Johnson Controls Frick RWF 100, Installation Manual

Page 1: ...EAD THOROUGHLY BEFORE BEGINNING INSTALLATION FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DAMAGE OR IMPROPER OPERATION OF THE UNIT 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 Please check www frickcold com for the latest version of this publication ...

Page 2: ... SHUTDOWN and START UP 21 GENERAL INSTRUCTIONS FOR REPLACING COMPRESSOR UNIT COMPONENTS 22 OIL FILTER OF 1 MAIN SINGLE DUAL 22 STRAINER DEMAND OIL PUMP 22 STRAINER LIQUID INJECTION 23 COALESCER FILTER ELEMENT S 23 CHANGING OIL 23 DEMAND PUMP 24 RECOMMENDEDMAINTENANCE PROGRAM 28 VIBRATION ANALYSIS 28 MOTOR BEARINGS 28 OIL QUALITY and ANALYSIS 28 OPERATING LOG 29 MAINTENANCE SCHEDULE 29 TROUBLESHOOT...

Page 3: ...wn and provisions made for control operating cycles and de frost ing periods are reasonable and that high side condensers are sized within system and compressor design limits It is recommended that the entering vapor temperature to the compressor be superheated to 10 F above the refriger ant saturation temperature This assures that all refrigerant at the compressor suction is in the vapor state DE...

Page 4: ...ructure However this may increase package vibration levels because the compressor is not in contact with any damping mass The mounting and support of suction and discharge lines is also very important Rubber or spring pipe supports may be required to avoid exciting the build ing structure at any pipe supports close to the compressor package It is best to employ a vibration expert in the design of ...

Page 5: ...E LUBE TORQUE Size ft lb Nm ft lb Nm BPU 38 22 29 8 13 17 6 BPU 41 55 74 6 13 17 6 BPU 47 120 162 7 13 17 6 BPU 54 120 162 7 13 17 6 OIL PUMP COUPLING Compressor units with direct motor pump coupled pumps need no pump motor coupling alignment since this is main tained by the close coupled arrangement HOLDING CHARGE AND STORAGE Each RWF II compressor unit is pressure and leak tested at the Johnson ...

Page 6: ...at the condenser tem perature in a plate and shell vessel cooling the oil to within 15 F of that temperature The vapor at condensing pressure is vented to the condenser inlet and reliquified This method is the most cost effective of all currently applied cooling systems since no compres sor capacity is lost or compressor power penalties in curred The vapor from the cooler need only be con densed n...

Page 7: ...o control oil temperature It is IMPERATIVE that an uninterrupted supply of high pres sure liquid refrigerant be provided to the injection system at all times Two items of EXTREME IMPOR TANCE are the design of the receiver liquid injection supply and the size of the liquid line It is recommended that the receiver be oversized sufficient ly to retain a 5 minute supply of refrig erant for oil cooling...

Page 8: ...eat exchanger It is important to establish regular cleaning schedules Cleaning A 3 solution of Phosphoric or Oxalic Acid is recommended Other cleaning solutions can be obtained from your local distributor but they must be suitable for stainless steel The oil cooler may be cleaned in place by back flushing with recommended solution for approximately 30 minutes After back flushing rinse the heat exc...

Page 9: ...d result in motor overload Example A system feeding liquid to the flash vessel in batches The recommended economizer systems are shown below Notice that in all systems there should be a strainer STR and a check valve VCK between the economizer vessel and the economizer port on the compressor The strainer prevents dirt from passing into the compressor and the check valve prevents oil from flowing f...

Page 10: ...antum the panel may not see the loss of the 3 phase voltage on the motor because the UPS could prevent the motor starter contactor from dropping out With the starter contactor still energized the compressor auxiliary will continue to feed an Okay signal to the panel This will allow the motor to be subjected to a fault condition on the 3 phase bus Some fault scenarios are 1 The 3 phase bus has powe...

Page 11: ...sor motor starter coil s NOTE Do not install a compressor HAND OFF AUTO switch in the starter package as this would bypass the compressor safety devices 7 The compressor motor Current Transformer CT is in stalled on any one phase of the compressor leads NOTE The CT must see all the current of any one phase therefore in wye delta applications BOTH leads of any one phase must pass through the CT CUR...

Page 12: ... 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 23 112 4 120 VA 60 HZ SHOWN HERE CONSULT FRICK FOR OTHER VOLTAGES HZ SOLA ENCLOSURE GND TERM 2A 6A 2 3 PS 1 1 LINE LOAD GREEN FERRITE TUBE 2B 2 GND LUG IN H2 H1 LUG X2 GREEN GND TERM IN MICRO 2 N Figure 11 Recommended Regulator Installation...

Page 13: ...suction port to avoid performance penalties from superheating suction gas 9 Shaft seal design to maintain operating pressure on 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 clockwise facing compressor suitable for all types of drives SEE FOLLOWIN...

Page 14: ...n easier start and the discharge check valve will seat more tightly See the SUC TION CHECK VALVE BYPASS section for operation NOTE For alarm descriptions and shutdown or cutout parameters see publication S90 010 O 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 compress...

Page 15: ... bypass Booster Compressor Loading The compressor loads when MSV solenoid YY2 is energized and oil flows from the oil manifold through valve ports P and B to cylinder port SC2 and enters the load side of the cylinder Simultaneously oil con tained in the unload side of the cylinder flows out cyl inder port SC1 through valve ports A and T to com pressor suction Booster Compressor Unloading The compr...

Page 16: ...njection system is design ed to obtain the most efficient compressor performance at high and low compression ratios by permitting injection of liquid refriger ant into one of two ports optimally located on the com pressor This minimizes the performance penalty incurred with liquid injection oil cooling The dual port system contains all the com ponents of the single port system with the addition of...

Page 17: ...ion valve look at the power head of the Thermal Expansion Valve If the unit is using Halocarbon as a refrigerant and is for low temperature the Sporlan number on the power head should be L3 Set the oil temperature for 135 F If the unit is using Halocarbon as a refrigerant and is for high temperature the Sporlan number on the power head should be Y1200 or Y1202 Set the oil temperature for 160 F Whe...

Page 18: ...justment to the Proportional gain may be necessary The use of values in the integral and derivative gains should not be necessary Setpoint 150 F for Ammonia 160 F for R 22 R134A and R507 Dead Band 2 0 F Proportional Gain 5 00 Integral Gain 0 00 Figure 19 Derivative Gain 0 00 High Limit 100 Low Limit 0 Off Value 0 Use the Control Action and Off Value keys to set the following Set the Control for Wh...

Page 19: ...o equalize to suction pressure after shutdown HV 2 can be opened slightly See Figure 20 SE 1 SC 5 FROM SEPARATOR COLD START VALVE SUCTION GAS TO THE COMPR HV 1 HV 2 CK 1 Figure 20 Check valve CK 1 is installed on all RWF packages with suction pressure below atmospheric or when installed with economizer option utilized on multiple compressor plants On high stage systems check valve CK 1 should be i...

Page 20: ...close the valve at any time while the compressor is running The second method is used for compressors with Liquid Injection Oil Cooling Because the discharge temperature is controlled by the Liquid Injection Thermal Expansion Valve you will not be able adjust for the correct oil flow by using the discharge temperature Before the initial startup of the compressor close the hand expansion valve comp...

Page 21: ...onnect 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 MAINTENANCE Proper maintenance is important in order to assure long and trouble free service from your screw compressor unit Some areas critical to good compressor operation are 1 Keep refrigerant and oil clean and dry avoid moisture ...

Page 22: ...vent a sudden pressure drop which could cause an oil filter dif ferential alarm 2 Close outlet then inlet service valves of filter being serviced 3 Open bleed valve and purge pressure from the oil filter cartridge NOTE Recover or transfer all refrigerant vapor in accordance with local ordinances before opening to atmosphere 4 Remove the plug from the bottom of the filter canister and drain the oil...

Page 23: ...Torque nut to 21 ft lb DO NOT OVERTIGHTEN NUT 7 Install new manway gasket and replace manway cover 8 Tighten manway bolts NOTE RE TIGHTEN AFTERTHE COM PRESSOR UNIT IS REPRESSURIZED SINCE MAN WAY BOLTS WILL LOOSEN 9 Refer to CHANGING OIL Steps 9 through 14 CHANGING OIL DO NOT MIX OILS of different brands manufacturers or types Mixing of oils may cause excessive oil foaming nuisance oil level cutout...

Page 24: ...move locknut See Figure 21 or 22 6 Loosen two setscrews in face of bearing housing and turn thrust bearing assembly counterclockwise and remove from casing See Figure 21 or 22 7 GG HJ HL Remove snap ring from shaft See Figure 21 AS AK AL Remove bearing spacer from shaft See Figure 22 8 Remove brass bar or piece of hardwood from port opening 9 The rotor and shaft can now be removed by tapping on en...

Page 25: ...al housing bore Make 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 necessary protect seal face with a clean cardboard disc and gently tap it in place with a piece of wood Be sure seal seat is completely seated in the bore 4 Place tapered installation sleeve on ...

Page 26: ...dd additional 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 2 003 INSTALLATION OF CARBON GRAPHITE BUSHINGS When installing carbon graphite bushings extreme care must be taken to prevent breaking Carbon graphite is a brittle material and easily cracked If c...

Page 27: ...ty 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 speed and is it wired up correctly e Relief valve set too low or stuck open f Pump worn out g Tighten end clearance h Head position incorrect 5 Pump takes too much power a Running too fast is correct mo...

Page 28: ... included in this manual see Table of Contents permits thorough analysis of the operation of a refrigeration system by those responsible for its mainte nance 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 de viations from...

Page 29: ...ing is to define the limits of the problem If for example the compressor peri odically experiences high oil tempera tures do not rely on this observation alone to help identify the problem On the basis of this information the apparent corrective measure would appear to be a readjustment of the liquid injection system Lowering the equalizing pres sure on the thermal expansion valve would increase t...

Page 30: ...s condensed refrigerant often is trapped between the cold start valve and the stop valve Exposure to refrigerant fumes can cause injury or death Inside the valve see Figure 28 there is a very heavy tight spring 15 Provided the valve is intact the spring presents no danger when dismantling The spring is compressed with a large bolt 7 If it is necessary to repair the valve it can be dismantled as fo...

Page 31: ... WHT and BLK on the SBC 13 Measure the voltage of PE 1 on connector P4 terminals WHT and BLK on the SBC 14 These two voltages should be within 04 VDC of one another 15 Test is complete PRESSURE TRANSDUCERS REPLACEMENT 1 Shut off control power 2 Close the applicable transducer isolation valve NOTE To change the discharge pressure transducer PE 3 it will be necessary to depressurize the entire compr...

Page 32: ...is greater than 0 adjust potentio meter POT 4 on the SBC until 0 is indicated If 0 is not attainable get as close as possible and then proceed to the next step The adjust ments of POT 4 and POT 3 are interactive and POT 3 may require adjustment to allow POT 4 to come into range Completely load the slide valve The display at this time should indicate 100 If the display is less than 100 adjust poten...

Page 33: ...onnector plug from transmitter Figure 30 3 Unscrew knurled ring and remove transmitter unit 4 Apply thermal compound to new sensor assembly insert into thermal well and tighten knurled ring 5 Apply DIN connector plug to transmitter 6 Turn on control power NOTE The temperature sensor is factory set If cali bration is required refer to Analog Calibration instruc tions in publication S90 010 O OIL LE...

Page 34: ...the probable cause If a mechanical problem is suspected contact the Service Department Frick DO NOT ATTEMPT TO DISASSEMBLE COMPRESSOR 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 SECTION SIGHT GLASS Refrigerant carryover or liquid injection overfeed ing correct ope...

Page 35: ...de solenoid valve preventing valve from operating both ways Clean Check LED on coil If lit valve is functioning mechanically Problem is electrical Solenoid may be actuated mechanically by inserting a piece of 3 16 rod against armature pin and pushing spool to opposite end Push A side to confirm unload capability If valve works problem is electrical SLIDE STOP WILL NOT FUNCTION Solenoid coils may b...

Page 36: ...FERENTIAL ALARM OIL PRESSURE FLUCTUATES Liquid injection overfeeding or refrigerant flood back from system Make necessary adjustments or correc tions NOISE and VIBRATION Pump strainer blocked Clean Liquid refrigerant overfeed Adjust liquid injec tion Pump worn out Repair or replace GREASE LEAKS FROM VENT PORT Normal leakage which will cease after initial operation Black oil leaking IN THE SIDE OF ...

Page 37: ...GE THE VALVE S PERFORMANCE THIS ADJUSTMENT IS PRESET AT THE FACTORY ONLY AD JUST 1 4 BLEED VALVE ON EQUALIZING LINE Figure 31 TYPE D 1 15 TONS R 717 Figure 32 TYPE A 20 100 TONS R 717 Figure 33 TYPE H 2 1 2 TO 16 TONS R 22 TX VALVE MODE PORT SIZE DISCHARGE TUBE SIZE DAE 1 1 16 1 32 DAE 2 1 16 1 16 DAE 5 7 64 5 64 DAE 10 3 16 7 64 DAE 15 3 16 5 32 AAE 20 5 16 1 8 AAE 30 5 16 5 32 AAE 50 3 8 3 16 AA...

Page 38: ...hat 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 to the left and the slot in the valve disc is on the top this valve is set for Direct Acting see Figure 37 To change the action of the valve to Reverse Act ing simply rotate the valve plate and the ...

Page 39: ...nd wiring that is connected to the compressor 3 Disconnect the coupling from the motor shaft 4 While supporting the motor and compressor assembly with a crane remove the bolts at the motor feet compressor feet and separator flange 5 Thoroughly clean the compressor and motor feet and mounting pads of burrs and other foreign matter to ensure firm seating of the compressor 6 Clean the discharge flang...

Page 40: ...RWF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE S70 600 IOM OCT04 Page 40 P I DIAGRAM ...

Page 41: ...H 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 CONTROLLER TCV THERMAL CONTROL VALVE TE TEMPERATURE ELEMENT TI TEMPERATURE INDICATOR TS TEMPERATURE SWITCH TSH TEMPERATURE SWITCH HIGH ALARM TW THERMOWELL VI VI CONTROL SB 2 INLET BEARING BALANCE PISTON SB ...

Page 42: ...RWF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE S70 600 IOM OCT04 Page 42 P I DIAGRAM LIQUID INJECTION SINGLE PORT P I DIAGRAM LIQUID INJECTION DUAL PORT ...

Page 43: ...RWF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE S70 600 IOM OCT04 Page 43 P I DIAGRAM LIQUID INJECTION BOOSTER ...

Page 44: ...RWF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE S70 600 IOM OCT04 Page 44 WIRING HARNESS Quantum 4 External Transducers for Board 1 ...

Page 45: ...RWF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE S70 600 IOM OCT04 Page 45 WIRING HARNESS Quantum 4A External Transducers for Board 1 ...

Page 46: ...RWF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE S70 600 IOM OCT04 Page 46 WIRING HARNESS Quantum 4 External AC to Heaters and Valves ...

Page 47: ...RWF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE S70 600 IOM OCT04 Page 47 WIRING HARNESS Quantum 4A External AC to Heaters and Valves ...

Page 48: ...2 1 1 2 3 G 1 4 1 1 4 5 1 1 5 6 1 2 1 7 1 2 2 8 G 2 9 1 2 4 10 1 2 5 11 1 3 4 12 1 3 5 13 1 3 6 14 1 4 1 15 1 4 2 16 1 4 3 17 1 4 4 18 1 4 5 19 1 4 6 20 1 5 1 21 1 5 2 22 1 5 3 23 1 7 4 24 1 7 5 25 1 7 6 26 G 3 27 1 8 1 28 1 8 3 29 1 8 2 30 1001 31 1000 32 1002 33 SEAL PLUG WIRING HARNESS Quantum 4 only Internal Analog Board 1 WIRING HARNESS AC Conduit Quantum to DBS Panel WIRING HARNESS Quantum 4...

Page 49: ...o 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 caused by large loads such as heaters and contactors and solenoids These sudden dips in voltage can cause the processor whether it be a microprocessor a computer or a PLC to malfunction momentarily or cause a complete reset of the control sys...

Page 50: ...n the same conduit with 120 volt wires Figure 42 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 These wires may be carrying large transients that will interfere with the operation of the control An extreme example of this would be to run the 480 volts from a motor starter throu...

Page 51: ...lly 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 interfere with the electronics if run too close to the circuitry Never daisy chain or parallel connect power or ground wires to electronic control panels Each electronic control panel must have its own...

Page 52: ...RWF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE S70 600 IOM OCT04 Page 52 OPERATING LOG SHEET ...

Page 53: ...trol 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 sizing and instal lation __ Check all point to point wiring between the micro and motor starter __ Confirm all interconnections between micro motor starter and the system are made and are correct After the ...

Page 54: ...Board 1 Serial _ ______________Rev ______ U13 Analog Ver __________ and Date_ ______________ Analog Board 2 Serial _ ______________Rev ______ U13 Analog Ver __________ and Date_ ______________ Compressor Motor Information Manufacturer___________________________________ Frame Size_______________ H P _____________ RPM_ __________ Serial _ ___________________________Service Factor _______________ Vol...

Page 55: ...p Load_ _____ Force Unload______ Alarm_______ Delay_______ Shutdown______ Delay______ High Oil Temperature Alarm________ Delay_______ Shutdown_______ Delay_ ______ Low Oil Temperature Alarm________ Delay_______ Shutdown_______ Delay_ ______ High Level Shutdown Delay_ _____ Low Separator Oil Temp Alarm________ Delay_______ Shutdown_______ Delay_ ______ Operating Log Sheet Date Time Hour Meter Readi...

Page 56: ...________________ Manufacturer and Size of Coupling _________________________ Motor Manufacturer RAM_________________________________ Motor Serial Number _ ___________________________________ RPM __________ Frame Size ___________ H P ______________ Refrigerant ______________________________ Ambient Room Temperature ______________ F Operating Conditions Vibration Data Sheet SUCTION DISCHARGE OIL SEP...

Page 57: ...RWF ROTARY SCREW COMPRESSOR UNITS MAINTENANCE S70 600 IOM OCT04 Page 57 ...

Page 58: ...uid system 27 Liquid vaporizing 26 27 misalignment 26 27 Pressure Gauge 27 pressure gauge 26 pump liquid chamber 26 Relief valve 27 sheave 27 Starving 27 Strainer 27 Suction line 26 suction port 26 vacuum gauge 26 differential pressure 14 dif feren tial pressure control valve 16 digital voltmeter 31 DIN connector 33 discharge check valve 14 19 discharge pressure 13 15 31 discharge pressure transdu...

Page 59: ...ng 49 power feed circuit 49 pump out connection 19 pump head 24 purge valve 22 P I DIAGRAM 40 R Recommended Spare Parts 57 refrigerant isolation valves 7 refriger ant vapor 13 22 regulating control transformer 11 rigging 4 rotors 13 S SBC 31 SBC Board 10 scaling rates 8 ScrewSelect 20 self lubricating 13 separator 5 service valve 23 service valves 24 setpoint 12 SGC compressor 15 shunting device 1...

Page 60: ...ts System integration is what we do Q NET supports open protocols for SCADA systems i e Allen Bradley DF1 Modbus RTU Modbus ASCII and Industrial Ethernet Protocols Q NET connects instantly for local or remote access no software required Q NET can be applied to both new and existing systems Q NET means precise control 24 hours a day seven days a week Q NET distributed architecture mean faster easie...