INSTALLATION, OPERATION, and MAIN Unpack all items and check against shipping lists for any TEN ANCE procedures as recommended by Johnson Controls discrepancy. Examine all items for damage in transit. for Frick RWH Rotary Screw Compres sor Units.
070.620-IOM (DEC 12) RWH ROTARY SCREW COMPRESSOR UNITS Page 4 GENERAL INFORMATION COMPRESSOR IDENTIFICATION Each compressor has an identification data plate (see below), containing compressor model and serial number mounted on the compressor body. COMPRESSOR DATA PLATE Rotary screw compressor serial numbers are defined by the following information: EXAMPLE: 10240A90000015Z GLOBAL ADDITIONAL...
RWH ROTARY SCREW COMPRESSOR UNITS 070.620-IOM (DEC 12) INSTALLATION Page 5 Installation 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 FOUNDATION directly to the structure.
070.620-IOM (DEC 12) RWH ROTARY SCREW COMPRESSOR UNITS Page 6 INSTALLATION The resultant force, Fr, is given by Equation (C1): Bump the motor to check for correct compressor rotation. After verification, install disc drive spacer, as applicable. where F x , F y , and F z are the force components along the x, y, and the zaxis, respectively The resultant moment Mr, is given by Equation (C.2): where M x , M y , and M z are the force components along the...
RWH ROTARY SCREW COMPRESSOR UNITS 070.620-IOM (DEC 12) INSTALLATION Page 7 not torque any locknuts at this time. Now pivot the unitized flex disc until the other bushing holes in the flex disc are in line with the bolt holes in the spacer. Install the rest of the spacer bolts at this time.
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070.620-IOM (DEC 12) RWH ROTARY SCREW COMPRESSOR UNITS Page 8 INSTALLATION NOTICE The use of a mirror is helpful in reading the indicator dial as coupling hubs are rotated. 5. Loosen motor anchor bolts and move or shim motor to correct the angular misalignment.
They must be re- capacity be required because of low ambient temperature, moved before pressure testing the system and before contact Johnson ControlsFrick . The heaters are energized charging the system with refrigerant. Failure to remove ®...
070.620-IOM (DEC 12) RWH ROTARY SCREW COMPRESSOR UNITS Page 10 INSTALLATION OIL FILTER(S) refrigerant liquid/vapor mixture in the return line is consid erably less than the density of the liquid in the supply line. This imbalance provides a differential pressure that sustains NOTICE a flow condi tion to the oil cooler.
RWH ROTARY SCREW COMPRESSOR UNITS 070.620-IOM (DEC 12) INSTALLATION Page 11 Figure 12 - Level Control LIQUID LINE SIZES/RECEIVER VOLUME Liquid line sizes and the additional receiver volume (quanti- ty of refrigerant required for 5 minutes of liquid injection oil Figure 10 - TSOC Piping Arrangement cooling) can be found in CoolWare.
070.620-IOM (DEC 12) RWH ROTARY SCREW COMPRESSOR UNITS Page 12 INSTALLATION ECONOMIZER - HIGH STAGE (OPTIONAL) the redundancy of a backpressure regulating valve on the vessel and each of the multiple compressors. Omit the BPR The economizer option provides an increase in system ca valve on the flash economizer vessel and use one on each pacity and efficiency by cooling liquid from the condenser compressor, as shown in Figure 16.
The singlebox control door must be kept tightly closed to supplied by the installer unless a starter package is pur chased prevent moisture and foreign mat ter from entry. separately from Johnson ControlsFrick. Starter packages should consist of: NOTICE 1. The compressor motor starter of the specified HP and voltage for the starting method specified (acrosstheline,...
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070.620-IOM (DEC 12) RWH ROTARY SCREW COMPRESSOR UNITS Page 14 INSTALLATION 6. One each normally open compressor motor and oil pump NOTICE motor starter auxiliary contact should be supplied. In addition to the compressor and oil pump motor starter coils, the CT If starting methods other than across-the-line are de- and CPT secondaries should be wired as shown on the starter sired, a motor/compressor torque analysis must be done...
RWH ROTARY SCREW COMPRESSOR UNITS 070.620-IOM (DEC 12) INSTALLATION Page 15 CURRENT TRANSFORMER (CT) RATIOS The CT ratio for various motor sizes (with a 5 amp second ary) is given in the following table: CT Factor Voltage 2300 3300 4000 4160 6000 6300...
070.620-IOM (DEC 12) RWH ROTARY SCREW COMPRESSOR UNITS Page 16 OPERATION all types of drives. SEE FOLLOWING WARNING. Operation WARNING OPERATION and START-UP INSTRUCTIONS Compressor rotation is clockwise when facing the The Frick RWH Rotary Screw Compressor Unit is an inte ®...
RWH ROTARY SCREW COMPRESSOR UNITS 070.620-IOM (DEC 12) OPERATION Page 17 FULL TIME PUMP SYSTEM The valve is controlled to maintain a minimum differential pressure that will provide oil flow and keep the oil pressure The full time pump system provides all oil flow requirements above the oil safeties.
070.620-IOM (DEC 12) RWH ROTARY SCREW COMPRESSOR UNITS Page 18 OPERATION Booster Compressor Loading: The compressor loads when Compressor Vi decrease: The volume ratio Vi is decreased MSV solenoid YY2 is energized and oil flows from the oil when MSS solenoid valve YY4 is energized and oil flows from manifold through valve ports P and B to cylinder port SC2 the oil manifold through valve ports P and B to compressor and enters the load side of the cylinder.
RWH ROTARY SCREW COMPRESSOR UNITS 070.620-IOM (DEC 12) OPERATION Page 19 Figure 23 - Port Locations QUANTUM ™ LX EZ-COOL ™ LIQUID INJECTION ADJUSTMENT PROCEDURE Figure 24 - Analog Output Calibration Use the following directions to set up and tune the EZ-Cool First, complete calibration of the analog output used for LIOC with a Quantum LX Control Panel.
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070.620-IOM (DEC 12) RWH ROTARY SCREW COMPRESSOR UNITS Page 20 OPERATION • Place the leads of a calibrated, quality meter to ter Quantum. The control setpoint will not be achieved minal one (positive) and terminal two (negative). Set with proportional control only. Integral control is the meter to read mA DC and power up the panel.
INITIAL START-UP Initial start-up must be performed under the super vision of a Johnson Controls-Frick authorized start-up represen- tative to prevent voiding the compressor warranty. Prior Figure 26 - Suction Check Valve Bypass to the start-up, the prestart check must be accomplish ed.
070.620-IOM (DEC 12) RWH ROTARY SCREW COMPRESSOR UNITS Page 22 OPERATION INITIAL START-UP PROCEDURE 3. Rotate and lubricate motor bearings according to manu facturer’s recommendations PRIOR to initial startup as Having performed the checkpoints on the prestart check required. list (see FORMS section), the compressor unit is ready for 4.
RWH ROTARY SCREW COMPRESSOR UNITS 070.620-IOM (DEC 12) MAINTENANCE Page 23 available today, they are not liquid pumps. Make certain to Maintenance maintain adequate superheat and properly size suction accu mulators to avoid dumping liquid refrigerant into compressor GENERAL INFORMATION suction.
070.620-IOM (DEC 12) RWH ROTARY SCREW COMPRESSOR UNITS Page 24 MAINTENANCE 1. Push [STOP] key on control panel to shut down unit. WARNING 2. Open disconnect switches for compressor and pump Open inlet service valve slowly to prevent a sudden motor starters.
RWH ROTARY SCREW COMPRESSOR UNITS 070.620-IOM (DEC 12) MAINTENANCE Page 27 PUMP ASSEMBLY The rotary member of the seal will come out with rotor and shaft. Assembly Notes On Standard Mechanical Seal (Synthetic 10. AS, AK, AL: Remove bearing retainer washer. The washer Rubber Bellows Type) may have stayed with rotor and shaft when removed or is against ball bearing.
070.620-IOM (DEC 12) RWH ROTARY SCREW COMPRESSOR UNITS Page 28 MAINTENANCE 5. Place seal spring on shaft against rotor hub. Refer to 17. Remove brass bar or hardwood from port opening. Figure 31. 18. Adjust pump end clearance. 6. Slide rotary member, with lapped contact surface fac ing away from spring, over installation sleeve on shaft until DANGER just con tacting the spring.
RWH ROTARY SCREW COMPRESSOR UNITS 070.620-IOM (DEC 12) MAINTENANCE Page 29 TROUBLESHOOTING THE PUMP Some of the following may also help pinpoint the problem: 1. Pump does not pump. DANGER a. Lost its prime air leak, low level in tank. b.
070.620-IOM (DEC 12) RWH ROTARY SCREW COMPRESSOR UNITS Page 30 MAINTENANCE PREVENTATIVE MAINTENANCE RECOMMENDED MAINTENANCE PROGRAM Performing a few preventative maintenance procedures will In order to obtain maximum compressor unit perform ance extend the life of your pump and reduce the cost per gallon and ensure reliable operation, a regular main tenance program pumped.
RWH ROTARY SCREW COMPRESSOR UNITS 070.620-IOM (DEC 12) MAINTENANCE Page 31 4. Vibration readings can be influenced by other equip ment operating in the vicinity or connected to the same piping as the unit. Locknut Locknut Valve Cap Valve Cap OIL QUALITY AND ANALYSIS DO NOT &...
070.620-IOM (DEC 12) RWH ROTARY SCREW COMPRESSOR UNITS Page 32 MAINTENANCE Figure 33 - For Schneider Electric Motors Only. For other manufacturers, follow their schedule. TROUBLESHOOTING GUIDE liquid injection will overfeed and oil temperature will drop. In solving the wrong problem a new problem was created. Successful problem solving requires an organized ap proach to When an operating problem develops, compare all operat ing define the problem, identify the cause, and make the proper...
RWH ROTARY SCREW COMPRESSOR UNITS 070.620-IOM (DEC 12) MAINTENANCE Page 33 Make a list of all deviations from normal plant operation and 10. The voltage reading should be between 1.1 VDC and 1.29 normal compressor unit operation. Delete any items which VDC at standard atmospheric pressure (see Step 12).
070.620-IOM (DEC 12) RWH ROTARY SCREW COMPRESSOR UNITS Page 34 MAINTENANCE PRESSURE TRANSDUCERS - REPLACEMENT SHADED AREA SHOWS END VIEW CAPACITY LINEAR TRANSMITTER 1. Shut off control power. 2. Close the applicable transducer isolation valve. STAINLESS STEEL WELL NOTICE DIN CONNECTOR To change the discharge pressure transducer (PE-3), it will be necessary to depressurize the entire compres- sor package.
RWH ROTARY SCREW COMPRESSOR UNITS 070.620-IOM (DEC 12) MAINTENANCE Page 35 6. Tighten set screws. 2. Remove DIN connector plug from transmitter. See Figure 36. 7. Apply DIN connector plug to transmitter. 3. Unscrew knurled ring and remove transmitter unit. 8.
RWH ROTARY SCREW COMPRESSOR UNITS 070.620-IOM (DEC 12) MAINTENANCE Page 37 TROUBLESHOOTING THE RWH COMPRESSOR SYMPTOM PROBABLE CAUSES and CORRECTIONS EXCESSIVE NOISE and VIBRATION Main oil injection valve may be closed. Open valve. Main oil injection valve may be open too far. Adjust. Bearing damage or excessive wear.
070.620-IOM (DEC 12) RWH ROTARY SCREW COMPRESSOR UNITS Page 38 MAINTENANCE 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 Refrigerant carryover or liquid injection overfeed ing. Correct operation. SECTION SIGHT GLASS Loss of suction superheat.
RWH ROTARY SCREW COMPRESSOR UNITS 070.620-IOM (DEC 12) MAINTENANCE Page 39 MOTOR and BARE COMPRESSOR SHUTDOWN DUE TO IMPROPER OIL REPLACEMENT PRESSURE (HIGH STAGE and BOOSTER) Refer to publication 070.660SM. The compressor must not operate with incorrect oil pressure. 1. Refer to CONTROL SETUP - "OIL SETPOINTS DISPLAY" in publication 090.022O.
RWH ROTARY SCREW COMPRESSOR UNITS 070.620-IOM (DEC 12) MAINTENANCE Page 43 SAMPLE P & I DIAGRAM See Legend next page! NOTICE This is a sample P & I. Actual content will be project specific.
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070.620-IOM (DEC 12) RWH ROTARY SCREW COMPRESSOR UNITS Page 44 MAINTENANCE LEGEND (Covers all P & I diagrams in this manual) VI CONTROL COMPRESSOR SB-2 INLET BEARING & BALANCE PISTON CHECK VALVE SB-3 DISCHARGE BEARINGS & SEAL DISCHARGE PRESSURE SC-1 SLIDE VALVE - UNLOAD FLOW GLASS HAND VALVE...
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RWH ROTARY SCREW COMPRESSOR UNITS 070.620-IOM (DEC 12) MAINTENANCE Page 45 SAMPLE P & I DIAGRAM, LIQUID INJECTION – SINGLE PORT NOTICE This is a sample P & I. Actual content will be project specific. SAMPLE P & I DIAGRAM, LIQUID INJECTION – DUAL PORT NOTICE This is a sample P &...
070.620-IOM (DEC 12) RWH ROTARY SCREW COMPRESSOR UNITS Page 46 PROPER INSTALLATION OF ELECTRONIC EQUIPMENT PROPER INSTALLATION OF ELECTRONIC EQUIPMENT IN AN INDUSTRIAL ENVIRONMENT In today’s refrigeration plants, electronic controls have a computer, or a PLC, to malfunction momentarily or cause found their way into almost every aspect of refrigeration a complete reset of the control system.
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This worked for the earlier relay systems, but it is in no way acceptable for electronic control equipment. Johnson ControlsFrick requires that the ground conductor ® Conduit is made of steel and is a poor conductor relative meet the following: to an insulated stranded copper wire.
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All national and local codes must be followed for conduit with regard to materials, spacing and grounding. In addition, WIRING PRACTICES Johnson Controls-Frick requirements must be followed where they exceed or match national or local codes. Con- Do not mix wires of different voltages in the same conduit.
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RWH ROTARY SCREW COMPRESSOR UNITS 070.620-IOM (DEC 12) PROPER INSTALLATION OF ELECTRONIC EQUIPMENT Page 49 These holes are strategically placed so that the field wiring Never run refrigerant tubing inside an electronic control does not interfere with the electronics in the panel. Never panel.
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LX PANELS ™ The use of communications such as serial and ethernet Johnson Controls, Inc. does not advise nor support the use in industrial environments are commonplace. The proper of uninterrupted power supply systems for use with the installation of these networks is as important to the proper Quantum LX panel.
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070.620-IOM (DEC 12) RWH ROTARY SCREW COMPRESSOR UNITS Page 52 MAINTENANCE READ THIS FIRST: RWH COMPRESSOR PRESTART CHECKLIST The following items MUST be checked and completed by the installer prior to the arrival of the Frick Field Service Supervisor. Details on the checklist can be found in this manual. Certain items on this checklist will be reverified by the Frick Field Service Supervisor prior to the actual start-up.
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RWH ROTARY SCREW COMPRESSOR UNITS 070.620-IOM (DEC 12) MAINTENANCE Page 53 Start-up Report Frick Order No: ________________________ Sold To: _______________________________________ Contact Name:__________________________ Date:__________________ End User: ______________________________________ Contact Name:__________________________ Phone:__________________ End User Address: ______________________________________________________________________ Fax No:__________________ City, State, Zip: _________________________________ Startup Representative _________________ Unit General Information Unit Model # ___________________________________________ Customer Package Identification # _________________________ Compressor Serial # _____________________________________ Separator National Board # ________________________________...
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070.620-IOM (DEC 12) RWH ROTARY SCREW COMPRESSOR UNITS Page 54 MAINTENANCE Page 2 Unit Serial # _____________________________ Frick Order No: ____________________________ Capacity Control Setpoints Mode __________________ Mode __________________ Setpoint ________ Regulation Safeties Setpoint ________ Regulation Safeties High Load Inhibit ________ High Load Inhibit _________ Prop.
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RWH ROTARY SCREW COMPRESSOR UNITS 070.620-IOM (DEC 12) MAINTENANCE Page 55 Page 3 Unit Serial # _____________________________ Frick Order No: ____________________________ Compressor Motor Setpoints and Information Motor Name Plate Manufacturer ________________ Motor Amps ___________ Maximum Drive Output ___ % Frame Size ______________ Volts ___________ Minimum Drive Output ___ % H.P.
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070.620-IOM (DEC 12) RWH ROTARY SCREW COMPRESSOR UNITS Page 56 MAINTENANCE Page 4 Unit Serial # ________________ Frick Order No: __________________________________________ P&ID Setpoints Name _________________ __________ _________________ ____________ Control ____________ ____________ ____________ ____________ Action __________________ ____________ __________________ ____________ Control Point __________________ ____________ __________________ ____________ Device Source...
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RWH ROTARY SCREW COMPRESSOR UNITS 070.620-IOM (DEC 12) MAINTENANCE Page 57 VIBRATION DATA SHEET Date: __________________________________________ Sales Order Number: ________________________________ End User: _______________________________________ Installing Contractor: ________________________________ Address: __________________________________________ Service Technician: __________________________________ ___________________________________________________ ___________________________________________________ Final Hot Alignment Equipment ID (As in Microlog): _________________________ Compressor Model Number: _______________________________ Face...
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070.620-IOM (DEC 12) RWH ROTARY SCREW COMPRESSOR UNITS Page 64 INSTALLATION - OPERATION - MAINTENANCE Form 070.620-IoM (2012-12) Johnson Controls Supersedes: NOTHING 100 CV Avenue Subject to change without notice Waynesboro, PA 17268-1206 USA Published in USA • GUI • 12-12 PDF Phone: 717-762-2121 •...
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