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ROTARY SCREW COMPRESSOR UNITS
ALL REFRIGERANTS
100 through 480
THIS MANUAL CONTAINS RIGGING, ASSEMBLY, START-UP, AND
MAINTENANCE INSTRUCTIONS. READ THOROUGHLY BEFORE
BEGINNING INSTALLATION. FAILURE TO FOLLOW THESE
INSTRUCTIONS COULD RESULT IN DAMAGE OR IMPROPER
OPERATION OF THE UNIT.
Please check www.frickcold.com for the latest version of this publication.
Form S70-600 IOM (OCT 2004)
INSTALLATION - OPERATION - MAINTENANCE
File:
Replaces:
Dist:
RWF
MODELS
EQUIPMENT MANUAL - Section 70
S70-600 IOM/MAY 2001
3, 3a, 3b, 3c
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Summary of Contents for Johnson Controls Frick RWF 100
- Page 1 Form S70-600 IOM (OCT 2004) INSTALLATION - OPERATION - MAINTENANCE File: EQUIPMENT MANUAL - Section 70 Replaces: S70-600 IOM/MAY 2001 Dist: 3, 3a, 3b, 3c ROTARY SCREW COMPRESSOR UNITS ALL REFRIGERANTS MODELS 100 through 480 THIS MANUAL CONTAINS RIGGING, ASSEMBLY, START-UP, AND MAINTENANCE INSTRUCTIONS.
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Page 2: Table Of Contents
S70-600 IOM (OCT04) RWF ROTARY SCREW COMPRESSOR UNITS Page 2 INSTALLATION - OPERATION - MAINTENANCE Contents PREFACE ................3 MAINTENANCE DESIGN LIMITATIONS ............3 GENERAL INFORMATION ..........21 JOB INSPECTION .............3 NORMAL MAINTENANCE OPERATIONS ......21 TRANSIT DAMAGE CLAIMS ..........3 GENERAL MAINTENANCE ..........21 COMPRESSOR and UNIT IDENTIFICATION ....3 COMPRESSOR SHUTDOWN and START-UP ....21 INSTALLATION GENERAL INSTRUCTIONS FOR REPLACING... -
Page 3: Preface
It is most important that these units be properly applied to an from these data plates. adequately controlled refrigeration system. Your authori zed Johnson Controls-Frick representative should be con sulted for his expert guidance in this determination. Proper performance and continued satisfaction with these... -
Page 4: Installation
S70-600 IOM (OCT04) RWF ROTARY SCREW COMPRESSOR UNITS Page 4 INSTALLATION vertical pipe run) so that the lines won’t move if disconnected Installation from the compressor. See table for Allowable Flange Loads. FOUNDATION ALLOWABLE FLANGE LOADS NOZ. MOMENTS (ft-lbf) LOAD (lbf) Each RWF Rotary Screw Compressor Unit is shipped SIZE AXIAL VERT. -
Page 5: Checking Motor/Compress Or Rota Tion
After verification, install disk drive spacer, as applicable. Each RWF II compressor unit is pressure and leak tested at the Johnson Controls-Frick factory and then thoroughly evacuated and charged with dry nitrogen to ensure the COMPRESSOR/MOTOR COUPLING integrity of the unit during shipping and short term storage prior to installation. -
Page 6: Oil Charge
S70-600 IOM (OCT04) RWF ROTARY SCREW COMPRESSOR UNITS Page 6 INSTALLATION OIL CHARGE con densed, not compressed. Refrigerant flow to the cooler is BASIC* automatic, driven by the thermosyphon principle and cooling MODEL CHARGE The normal charging level is mid- flow increases as the oil inlet temperature rises. -
Page 7: Liquid Injection Oil Cooling (Optional)
RWF ROTARY SCREW COMPRESSOR UNITS S70-600 IOM (OCT04) INSTALLATION Page 7 INSTALLATION - The plate and shell type thermosyphon oil 2. The liquid level in the refrigerant source must be 6 to 8 cooler with oil-side piping and a thermostatically controlled feet minimum above the center of the oil cooler. -
Page 8: Liquid Line Sizes/Receiver Volume
S70-600 IOM (OCT04) RWF ROTARY SCREW COMPRESSOR UNITS Page 8 INSTALLATION WATER-COOLED OIL COOLING (OPTION AL) The level-control method (Figure 5) utilizes a float level control on the receiver to close a solenoid valve feeding the The plate and shell type water-cooled oil cooler is mounted evaporator when the liquid falls below that amount necessary on the unit complete with all oil piping. -
Page 9: Economizer - High Stage (Optional)
RWF ROTARY SCREW COMPRESSOR UNITS S70-600 IOM (OCT04) INSTALLATION Page 9 ECONOMIZER - HIGH STAGE (OPTIONAL) The recommended economizer systems are shown below. Notice that in all systems there should be a strainer (STR) The economizer option provides an increase in system ca- and a check valve (VCK) between the economizer vessel pacity and efficiency by subcooling liquid from the condenser and the economizer port on the compressor. -
Page 10: Electrical
S70-600 IOM (OCT04) RWF ROTARY SCREW COMPRESSOR UNITS Page 10 INSTALLATION the PRR unit and the liquid feed solenoid on the DX vessel 1. The 3-phase bus has power “on” and “off” in a continuous off of a common signal to avoid liquid overfeed on the DX cyclic manner which may cause the motor to overheat economizer system. -
Page 11: Current Transformer (Ct) Ratios
RWF ROTARY SCREW COMPRESSOR UNITS S70-600 IOM (OCT04) INSTALLATION Page 11 3. The oil pump starter with fuses, or in the case where the 7. The compressor motor Current Transformer (CT) is in- stalled on any one phase of the compressor leads. compressor motor is a different voltage from the oil pump motor, with a circuit breaker disconnect suitable for sepa rate NOTE: The CT must see all the current of any one phase,... -
Page 12: Control Power Regulator
S70-600 IOM (OCT04) RWF ROTARY SCREW COMPRESSOR UNITS Page 12 INSTALLATION CONTROL POWER REGULATOR Compressor units that will be used in areas that suffer brown- outs and other significant power fluctuations can be supplied with a control power regulator. See Figure 11, Recommended Regulator Installation. -
Page 13: Operation
RWF ROTARY SCREW COMPRESSOR UNITS S70-600 IOM (OCT04) OPERATION Page 13 11. Shaft rotation clockwise facing compressor, suitable for Operation all types of drives. SEE FOLLOWING CAUTION. Compressor rotation is clockwise OPERATION and START-UP INSTRUCTIONS when facing the compressor drive The Frick RWF Rotary Screw Compressor Unit is an inte- shaft. -
Page 14: Cold-Start System
S70-600 IOM (OCT04) RWF ROTARY SCREW COMPRESSOR UNITS Page 14 OPERATION For normal high-stage operation an oil pump is not NOTE: For alarm descriptions and shutdown or cutout parameters, see publication S90-010 O. required. COLD-START SYSTEM DEMAND PUMP OIL SYSTEM The RWF package is equipped with a special "cold start"... -
Page 15: Compressor Hydraulic System
RWF ROTARY SCREW COMPRESSOR UNITS S70-600 IOM (OCT04) OPERATION Page 15 COMPRESSOR HYDRAULIC SYSTEM SEE HYDRAULIC SCHEMATIC The compressor hydraulic system moves the movable slide FOR FUNCTIONAL valve (MSV) to load and unload the compressor. It also moves VIEW OF VALVE the movable slide stop (MSS) to increase or decrease the OPERATION compressor’s volume ratio (Vi). -
Page 16: Compressor Oil Cooling Systems
S70-600 IOM (OCT04) RWF ROTARY SCREW COMPRESSOR UNITS Page 16 OPERATION COMPRESSOR OIL COOLING SYSTEMS DUAL-PORT LIQUID INJECTION The RWF unit can be equipped with one of several systems The dual-port liquid injection system is design ed to obtain for controlling the compressor oil tempera ture. They are single the most efficient compressor performance at high and low or dual-port liquid injection and thermo syphon or water- compression ratios by permitting injection of liquid refriger ant... -
Page 17: Easy-Cool™ Liquid Injectionadjustment
RWF ROTARY SCREW COMPRESSOR UNITS S70-600 IOM (OCT04) OPERATION Page 17 After the adjustment s been, made wait until the oil and If the unit is using Halocarbon as a refrigerant and is for high temperature, the Sporlan number on the power head should discharge temperatures have had a chance to stabilize before readjusting. - Page 18 S70-600 IOM (OCT04) RWF ROTARY SCREW COMPRESSOR UNITS Page 18 OPERATION • Press [Menu] > [Control Setup] > [More] > [PID • Press [PID Setup] for Output Channel 1 PID. Setup], you should see the screen in Figure 18. Figure 18 Figure 19 Refer to the screen in Figure 19 for the following steps: Derivative Gain: 0.00...
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Page 19: Suction Check Valve Bypass
RWF ROTARY SCREW COMPRESSOR UNITS S70-600 IOM (OCT04) OPERATION Page 19 • The Output should be reading 0% with the machine off On booster systems, check valve CK-1 should be installed line. with a 15 psi spring to avoid the possibility of air ingress With the machine off line press [Menu] >... -
Page 20: Initial Start-Up
S70-600 IOM (OCT04) RWF ROTARY SCREW COMPRESSOR UNITS Page 20 OPERATION INITIAL START-UP 2. For proper and safe operation, the compressor must be run at the proper speed and discharge pressure. Exceeding Initial start-up must be performed under the super vision design conditions creates a potential hazard. -
Page 21: Maintenance
RWF ROTARY SCREW COMPRESSOR UNITS S70-600 IOM (OCT04) MAINTENANCE Page 21 Maintenance GENERAL INFORMATION 1. IF UNIT IS RUNNING, PRESS [STOP] KEY. This section provides instructions for normal main tenance, 2. DISCONNECT POWER FROM UNIT BEFORE PER- a recommended maintenance program, troubleshooting and FORMING ANY MAINTENANCE. -
Page 22: General Instructions For Replacing Compressor Unit Components
S70-600 IOM (OCT04) RWF ROTARY SCREW COMPRESSOR UNITS Page 22 MAINTENANCE GENERAL INSTRUCTIONS FOR REPLACING 3. Open bleed valve and purge pressure from the oil filter cartridge. NOTE: Recover or transfer all refrigerant vapor, COMPRESSOR UNIT COMPONENTS in accordance with local ordinances, before opening to atmosphere. -
Page 23: Strainer - Liquid Injection
RWF ROTARY SCREW COMPRESSOR UNITS S70-600 IOM (OCT04) MAINTENANCE Page 23 STRAINER - LIQUID INJECTION 6. Replace coalescer filter retainer and nut. Torque nut to 21 ft-lb. DO NOT OVERTIGHTEN NUT. To clean the liquid injection strainer the unit must be shut 7. -
Page 24: Demand Pump
S70-600 IOM (OCT04) RWF ROTARY SCREW COMPRESSOR UNITS Page 24 MAINTENANCE sight glass. Refer to the table in the OIL CHARGE section the locknut counterclockwise and remove locknut. See Figure 21 or 22. for approximate oil charge quantities. 12. Open the suction and discharge service valves, and 6. - Page 25 RWF ROTARY SCREW COMPRESSOR UNITS S70-600 IOM (OCT04) MAINTENANCE Page 25 3. Start seal seat in seal housing bore. If force is necessary, Clean all parts thoroughly and examine for wear or damage. Check lip seals, ball bearings, bushing, and idler pin and protect seal face with a clean cardboard disc and gently tap it replace if necessary.
- Page 26 S70-600 IOM (OCT04) RWF ROTARY SCREW COMPRESSOR UNITS Page 26 MAINTENANCE INSTALLATION OF 13. Pack lubrication chamber between inner ball bearing and double-row ball bearing in the thrust-bearing assembly CARBON GRAPHITE BUSHINGS approximately one-half full of multipurpose grease, NLGI #2. The thrust-bearing assembly will take the remaining space.
- Page 27 RWF ROTARY SCREW COMPRESSOR UNITS S70-600 IOM (OCT04) MAINTENANCE Page 27 Pressure Gauge - Discharge Port d. Running too slowly - is motor the correct speed and is it wired up correctly 1. High reading would indicate: e. Relief valve set too low or stuck open. a.
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Page 28: Recommendedmaintenance Program
S70-600 IOM (OCT04) RWF ROTARY SCREW COMPRESSOR UNITS Page 28 MAINTENANCE RECOMMENDED 1. Only use Frick refrigeration oil and filter elements or warranty claim may be denied. MAINTENANCE PROGRAM 2. Participate in a regular, periodic oil analysis program to In order to obtain maximum compressor unit perform ance maintain oil and system integrity. -
Page 29: Troubleshooting Guide
RWF ROTARY SCREW COMPRESSOR UNITS S70-600 IOM (OCT04) MAINTENANCE Page 29 NLGI Grease Compatibility Chart 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. -
Page 30: Servicing The Cold-Start Valve
S70-600 IOM (OCT04) RWF ROTARY SCREW COMPRESSOR UNITS Page 30 MAINTENANCE 5. Inadequate refrigerant charge or low receiver level. NOTE: Step 1 is not strictly necessary when dismantling the valve, but will prevent the valve seat gasket from be- 6. Excessively high or low temperature coolant to the oil ing exposed to a shear load, and it will keep all internal cooler. -
Page 31: Pressure Transducers - Testing
RWF ROTARY SCREW COMPRESSOR UNITS S70-600 IOM (OCT04) MAINTENANCE Page 31 BONNET CAP SCREW TORQUE VALUES PRESSURE TRANSDUCER CONVERSION DATA 200 psi 500 psi Valve Valve Screw Sensor Range - PSI Range - PSIG* Size Torque Size Torque Size Voltage high high DN (mm) -
Page 32: Position Potentiometer Replacement And Adjust Ment
S70-600 IOM (OCT04) RWF ROTARY SCREW COMPRESSOR UNITS Page 32 MAINTENANCE 4. Loosen screw and disconnect wiring harness connector The resistance should be 1000 +/- 50 ohms. If adjustment is from transducer. necessary, loosen the locknut and rotate the potentiometer clockwise or counterclock wise until the resistance reading 5. -
Page 33: Volumizer® Transmitter Replacement - Slide Stop
RWF ROTARY SCREW COMPRESSOR UNITS S70-600 IOM (OCT04) MAINTENANCE Page 33 7. Apply DIN connector plug to transmitter. 5. Apply DIN connector plug to transmitter. 8. Turn on control power. 6. Turn on control power. NOTE: For calibration instructions, refer to Quantum ™... -
Page 34: Troubleshooting The Rwf Compressor
S70-600 IOM (OCT04) RWF ROTARY SCREW COMPRESSOR UNITS Page 34 MAINTENANCE TROUBLESHOOTING THE RWF COMPRESSOR SYMPTOM PROBABLE CAUSES and CORRECTIONS EXCESSIVE NOISE and VIBRATION Main oil injection valve may be closed. Open valve. Bearing damage or excessive wear. CONTACT Frick Factor or Frick service. Coupling loose on shaft. -
Page 35: Hydraulic System
RWF ROTARY SCREW COMPRESSOR UNITS S70-600 IOM (OCT04) MAINTENANCE Page 35 TROUBLESHOOTING THE HYDRAULIC SYSTEM SYMPTOM PROBABLE CAUSES and CORRECTIONS SLIDE VALVE WILL NOT LOAD OR Solenoid coils may be burned out. Replace. UNLOAD Valve may be closed. Open hydraulic service valves. Solenoid spool may be stuck or centering spring broken. -
Page 36: Demand Pump System
S70-600 IOM (OCT04) RWF ROTARY SCREW COMPRESSOR UNITS Page 36 MAINTENANCE TROUBLESHOOTING THE DEMAND PUMP SYSTEM SYMPTOM PROBABLE CAUSES and CORRECTIONS PUMP WILL NOT PRODUCE Check pump rotation. ENOUGH OIL PRESSURE TO START COMPRESSOR Check that service valves are open. Filter cartridges may be blocked. -
Page 37: Thermal Expansion Valves
RWF ROTARY SCREW COMPRESSOR UNITS S70-600 IOM (OCT04) MAINTENANCE Page 37 THERMAL EXPANSION VALVES In situations where system load conditions increase or de- crease over extended periods of time and the liquid injection thermal expansion valve is not adequate for the new condi- tions, an improvement in valve perfor mance may be achieved by increasing or decreasing discharge tube size. -
Page 38: Jordantemperature Regulator Valve
S70-600 IOM (OCT04) RWF ROTARY SCREW COMPRESSOR UNITS Page 38 MAINTENANCE JORDAN If the hole in the valve plate is to the left and the slot in the valve disc is on the top this valve is set for Direct Acting (see TEMPERATURE REGULATOR VALVE Figure 37). -
Page 39: Motor Replacement
RWF ROTARY SCREW COMPRESSOR UNITS S70-600 IOM (OCT04) MAINTENANCE Page 39 Install the valve and adjust the spring tension accordingly 10. Using the crane, set the new assembly in place and shim to maintain the predetermined oil temperature. The rec- the motor and compressor feet wherer required. -
Page 40: P & I Diagram
S70-600 IOM (OCT04) RWF ROTARY SCREW COMPRESSOR UNITS Page 40 MAINTENANCE P & I DIAGRAM... - Page 41 RWF ROTARY SCREW COMPRESSOR UNITS S70-600 IOM (OCT04) MAINTENANCE Page 41 P & I DIAGRAM - OPTIONAL DUAL OIL FILTERS, DEMAND OIL PUMP, THERMAL CONTROL VALVE SEPARATOR TO COMPRESSOR PALL TAHH OPTIONAL CV-2 DEMAND STR-2 OIL PUMP PM-1 CV-1 PDAH OF-1 OPTIONAL THERMAL...
- Page 42 S70-600 IOM (OCT04) RWF ROTARY SCREW COMPRESSOR UNITS Page 42 MAINTENANCE P & I DIAGRAM, LIQUID INJECTION – SINGLE PORT P & I DIAGRAM, LIQUID INJECTION – DUAL PORT...
- Page 43 RWF ROTARY SCREW COMPRESSOR UNITS S70-600 IOM (OCT04) MAINTENANCE Page 43 P & I DIAGRAM, LIQUID INJECTION – BOOSTER...
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Page 44: Wiring Harness
S70-600 IOM (OCT04) RWF ROTARY SCREW COMPRESSOR UNITS Page 44 MAINTENANCE WIRING HARNESS (Quantum 4) - External Transducers for Board #1... - Page 45 RWF ROTARY SCREW COMPRESSOR UNITS S70-600 IOM (OCT04) MAINTENANCE Page 45 WIRING HARNESS (Quantum 4A) - External Transducers for Board #1...
- Page 46 S70-600 IOM (OCT04) RWF ROTARY SCREW COMPRESSOR UNITS Page 46 MAINTENANCE WIRING HARNESS (Quantum 4) - External AC to Heaters and Valves...
- Page 47 RWF ROTARY SCREW COMPRESSOR UNITS S70-600 IOM (OCT04) MAINTENANCE Page 47 WIRING HARNESS (Quantum 4A) - External AC to Heaters and Valves...
- Page 48 S70-600 IOM (OCT04) RWF ROTARY SCREW COMPRESSOR UNITS Page 48 MAINTENANCE WIRING HARNESS (Quantum 4 only) - Internal Analog Board #1 CAV NO. WIRE NO. 1.1.1 1.1.2 1.1.4 1.1.5 1.2.1 1.2.2 1.2.4 1.2.5 1.3.4 1.3.5 1.3.6 1.4.1 1.4.2 1.4.3 1.4.4 1.4.5 1.4.6 1.5.1...
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Page 49: Proper Installation Of Electronic Equipment In An Industrial Environment
RWF ROTARY SCREW COMPRESSOR UNITS S70-600 IOM (OCT04) PROPER INSTALLATION OF ELECTRONIC EQUIPMENT Page 49 PROPER INSTALLATION OF ELECTRONIC EQUIPMENT IN AN INDUSTRIAL ENVIRONMENT VOLTAGE SOURCE In today’s refrigeration plants, electronic controls have found their way into almost every aspect of refrigeration control. Electronic controls have brought to the industry more precise Selecting the voltage source is extremely important for control, improved energy savings and operator conveniences. - Page 50 S70-600 IOM (OCT04) RWF ROTARY SCREW COMPRESSOR UNITS Page 50 PROPER INSTALLATION OF ELECTRONIC EQUIPMENT GROUNDING 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 a junction box. Grounding is the most important factor for successful op- These wires may be carrying large transients that will interfere eration and is also the most overlooked.
- Page 51 RWF ROTARY SCREW COMPRESSOR UNITS S70-600 IOM (OCT04) PROPER INSTALLATION OF ELECTRONIC EQUIPMENT Page 51 Never add relays, starters, timers, transformers, etc. in- PLANT SUPPLY side an electronic control panel without first contacting TRANSFORMER the manufacturer. Contact arcing and EMI emitted from 3-PHASE these devices can interfere with the electronics.
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Page 52: Forms
S70-600 IOM (OCT04) RWF ROTARY SCREW COMPRESSOR UNITS Page 52 MAINTENANCE OPERATING LOG SHEET... - Page 53 RWF ROTARY SCREW COMPRESSOR UNITS S70-600 IOM (OCT04) MAINTENANCE Page 53 RWF 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.
- Page 54 S70-600 IOM (OCT04) RWF ROTARY SCREW COMPRESSOR UNITS Page 54 MAINTENANCE START-UP REPORT Sold To: _____________________________________ Contact Name: _______________________ Date: ________________ End User: ___________________________________ Contact Name: _______________________ Phone: ______________ End User Address: _________________________________________________________________ Fax No: ______________ City, State, Zip: ________________________________________________ Start-up Rep. _____________________________ Unit General Information Unit Model # _______________________________ Customer Package Identification # _____________________________...
- Page 55 RWF ROTARY SCREW COMPRESSOR UNITS S70-600 IOM (OCT04) MAINTENANCE Page 55 Adjustable Safety Setpoints High Discharge Pressure Stop Load _____ Force Unload _____ Alarm ______ Delay ______ Shutdown _____ Delay _____ High Discharge Temp. Stop Load _____ Force Unload _____ Alarm ______ Delay ______ Shutdown _____ Delay _____ Motor Amps ______ Volts ______ Service Factor _______ Horsepower________ CT Factor ______ Recycle Delay _______ Low Motor Amps Shutdown ______ Delay ______ Force Unload Inhibit Delay _______...
- Page 56 S70-600 IOM (OCT04) RWF ROTARY SCREW COMPRESSOR UNITS Page 56 MAINTENANCE VIBRATION DATA SHEET Date: ______________________________________ Sales Order Number: _____________________________ End User: ___________________________________ Installing Contractor: _____________________________ Address: ______________________________________ Service Technician: ______________________________ ______________________________________________ ______________________________________________ _________________________ Equipment ID (As in Microlog): Compressor Serial Number: ______________________________ Unit Serial Number: _____________________________________ National Board Number: _________________________________ Running Hours: ________________________________________...
- Page 57 RWF ROTARY SCREW COMPRESSOR UNITS S70-600 IOM (OCT04) MAINTENANCE Page 57...
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Page 58: Index
S70-600 IOM (OCT04) RWF ROTARY SCREW COMPRESSOR UNITS Page 58 NOTES Index carbon graphite bushings, 26 gas flow, 9 End Clearance Adjustment, 27 isolation valve, 9 idler, 25 liquid feed solenoid, 9,10 idler bushing, 24 outlet pressure regulator, 9 idler pin, 24 Packaged Refrigerant Recirculation, 9 across-the-line starters, 11 inner ball bearing, 25... - Page 59 RWF ROTARY SCREW COMPRESSOR UNITS S70-600 IOM (OCT04) NOTES Page 59 interposing relay, 11 Oil Level Transmitter, 33 suction service valve, 23 oil pump, 13,23 suction superheat, 29 Oil Pump Coupling, 5 suction valve, 23 keyway setscrews, 5 oil pump starter, 11 superheating suction gas, 13 Oil quality, 28 system suction pressure, 14,19...
- Page 60 Supersedes: S70-600 IOM (MAY01) 100 CV Avenue • P.O. Box 997 Subject to change without notice Waynesboro, PA USA 17268-0997 Published in USA • GUI 1C Phone: 717-762-2121 • FAX: 717-762-8624 www.johnsoncontrols.com © 2008 Johnson Controls Inc. - ALL RIGHTS RESERVED...
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