070.250-IOM (APR 11)
Page 19
408 MM ROTARY SCREW COMPRESSOR
MAINTENANCE
MAINTENANCE SCHEDULE
This schedule should be followed to ensure trouble-free operation of the compressor unit.
FREQUENCY OR HOURS OF OPERATION (MAXIMUM)
MAINTENANCE
200
1000
5000
8000
10
,000
15
,000
20
,000
25
,000
30
,000
35
,000
40
,000
45
,000
50
,000
55
,000
60
,000
65
,000
70
,000
75
,000
80
,000
85
,000
90
,000
95
,000
Change Oil
As Directed By Oil Analysis
Oil Analysis
n
Every 6 Months
Replace Oil Filters
n
n
n
n
n
n
n
n
n
n
n
Clean Oil Strainers
n
n
n
n
n
n
n
n
n
n
n
Clean Liquid Strainers
n
n
n
n
n
n
n
n
n
n
n
Replace Coalescers
n
n
n
Check and Clean Suction Strainer
n
n
n
n
n
n
n
n
n
n
n
Vibration Analysis
n
Every 6 Months, More Frequently If Levels Increase
Replace Shaft Seal
When Leak Rate Exceeds 7 - 8 Drops Per Minute
2. Use vibration readings taken from the new unit at start-
up as the baseline reference.
3. Evaluate vibration readings carefully as the instrument
range and function used can vary. Findings can be easily
misinterpreted.
4. Vibration readings can be influenced by other equipment
operating in the vicinity or connected to the same piping as
the unit.
OIL QUALITY AND ANALYSIS
High quality and suitable oil is necessary to ensure
compressor longevity and reliability. Oil quality will rapidly
deteriorate in systems containing moisture and air or other
contaminants. In order to ensure the quality of the oil in the
compressor unit:
1. Only use Frick oil or high quality oils approved by
Johnson Controls-Frick for your application.
2. Only use Frick filter elements. Substitutions must be
approved in writing by Johnson Controls-Frick engineering
or warranty claim may be denied.
3. Participate in a regular, periodic oil analysis program to
maintain oil and system 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 any deviations
from normal operating conditions. It is recommended that
readings be taken at least daily.
TROUBLESHOOTING GUIDE
Successful problem solving requires an organized approach
to define the problem, identify the cause, and make the
proper correction. Sometimes it is possible that two
relatively obvious problems combine to provide a set of
symptoms that can mislead the troubleshooter. Be aware of
this possibility and avoid solving the “wrong problem”.
ABNORMAL OPERATION ANALYSIS AND CORRECTION
Four logical steps are required to analyze an operational
problem effectively and make the necessary corrections:
1. Define the problem and its limits.
2. Identify all possible causes.
3. Test each cause until the source of the problem is found.
4. Make the necessary corrections.
The first step in effective problem solving is to define the
limits of the problem. The following list of abnormal system
conditions can cause abnormal operation of the 408 mm
compressor:
1. Insufficient or excessive refrigerant or gas load.
2. Excessively high suction pressure.
3. Excessively high discharge pressure.
4. Excessively high or low temperature coolant to the oil
cooler.
5. Excessive liquid entering the compressor (slugging).
6. Insufficient oil cooling.
7. Excessive oil cooling
8. Incorrect gas line sizing.
9. Improper system piping.
10. Wrong operation of hydraulic operated slide valve.
11. Problems in electrical service to compressor.
12. Moisture present in the system.
Make a list of all deviations from normal compressor
operation. Delete any items, which do not relate to the
symptom and separately list those items that might relate
to the symptom. Use the list as a guide to further investigate
the problem.
The second step in problem solving is to decide which
items on the list are possible causes and which items are
additional symptoms. High discharge temperature and high
oil temperature readings on a display may both be symptoms
of a problem and not causally related.
