Johnson Controls RWF 1080, Operating Manual

Page 1: ...SAB 355 including ATEX Screw compressor unit Operating manual en ...

Page 2: ......

Page 3: ...oler Water cooled oil cooler Liquid injection in compressor Single port Dual port Discharge port Standard AC Low Vi port Oil pump Economiser system ECO system Economiser connection Economiser type _________ Ex execution ATEX T3 T4 Other _________ Supply voltage Motor 3 x _________V _________ Hz Control 1 x _________V ________ Hz Heating elements phasing 1 x _________V ________ Hz Motor IP23 IP55 P...

Page 4: ...ing to EN 13136 Vessel data Type External surface m2 Design pressure bar Condenser Evaporator Liquid separator Oil separator Oil cooler Economiser Other Pressure loss if any from safety valve to customer connection based on design pressure bar _____________ Safety valve type Back pressure dependent Back pressure independent ...

Page 5: ...ate 15 3 4 Compressor name plate ATEX 16 3 5 Labelling of explosion proof equipment 17 3 7 Vessel name plate 18 4 Safety precautions 19 4 1 Signs 19 4 2 During operation 20 4 3 Safety during maintenance and service 21 4 4 Electrical installations 22 4 5 Lubricating oils 22 4 6 Purging a refrigeration plant 23 4 7 F gas regulation fluorinated greenhouse gases 23 4 8 Sound and noise data 25 4 8 1 No...

Page 6: ...lve by pass 41 6 18 Balance piston pressure regulator 42 6 19 Low ambient temperature operation 43 6 20 Heating element 43 6 21 Start up 43 6 22 Initial start up procedure 44 6 23 Stopping routine 46 6 24 Long term storage 46 7 Troubleshooting 47 8 Maintenance instructions 52 8 1 Maintenance of compressor unit 52 8 2 Maintenance intervals 53 8 3 Monitoring of operation 54 8 4 Oil 56 8 5 Oil change...

Page 7: ...erators and service engineers It is important that the operating personnel familiarise themselves with the contents of this man ual in order to ensure proper and efficient operation Johnson Controls Denmark is not liable for damage occurring during the warranty period where this is attributable to incorrect operation All compressor intervention within the warranty period must be performed by compe...

Page 8: ...f the declarations of conformity Unit and ATEX are now only contained in the printed manual delivered with the unit and the pdf version uploaded with the order specific documentation Various minor changes 2017 12 Version 1 ATEX information has been added for example table with temperature classes Name plates with EurAsian Conformity mark EAC have been added F gas regulation section has been update...

Page 9: ...trols Denmark ApS This manual must not be copied without the written permission of Johnson Controls Denmark and the contents must not be imparted to a third party nor be used for any unauthorised purpo ses Contravention will be prosecuted The original version of this manual is the English language version If there are any discrepancies or conflicts between the English and any other version that ha...

Page 10: ...pment and or minor injury Note Indicates an operating procedure practice or portion thereof which is essential to highlight 1 4 Requirements for competent persons Personnel working on the unit must be competent in accordance with national safety rules and regulations relating to flammable refrigerants or according to EN 13313 Maintenance work must be performed according to EN 378 or ISO 5149 suppo...

Page 11: ...s initiated by the customer after delivery ATEX The compressor is approved for application in potentially explosive atmospheres provided it is fitted with explosion proof equipment If it is ATEX approved there will be an EX name plate fixed on the unit Please note that special non sparking tools must be used for all maintenance work on the compressor The compressor must NOT be used to evacuate the...

Page 12: ... SAB 355 including ATEX 12 63 004059 en 2019 11 Identification 3 Identification 3 1 Identification All Johnson Controls Denmark equipment can be identified by one or several name plates as illus trated in the following ...

Page 13: ... pressure Allowable pressure Category Pressure system Refrigerant charge Max Allowable temp Min Max Refrigeration unit No Type Year Fluid Group Control V Hz kg bar g bar g C LP side HP side Johnson Controls Denmark ApS Christian X s Vej 201 8270 Højbjerg Denmark www sabroe com 2516 343 Main Fig 2 Name plate for ATEX unit Установка холодильная Назначение Код стандарта сертификата Хладагент Жидкость...

Page 14: ...m The low pressure side of the unit piping system is referred to as the LP side The high pressure side of the unit piping system is referred to as the HP side Category For EC PED approval The maximum category of the piping system CAT 1 2 or 3 or of the assembly unit and piping CAT 3 or 4 Allowable pressure max The max pressure pressure relative to atmospheric pressure that the unit piping system h...

Page 15: ... Plant Decade Month Year Global seq no Additional remarks 1024 0 A 9 0000015 Z Month A JAN B FEB C MAR D APR E MAY F JUN G JUL H AUG K SEP L OCT M NOV N DEC Additional remarks R Remanufactured Z Deviation from standard configuration The compressor name plate contains this information Model no Manufacturer type designation Part no Manufacturer part number Serial no Compressor manufacturing number M...

Page 16: ...sor The ATEX compressor name plate contains this information Model no Manufacturer type designation Part no Manufacturer part number Serial no Compressor manufacturing number Max driver speed rpm Maximum number of revolutions allowed Max allowable pressure psig bar Maximum working pressure of compressor psig bar Assembled in Manufacturing country ...

Page 17: ... the surface temperatures that may occur on the compressor Warning On ATEX executions the limits in Table 2 must always be respected Temp class Max surface temp Max temperature of oil to shaft seal Min ignition temperature of oil T1 450 C 380 C 500 C T2 300 C 230 C 350 C T3 200 C 130 C 250 C T4 135 C 65 C 185 C T5 100 C 30 C 150 C T6 85 C 15 C 135 C Table 2 Temperature classes screw compressors 3 ...

Page 18: ...rty notified body For EC PED approval CAT Category 1 2 3 or 4 according to the PED directive Side For heat exchangers only Refers to the columns Shell side and Tube side Fluid Designation of the primary refrigerant s and the secondary re frigerant s For EC PED approval Designation of the refrigerant s and or the highest fluid group Group 1 or 2 according to the PED directive Allowable pressure PS ...

Page 19: ...ressor blocks and units are usu ally delivered without refrigerant and oil To protect the compressors against internal corrosion they are delivered evacuated of all atmospheric air and charged with dry Nitrogen N2 to an overpressure of 0 5 bar 7 3 PSI In such cases a yellow sign is affixed to a visible spot on the compressor The magnetic field on the rotor may affect pacemakers The motor rotor con...

Page 20: ...The owner of the refrigeration plant is responsible for ensuring that all codes regulations and industry standards are complied with 4 2 During operation Warning All safety features disengagement and interlocks must be in place and function correctly before the equipment is put in operation Never by pass or wire around any safety device Ventilation Before operating the unit always check the functi...

Page 21: ...ecessary stop valves Use the prescribed tools and check that they are properly maintained and in good work ing condition In explosion proof areas use tools suited for this specific purpose Use only Johnson Controls Denmark original spare parts other parts may impair the safety of the compressor unit When performing maintenance the main switch must be locked Use gloves and protective goggles and ma...

Page 22: ...ude the following oil types Code design Oil types M Mineral oil naphtenic base A Synthetic oils based on alkylated aromatics alkyl benzene AP Synthetic oils blended from alkyl benzene and poly alfa olefin base stocks S Semi synthetic oils hydro treated mineral oil on paraffinic base PAO Synthetic oils based on poly alfa olefin POE Synthetic oils based on polyol esters PAG Synthetic oils based on p...

Page 23: ...igeration and air conditioning systems to the atmosphere Note The occurrence of air is usually an indication of poor maintenance or lack of thoroughness at installation Note Ammonia systems should be purged on a regular basis to avoid atmospheric air and other non condensable gases 4 7 F gas regulation fluorinated greenhouse gases In the European F gas regulation No 517 2014 about reduction of har...

Page 24: ...ction system is installed at least every 12 months for equipment that contains fluorinated greenhouse gases in quantities of 500 tonnes of CO2eq or more at least every three months or where a leakage detection system is in stalled at least every six months The equipment must be checked for leakage within one month after a leak has been repaired to ensure that the repair has been effective Recovery...

Page 25: ...vels Type of unit SWL SPL SAB 355 S 112 89 SAB 355 L 112 89 SAB 355 E 112 89 SAB 355 X 112 89 Table 5 Noise data Noise data for other operating conditions can be provided by Johnson Controls Denmark on request Note The actual SPL value on site will be between the stated SPL and SWL depending on the acoustic environment in the machine room In a typical machine room without any noise absorbing mater...

Page 26: ... design considerations regarding function vibrations ther mal expansion and pre stress after welding in order to avoid high load on the compressor unit connections 5 Leak and pressure test according to the applied local codes and rules Isolate the com pressor unit from the test pressure or disconnect pressure transducers and safety valves Never exceed the test pressure of the unit stated on the un...

Page 27: ...Read chapter 4 Safety precautions carefully before operating the unit 6 1 Description of the unit Control system The compressor unit is controlled by an electronic control system The control system is described in a separate manual delivered with the unit Principle drawing Fig 9 Position of valves and components ...

Page 28: ...Operating manual SAB 355 including ATEX 28 63 004059 en 2019 11 Operating instructions Fig 10 Position of valves and components 200 113 101 ...

Page 29: ...rating manual SAB 355 including ATEX 004059 en 2019 11 29 63 Operating instructions 6 2 General P I diagram Fig 11 General P I diagram SAB 355 with oil cooler dual oil filters and oil pump 4809 050 R e v 2 ...

Page 30: ... high Vi PDAH High pressure differential alarm SM 1 Main oil injection PDI Pressure differential indicator SV 1 Vapour injection tongue and groove PDSLL Compressor low diff pressure cut out SD 1 Threaded hole for oil return from coalescer TW 1 Thermowell PE Pressure transducer Pressure transducers indicate PI Pressure indicator PE 1 Oil pressure manifold PIC Pressure indicator controller PE 2 Oil ...

Page 31: ... P I diagram liquid injection dual port Compressor Low Vi Liquid refrigerant from receiver Solenoid valve Strainer Liquid line Sight glass Motorised expansion valve Tubing line 5 170 165 Compressor Low Vi Compressor High Vi To separator Tubing line Motorised expansion valve Solenoid valve Strainer Sight glass Liquid line Liquid refrigerant from receiver Compressor suction pressure 5 170 165 171 ...

Page 32: ...valve pressure transducer Open 123 Stop valve after oil filter Open 124 Regulating valve oil flow Open partly Adjusted acc to manual 125 Service valve pressure transducer Open 126 Cold start valve Open 127 Compressor protection valve Closed Controlled by pilot valve 128 Pilot valve for pos 127 Closed Fixed set point 200 Stop valves oil return Open Dual oil filter optional 135 136 Stop valve before...

Page 33: ... duty roller bearings to carry radial loads at both the inlet and outlet ends of the compressor Heavy duty four point angular contact ball bearings to carry axial loads are mounted at the discharge end of compressor Balance pistons located in the inlet end of the compressor to reduce axial loads on the ax ial load bearings and increase the bearing life Movable slide valve to provide fully modulati...

Page 34: ...t rotor contact or gas bypassing The compressor unit may be equipped with either a no pump or a demand pump lubrication system Additionally either system may contain Dual oil filters and liquid injection Water cooled or thermosyphon oil cooler for compressor oil cooling The rotors are constructed with an asymmetrical profile The male rotor has four lobes and the female rotor has six see Fig 15 Fig...

Page 35: ... gas flow in the oil charge reservoir Some oil however is discharged as a mist which does not separate readily from the gas flow and is carried past the oil charge reservoir One or more coalescer elements then coalesce the oil mist into droplets which fall to the bottom of the coalescer section of the oil separator See Fig 16 The return of this oil to the compressor is con trolled by a throttling ...

Page 36: ...e pressure loss of the gas flow through the nozzle pos 7 is unable to move the piston pos 7 However the pressure loss of the oil flow through the nozzle pos 7 is able to move the piston pos 7 Thus the spring force pos 9 is equalised and a transverse bore pos 10 with a considerably larger bore than pos 7 will open Because the bore is larger oil collections at the oil return valve inlet can quickly ...

Page 37: ...t valve and the stop valve A bleed valve on the side of the check valve is used to vent the space between the check valve and the stop valve Exposure to refrigerant fumes can cause injury or death Warning Inside the valve there is a very heavy tight spring Provided the valve is intact the spring presents no danger when dismantling High stage units For high stage units the cold start valve is equip...

Page 38: ...oduces 0 5 bar 7 psi oil pressure above suction pressure before it fully powers open An oil pump is required to ensure compressor lubrication The unit is also equipped with a suction check valve by pass The oil separator will slowly bleed down to approximate system suction pressure when the unit is stopped This allows the compres sor drive motor to have an easier start and the discharge check valv...

Page 39: ...oading The compressor loads when the MSV solenoid valve YY2 is energised and oil flows from the un loading side of the cylinder out of the port SC1 through the valve ports A and T to the compres sor suction side Simultaneously the discharge pressure loads the slide valve High stage compressor unloading The compressor unloads when the MSV solenoid valve YY1 is energised and oil flows from the oil m...

Page 40: ... If additional control is needed throttle SC2 or BP Note To slow all valve movements i e loading unloading and Vi change throttle valve 186 Fig 21 Volumizer volume ratio control Caution Never open valve BP and valve SC2 at the same time during compressor operation 6 13 Volumizer volume ratio control Note See Fig 20 Compressor hydraulic system for port references Open valve at SC3 6 14 Compressor V...

Page 41: ...uble acting solenoid valve YY9 and it operates as outlined The solenoid valve YY5 is energised by the microprocessor when the temperature sensor in stalled in the oil manifold exceeds the LIOC set point Liquid refrigerant is then passed through the temperature control valve TCV to the double acting solenoid valve YY9 Depending on the compressor s operating volume ratio Vi the microprocessor will s...

Page 42: ...piston pressure regulator is required on some models 496 1080 355 H to reduce the extended overbalance from the thrust balance piston at part load High stage SB 2 oil supply line diagram the diagram shows the three additions described below arranged in parallel Pressure regulating valve Discharge pressure determines compressor thrust balance The proper setting for the pressure regulating valve is ...

Page 43: ... refrigerant in the oil the oil loses its lubricating properties Warning The heating element must not be switched on if the oil level in the reservoir is below minimum in the sight glass Normally it must be turned off when the compressor is in operation Remember to turn off the heating element before draining the oil through the compressor service valve and before opening into the oil reservoir fo...

Page 44: ...sed oil injection valve Some units usually if they have variable speed control VSD are equipped with a motorised valve that controls the amount of oil being led to the rotors This control uses the rotational speed to set the appropriate opening degree of the valve and thereby regulate the amount of oil for the rotor injection so that it follows the rpm of the compressor The motorised valve replace...

Page 45: ...tely Open the valve back up and count the turns that it takes to fully open the valve After the initial start up close the valve halfway If it took 10 turns to open the valve completely then turn it 5 turns If it took 7 turns to open then close the valve 3 turns Do not close the valve any more than the number of turns required to fully open it Note Failure to properly adjust the hand expansion val...

Page 46: ...e closed To reduce the risk of bearing damage it is recommended to rotate to a new position the motor and compressor on a monthly basis If the screw compressor unit is exposed to vibrations during a long shutdown period the interval should be changed to weekly Avoid high vibration level 6 24 Long term storage Long term storage 6 months to 5 years provisions are required regardless of the storage e...

Page 47: ...heck valves strainers etc Malfunction of evaporator Check evaporator fouling accumu lated oil etc liquid expansion valve system filter in liquid line re frigerant charge insufficient Discharge pressure excessively high Safety cut out set too low Check the setting of alarms and warnings control system and the separate safety pressure cut out High discharge line loss Check the valves check valve etc...

Page 48: ...ficient oil cooling function re frigerant cooled Check drain accumulated oil in the oil cooler Check that the gravity fed refrigerant system is full flooded Insufficient oil cooling function liquid injection Check the settings in control system valves and strainer in liquid injection line Compressor protection valve is open or leaking Check the discharge pressure safety cut out settings Check the ...

Page 49: ...il damaged or not seated coalescer elements Replace oil charge and coalescers Coalescer return valve closed Open return valve Coalescing oil return line strainer blocked Clean strainer Rapid loss with no oil level in the coalescer section sight glass On shutdown compressor unit suc tion check valve did not close Repair valve Suction check valve bypass open too far Close valve Coalescers loose or n...

Page 50: ...er or under compression Calibrate Coupling loose on shaft Tighten coupling Replace if damaged Refrigerant flood back Liquid slugging Correct system problem Capacity slide valve and or slide stop will not move Cannot unload load or both Oil pressure is not sufficient Check oil pressure Solenoid coils may be burned out Replace Incorrect setting of valves in the hy draulic system Check according to h...

Page 51: ...tling valve too wide open or oil pressure regulating valve improperly adjusted Readjust both valves Oil pressure fluctuates Liquid injection overfeeding or re frigerant flood back from system Make necessary adjustments or corrections Noise and vibrations Pump strainer blocked Clean strainer Liquid refrigerant overfeed Adjust liquid injection Pump worn out Repair or replace Grease leaks from vent p...

Page 52: ...groups 1 Daily maintenance minimum twice a week Daily maintenance consists of visual inspections Inspect the compressor unit and check that both noise and vibrations are normal To observe trends it is recommended to enter the observed operating data into an operations log see subsection Check that all operating values are within the per missible ranges Compare them with previous values to detect t...

Page 53: ...seal When leak rate exceeds 7 8 drops per minute a Check bolts shim packs centre inserts keys and all bolt torque b Check and torque all terminals in the processor and starter panel per the specification posted in the enclosure c Check calibration of slide valve slide stop and pressure d Booster 20 000 h High stage air conditioning 10 000 h One stage 30 000 h e Not for flange motors f Vibration me...

Page 54: ...is required that you enter certain routines in a logbook on a regular basis You can use the items listed in the Start up log which is page 2 of the Checklist il lustrated in Fig 24 The service engineer will need this information in connection with for exam ple error reports In addition to the items listed in the start up log all other activities of service maintenance or re pair work must be enter...

Page 55: ...hird party components electric motors valves etc Check unit installation and vibration damper adjustment Carry out functional testing of safety equipment Read the opening pressures on all safety valves and check that they are correct Carry out vacuum test Check Unisab set up see list of settings and check VSD set up as applicable Check oil level Check that the heating element in the oil has been o...

Page 56: ...you to let Johnson Controls Denmark s service organisation change the oil as it is rec ommended to replace all filters in the unit at the same time Type of unit Oil separator Total Volume Amount of oil per 10 mm Sight glass level Volume litres Volume gallon Volume litres Volume gallon SAB 355 OHU 6041 5030 Upper 667 176 15 4 Middle 588 155 16 4 Lower 507 134 17 4 SAB 355 OHU 7650 6050 Upper 2 piec...

Page 57: ...ualise the pressure The hoses can now be dismantled 7 Loosen the non return valve carefully to equalise the remaining pressure Remember to mount the cap nut on the charge valve and to seal the oil barrel if there is any oil left Fig 25 Oil charging Fig 26 Piping diagram for oil charging Length 460 mm Height 350 mm Width 340 mm Weight 22 kg Part number 4541 001 3 8 RG 1 4 RG 1 2 RG 7 8 RG RG Pipeth...

Page 58: ...otor lubrication In connection with electric motors it is absolutely essential to lubricate the bearings correctly and use the appropriate type of grease Please refer to the motor manual and or the motor name plate Replacing motor bearings Please contact Johnson Controls Denmark s service organisation ...

Page 59: ...y careful when using cutting tools such as angle grinders or flame cutters during the dis mantling process as pipes and the like contain oil residue and refrigerant which may be toxic and or flammable 9 2 Waste disposal Machine parts When dismantling the plant it is important to properly sort the parts that should be disposed of The compressor frame containers and so on belonging to the category o...

Page 60: ... version of the declaration however not filled in with the specific data for your unit The translated version is also included in the operating manual that is available for download with the rest of the order specific documentation The original signed declaration of conformity is sent separately in accordance with the Guide to application of the Machinery Directive If more than one declaration of ...

Page 61: ... Compressor lubrication system 34 Compressor name explanation 8 Compressor name plate 15 Compressor name plate ATEX 16 Compressor oil cooling systems 41 Compressor oil separation system 35 Compressor Vi decrease 40 Compressor Vi increase 40 Cooling water system 21 D Declaration of conformity 60 Demand pump oil system 35 Descriptions of main components and systems 33 Dual port liquid injection 41 F...

Page 62: ... 54 Motor lubrication 58 N Noise data 25 Normal start up procedure 45 O Oil change 56 Oil return valve 36 Oil types 22 P Power supply 22 Pressure 20 Pump oil system no pump oil system 34 Purging 23 R Refrigerants 22 Rotating parts 20 S SABROE 8 Safety during maintenance and service 21 Safety precaution definitions 10 Safety signs 19 Single port liquid injection 41 Stopping routine 46 Suction check...

Page 63: ...ting manual SAB 355 including ATEX 004059 en 2019 11 63 63 U Unit pipe system name plate 13 V Valve positions during operation 32 Vessel name plate 18 Vibration and noise 20 Volumizer volume ratio control 40 ...

Page 64: ...Johnson Controls Denmark ApS SABROE Factory Christian X s Vej 201 8270 Højbjerg Denmark Phone 45 87 36 70 00 www sabroe com Version 2 ...