070.610-IOM (JUL 21)
Page 2
RWF II Rotary Screw Compressor Units
Installation - Operation - Maintenance
Table of Contents
General information
Preface ..............................................................................3
Design limitations ..............................................................3
Job inspection ................................................................... 3
Transit damage claims .......................................................3
Unit identication ..............................................................3
Compressor identication ................................................. 4
Installation
Foundation ........................................................................5
Rigging and handling .........................................................5
Skid removal .....................................................................6
Compressor/motor coupling installation ............................ 6
Oil pump coupling .............................................................7
Holding charge and storage .............................................. 7
Piping connections ............................................................ 8
Compressor unit oil ........................................................... 8
Oil charge ..........................................................................8
Oil heaters ........................................................................8
Oil lters ...........................................................................9
Suction valve mounting ..................................................... 9
Thermosyphon oil cooling .................................................9
Liquid injection oil cooling - optional ..............................10
Water or glycol oil cooling - optional.............................11
High-stage economizer - optional ..................................11
Economizer load balancing ..............................................13
Economizer Vi control ..................................................... 13
Economizing with VSDs ...................................................13
Electrical .........................................................................13
Motor starter package .....................................................14
Current transformer (CT) ratios .......................................15
Installation of electronic equipment in
an industrial environment ........................................ 16
Minimum burden ratings ................................................. 16
Control power regulator ..................................................16
Wire sizing ......................................................................17
Voltage source ................................................................ 17
Grounding .......................................................................17
VFD applications .............................................................18
Conduit ...........................................................................19
Wiring practices .............................................................. 19
Communications .............................................................21
UPS power and Quantum
HD panels ...............................21
Operation
Operation and startup instructions ..................................23
SGC compressor .............................................................. 23
Compressor lubrication system ....................................... 23
No pump oil system ........................................................23
Demand pump oil system ................................................24
Compressor oil separation system .................................. 24
Cold-start system ...........................................................24
Compressor hydraulic system..........................................25
Volume ratio control .......................................................25
Compressor oil cooling systems ...................................... 26
Single-port liquid injection ..............................................26
Dual-port liquid injection ................................................26
Quantum
HD EZ-COOL Liquid injection adjustment
procedure ................................................................ 27
Operation of Danfoss liquid injection valve .....................28
Suction check valve bypass .............................................29
Low ambient operation ................................................... 29
Suction check valve power assist kit ...............................31
Balance piston pressure regulator ................................... 31
Initial start-up .................................................................31
Initial start-up procedure ................................................31
VFD skip frequencies .......................................................32
Normal start-up procedure .............................................32
Maintenance
General information ........................................................33
Normal maintenance operations .....................................33
General maintenance ......................................................33
Compressor shutdown and start-up ................................33
General instructions for replacing compressor unit
components ............................................................. 33
Oil filter (OF-1) cartridge style ........................................34
Strainer – demand oil pump ............................................35
Strainer – liquid injection ................................................ 35
Coalescer lter element ..................................................35
Changing oil ....................................................................36
Demand pump disassembly .............................................36
Demand pump assembly .................................................37
Thrust bearing adjustment ..............................................38
Installing carbon graphite bushings ................................. 39
Troubleshooting the demand pump .................................39
Maintenance schedule .....................................................40
Preventive maintenance .................................................. 40
Maintenance program ..................................................... 41
Vibration analysis ............................................................ 41
Oil quality and analysis ....................................................42
Oil sampling procedure ................................................... 42
Operating log ..................................................................42
Motor bearings ................................................................42
Relubrication interval and instructions –
WEG electric motor..................................................43
Relubrication interval and instructions – Marathon ........ 43
Grease compatibility ........................................................44
Troubleshooting guide .....................................................44
Abnormal operation analysis and correction ................... 44
Servicing the cold-start valve ......................................... 45
EZ-CAL High pressure cut-out check valve test block .....46
Pressure transducers – testing ........................................46
Pressure transducers – replacement ............................... 47
Capacity linear transmitter – slide valve ......................... 47
Volume ratio control transmitter – slide stop ..................47
Temperature sensor ........................................................ 48
Oil level transmitter ........................................................48
Troubleshooting the RWF II compressor ..........................50
Troubleshooting the demand pump system .....................50
Troubleshooting the oil separation system ...................... 51
Troubleshooting the hydraulic system ............................. 51
Motor and bare compressor replacement .......................52
Shutdown due to improper oil pressure (high stage and
booster) ...................................................................52
SAE straight thread o-ring ttings assembly procedure .. 52
Compressor port locations .............................................. 53
Piping and instrumentation diagrams .............................. 61
Forms
Operating log sheet ........................................................66
RWF II compressor prestart checklist .............................. 67
Vibration data sheet ........................................................72
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