RWB II ROTARY SCREW COMPRESSOR UNITS
INSTALLATION - OPERATION - MAINTENANCE
S70-210 IOM
Page 2
Contents
PREFACE .......................................................................... 3
DESIGN LIMITATIONS ...................................................... 3
JOB INSPECTION ............................................................. 3
TRANSIT DAMAGE CLAIMS ............................................ 3
COMPRESSOR and UNIT IDENTIFICATION ................... 3
Installation
FOUNDATION ................................................................... 4
RIGGING and HANDLING ................................................ 4
SKID REMOVAL ................................................................ 4
MOTOR MOUNTING ......................................................... 5
CHECKING MOTOR/COMPRESSOR ROTATION ............... 5
COMPRESSOR/MOTOR COUPLINGS INSTALLATION ... 5
COUPLING ALIGNMENT PROCEDURE .......................... 7
HOT ALIGNMENT OF COMPRESSOR/MOTOR ................ 9
OIL PUMP COUPLING ...................................................... 9
HOLDING CHARGE AND STORAGE ............................... 9
COMPRESSOR OIL .......................................................... 9
INITIAL OIL CHARGE ....................................................... 9
OIL HEATER(S) ............................................................... 10
OIL FILTER(S) ................................................................. 10
LIQUID INJECTION OIL COOLING ................................ 10
LIQUID LINE SIZES/RECEIVER VOLUME ..................... 10
WATER-COOLED OIL COOLING (OPTIONAL) ................ 11
THERMOSYPHON OIL COOLING (OPTIONAL) ............. 11
ECONOMIZER - HIGH STAGE (OPTIONAL) .................. 13
ELECTRICAL .................................................................. 14
MOTOR STARTER PACKAGE ........................................ 14
CURRENT TRANSFORMER (CT) RATIOS .................... 15
MINIMUM BURDEN RATINGS ........................................ 15
BATTERY BACKUP ......................................................... 15
Operation
OPERATION and START-UP INSTRUCTIONS ............... 16
TDSH COMPRESSOR .................................................... 16
COMPRESSOR LUBRICATION SYSTEM ...................... 16
PRELUBE OIL SYSTEM ................................................. 16
CYCLING FULL-LUBE OIL SYSTEM .............................. 17
FULL-LUBE OIL SYSTEM ............................................... 17
COMPRESSOR OIL SEPARATION SYSTEM ................. 17
COMPRESSOR HYDRAULIC SYSTEM ......................... 18
VOLUMIZER® VOLUME RATIO CONTROL ................... 18
COMPRESSOR OIL COOLING SYSTEMS .................... 19
SINGLE-PORT LIQUID INJECTION ............................... 19
RWB II BOOSTER OR SWING DUTY APPLICATION .... 19
DUAL-PORT LIQUID INJECTION ................................... 19
LIQUID INJECTION ADJUSTMENT PROCEDURE ....... 20
SUCTION CHECK VALVE ............................................... 21
SUCTION CHECK VALVE BYPASS ................................ 21
LOW AMBIENT OPERATION .......................................... 21
POWER ASSIST KIT ....................................................... 21
INITIAL START-UP .......................................................... 22
INITIAL START-UP PROCEDURE .................................. 22
NORMAL START-UP PROCEDURE ............................... 22
Maintenance
GENERAL INFORMATION .............................................. 23
NORMAL MAINTENANCE OPERATIONS ...................... 23
GENERAL MAINTENANCE ............................................ 23
COMPRESSOR SHUTDOWN and START-UP ................ 23
GENERAL INSTRUCTIONS FOR REPLACING
COMPRESSOR UNIT COMPONENTS. .................. 24
OIL FILTER (OF-1) MAIN SINGLE/DUAL ....................... 24
OIL FILTER/STRAINER - PRELUBE OIL PUMP ............... 24
STRAINER - FULL LUBE OIL PUMP .............................. 25
STRAINER - LIQUID INJECTION ................................... 25
COALESCER FILTER ELEMENT(S) ............................... 25
CHANGING OIL .............................................................. 25
RECOMMENDED MAINTENANCE PROGRAM ............... 26
VIBRATION ANALYSIS ................................................... 26
OIL QUALITY and ANALYSIS ......................................... 26
MAINTENANCE SCHEDULE .......................................... 26
OPERATING LOG ........................................................... 27
MOTOR BEARINGS ........................................................ 27
NLGI Grease Compatibility Chart .................................... 27
TROUBLESHOOTING GUIDE ........................................ 28
ABNORMAL OPERATION
ANALYSIS and CORRECTION ................................ 28
PRESSURE TRANSDUCERS - TESTING ...................... 29
PRESSURE TRANSDUCERS - REPLACEMENT ......... 29
SV POSITION POTENTIOMETER
REPLACEMENT AND ADJUSTMENT ..................... 31
VOLUMIZER
®
POTENTIOMETER REPLACEMENT ...... 31
TEMPERATURE and/or PRESSURE ADJUSTMENT ..... 31
TROUBLESHOOTING THE RWB II COMPRESSOR ..... 32
OIL SEPARATION SYSTEM .................................... 32
HYDRAULIC SYSTEM ............................................. 33
PRELUBE PUMP SYSTEM ..................................... 34
FULL TIME PUMP SYSTEM .................................... 34
LIQUID INJECTION OIL COOLING SYSTEM ......... 35
THERMAL EXPANSION VALVES .................................... 36
JORDAN TEMPERATURE REGULATOR VALVE ............ 37
BARE COMPRESSOR MOUNTING ............................... 38
BALANCE PISTON PRESSURE REGULATOR .............. 38
PROPER INSTALLATION OF ELECTRONIC EQUIPMENT
IN AN INDUSTRIAL ENVIRONMENT ...................... 43
FORMS ............................................................................ 46
RECOMMENDED SPARE PARTS .................................. 51
Indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
Indicates a potentially hazardous situation or practice which, if not avoided, will result in death
or serious injury.
SAFETY PRECAUTION DEFINITIONS
Indicates a potentially hazardous situation or practice which, if not avoided, will result in dam-
age to equipment and/or minor injury.
NOTE:
Indicates an operating procedure, practice, etc., or portion thereof which is essential to highlight.
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