inlet Housing Drain SC 11 1 5 16 12UN 2B Straight Thread O ring 3 4 14 NPTF Closed Thread Drain SC 13 9 16 18UNF 2B Straight Thread O ring Cylinder Oil Drain SC 14 9 16 18UN 2B Straight Thread O ring Inlet Pressure SC 15 1 5 16 12UN 2B Straight Thread O ring 1 11 1 2 NPTF Gear Box Oil Drain SC 16 1 1 16 12UN 2B Straight Thread O ring Discharge Housing Oil Drain SC 17 2 11 1 2 NPTF I...

Страница 10: ...Straight Thread O ring 1 4 18 NPTF Discharge Pressure SC 7 1 8 27 NPTF Seal Weepage SC 8 1 5 16 12UN 2B Straight Thread O ring Closed Thread Drain SC 9 9 16 18UNF 2B Straight Thread O ring Inlet Housing Drain SC 13 9 16 18UNF 2B Straight Thread O ring Cylinder Oil Drain SC 15 1 5 8 12UN 2B Straight Thread O ring 1 11 1 2 NPTF Gear Box Oil Drain SC 16 1 1 16 12UN 2B Straight Thread O ring Discharge...

Страница 11: ...NPTF Inlet Oil Drain SC 5 3 8 18 NPTF Inlet Pressure SC 6 3 8 18 NPTF Discharge Pressure SC 7 1 8 27 NPTF Seal Weepage SC 8 1 1 4 11 1 2 NPT Closed Thread Drain SC 9 1 1 2 11 1 2 NPT Closed Thread Drain SC 13 1 2 14 NPTF Cylinder Oil Drain SC 15 1 1 4 11 1 2 NPTF Gear Cover Oil Drain SC 16 1 1 2 11 1 2 NPT Discharge Housing Oil Drain SC 17 1 2 14 NPTF Discharge Housing Sump Drain SL 1 1 1 4 11 1 2...

Страница 12: ...00 lb NGC 450 13 200 lb NGC 250 4800 lb Screw compressors are capable of converting large quantities of shaft power into gas compression in a relatively small space The compression process creates relatively high frequency vibrations that require sufficient mass in the base to effectively dampen them The best insurance for a trouble free installation is to firmly anchor the compressor to a suitabl...

Страница 13: ...compressors are arranged for direct engine drive and require a flexible drive coupling to connect the compressor to the motor Coupling must be selected and installed so that it doesn t transmit any axial load to the compressor shaft Set up the minimum distance between compressor shaft and engine shaft to allow for seal removal and gear cover removal see Outline drawings 1 Coupling must be able to ...

Страница 14: ...e stop transmitter measures the position of the slide stop SS using a 4 to 20mA signal that is sent to your control system The controller will adjust the position of SS according to system pressures The correct SS position is important to achieve the most efficient compressor operation Connect to and signal Refer to Johnson Controls Frick compressor panel instructions S90 010 for calibration proce...

Страница 15: ...DRAULIC SYSTEM 24 VDC Solenoid valves and distribution block are available as sales order option The compressor hydraulic system See Figure 12 actuates the movable slide valve MSV to load and unload the compressor It also actuates the movable slide stop MSS to increase or decrease the compressor s volume ratio VI The hydraulic cylinder located at the inlet end of the NGC compressor serves a dual p...

Страница 16: ... increase The volume ratio Vi is increased when MSS solenoid valve YY3 is energized and oil flows from the oil manifold through valve ports P and A to compressor port SC3 enters the increase side of the cylinder and overcomes the decrease spring tension Simultaneously oil flows from SC4 port through valve ports B and T to compressor suction Compressor VI decrease The volume ration Vi is decreased ...

Страница 17: ... 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 oil and lead to premature bearing failure Dual oil filters are recommended so that the filters can be changed without shutting down the package 4 Avoid slugging compressor with liquids oil While screw compressors are proba...

Страница 18: ... and spike energy or acceleration enveloping data against frequency every 6 months or more frequently if levels are increasing If an FFT Spectrum Analyzer is not available vibration trending using an overall vibration meter may be substituted The overall vibration meter should be available to read Velocity zero peak in sec and Acceleration g s The overall vibration meter Velocity range should be 0...

Страница 19: ...ns in inches NGC NGCH Gear Dimensions GEAR SET SEGMENT 11 11A 12 12A 15 15A A 8 13 1 25 16 13 3 21 1 2 75 B 8 13 1 25 14 6 3 22 63 2 75 C 8 13 1 25 12 76 3 24 48 2 75 D 8 13 1 25 11 43 3 25 8 2 75 E 8 13 1 25 10 48 3 26 75 2 75 F 8 13 1 25 9 66 3 27 57 2 75 Dimensions in inches NOTE 1 All segments are labeled on the driveline Refer to corresponding tables for dimensions 2 Male rotor body diameter ...

Страница 20: ...tem integrity OPERATING LOG The use of an operating log as included in this manual permits thorough analysis of the operation of a system by those responsible for its maintenance 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 recognize immediately...

Страница 21: ...tion MAIN UNIT FILTER PSID IS TOO HIGH Filters clogged with dirt Replace Oil is too cold Allow oil to warm up and check again Service valve on filter outlet is partially closed Open valves fully TROUBLESHOOTING THE HYDRAULIC SYSTEM SYMPTOM PROBABLE CAUSES and CORRECTIONS SLIDE VALVE WILL NOT LOAD OR UNLOAD Solenoid coils burned out Replace Valve closed Open hydraulic service valves Solenoid spool ...

Страница 22: ...g the need to evacuate the compressor for replacement This type of transmitter is dedicated to volume ratio control and has no user adjustments 1 Shut off control power 2 Remove DIN connector plug from transmitter 3 Loosen setscrews 4 Remove transmitter unit 5 Install new transmitter unit 6 Tighten setscrews 7 Apply DIN connector plug to transmitter 8 Turn on control power NOTICE For calibration o...

Страница 23: ...070 550 IOM JUN 2016 Page 23 NGC GAS ROTARY SCREW COMPRESSOR MAINTENANCE ...

Страница 24: ...ompressor Engine Magnetic Center Checked Marked N A Compressor Coupling Hub Runout_____________________________ Motor Coupling Hub Runout______________________ Initial Cold Alignment Initial Hot Alignment Final Hot Alignment Face Rim Face Rim Face Rim Thickness of Shims Added Thickness of Shims Added Thickness of Shims Added OPERATING LOG SHEET Date Time Hour Meter Reading Equip Room Temp Suction ...

Страница 25: ..._____________ Running Hours _________________________________________ Manufacturer and Size of Coupling ________________________ Engine Manufacturer ___________________________________ Engine Serial Number ___________________________________ RPM ___________ Frame Size ___________ H P ____________ Refrigerant ____________________________________________ Ambient Temperature ___________________ F Ope...

Страница 26: ... Maintenance Maintenance Schedule 18 Vibration Data Sheet 23 male rotor 5 male rotor shaft 4 misalignment 13 MSV solenoid 16 N natural gas 3 needle valve 16 O Oil analysis 17 oil cooler 19 oil cooling system 16 oil filter 14 17 18 oil filter cartridges 17 OIL HEATER S 14 oil manifold 16 oil pressure 5 13 Oil pressure 7 oil pump 5 13 17 Oil quality 18 oil seal 5 oil strainer elements 17 oil supply ...

Страница 27: ... OPERATION MAINTENANCE U under compression 6 unloading 6 V vacuum 4 Vacuum 14 vacuum pump 14 valve ports 16 VAPOR PUMP 3 Vi 16 vibration analysis 13 16 18 Vibration Data Sheet 23 vibration level 17 VOLUME RATIO 16 VOLUMIZER volume ratio control 5 W Warranty 4 Water vapor 17 ...

Страница 28: ...ww johnsoncontrols com frick Form 070 550 IOM 2016 06 Supersedes 070 800 IOM 2015 03 Subject to change without notice Published in USA 06 16 PDF 2016 Johnson Controls Inc ALL RIGHTS RESERVED June 2016 Form Revisions p 13 Updated discharge temperature limit to 300 F Updated Frick IR logo throughout ...

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