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Johnson Controls Frick NGC 100 - User Manual

Johnson Controls Frick NGC 100
28 pages
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Form 070.550-IOM (JUN 2016)
INSTALLATION - OPERATION - MAINTENANCE
File: EQUIPMENT MANUAL - Section 070
Replaces: 070.550 - IOM (MAR 2015)
Dist: 3, 3a, 3b, 3c
NGC
ROTARY SCREW COMPRESSOR
Gas Compressor
MODELS 100, 150, 200, 250, 300, 400 and 450
ALL GEAR RATIOS
THIS MANUAL CONTAINS RIGGING, ASSEMBLY, START-UP,
AND MAINTENANCE INSTRUCTIONS. READ THOROUGHLY
BEFORE BEGINNING INSTALLATION. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR DEATH,
DAMAGE TO THE UNIT, OR IMPROPER OPERATION.
Please check www.johnsoncontrols.com/frick for the latest version of this publication.

Table of Contents

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Johnson Controls Frick NGC 100 Specifications

General IconGeneral
Controller TypeMicroprocessor-based
TypeScrew Compressor
DisplayLCD
Communication PortsRS-485
Capacity RangeVaries by model
RefrigerantR-22, R-134a, R-404A, R-507
Motor PowerVaries by model
Operating PressureVaries by model
Sound LevelVaries by model

Summary

General Information

Preface

Introduction to the Installation, Operation, and Maintenance manual for NGC compressors.

Compressor Basics

Explains the fundamental principles of screw compressors and key considerations for operation.

NGC Compressor Description

Details the features and design of the Frick NGC rotary screw compressor.

Compressor Lubrication System

Describes the functions and importance of the compressor's lubrication system.

Compressor Delivery and Identification

Job Inspection Upon Delivery

Procedures for inspecting the compressor upon arrival and checking for damage.

Transit Damage Claims Procedure

Guidelines for filing claims related to damage incurred during transit.

Compressor and Unit Identification

How to locate and interpret the compressor's identification data plate.

Long Term Storage Procedures

Preparing Compressor for Storage

Steps required to prepare the compressor for extended storage periods.

Maintaining Compressor During Storage

Ongoing maintenance tasks to ensure the compressor's condition during storage.

Construction Details of NGC Compressor

Housing Construction Details

Describes the material and integrity of the compressor housing.

Rotor Construction Details

Details the material, profile, and manufacturing tolerances of the rotors.

Bearing Specifications

Information on the types of bearings used and their expected life.

Gear Specifications

Details on gear material, design life, and replacement procedures.

Shaft Seal Details

Information on the single-face type shaft seal and its capabilities.

Volumizer Variable Volume Ratio Control

Explanation of the patented method for varying internal volume ratio.

Stepless Capacity Control

Describes the slide valve operation for modulating compressor capacity.

Design Limits and Specifications

Design Limits for NGC Compressors

Operating pressure and temperature limits for NGC compressors.

Piping Requirements and Connections

Specifies minimum connections required for system integration.

Holding Charge and Storage

Rigging and Handling Procedures

Dehydration and Evacuation Test

Foundation Requirements

Compressor Oil and Filters

Oil Pump Operation

Oil Heater and Cooling Requirements

Coupling Installation and Alignment

Compressor Rotation and Coupling

Critical information on compressor shaft rotation and coupling installation.

Compressor;Motor Coupling Requirements

Specifications and considerations for compressor and motor couplings.

Coupling Alignment Requirements

Procedures and critical tolerances for ensuring proper shaft alignment.

Compressor;Motor Couplings Installation

Electrical Installation

Slide Stop Transmitter Installation

Details on the slide stop transmitter, its function, and connection.

Capacity Slide Valve Transmitter Installation

Details on the capacity slide valve transmitter and its connection.

Directional Control Valves Wiring

Operation and Start-Up Instructions

Compressor Hydraulic System Overview

Explanation of the hydraulic system that actuates slide valves and stops.

Volumizer Volume Ratio Control

Low Ambient Operation Recommendations

Initial Startup Procedures

Initial Startup Procedure

Step-by-step guide for the initial startup of the compressor unit.

Normal Startup Procedure

Steps for performing a normal startup of the compressor.

Maintenance Introduction

Normal Maintenance Operations Safety

General Maintenance Practices

Changing Oil Procedure

Oil Pump Maintenance Information

Recommended Maintenance Program

Recommended Maintenance Schedule

Schedule of maintenance tasks based on operating hours.

Vibration Analysis in Maintenance

Guidelines for performing vibration analysis as part of maintenance.

Oil Analysis in Maintenance

Importance and participation in oil analysis programs.

Vibration Analysis Details

Early Failure Detection via Vibration Analysis

How vibration analysis helps in detecting early signs of compressor failure.

Oil Quality and Analysis Details

Operating Log Importance

The significance of maintaining a detailed operating log for system analysis.

Troubleshooting Guide Overview

Abnormal Operation Analysis & Correction

Logical steps to analyze and correct abnormal compressor operation.

Troubleshooting the NGC Compressor

Troubleshooting the Oil Pump and System

Troubleshooting the Hydraulic System

Troubleshooting Guide (Continued)

Capacity Linear Transmitter Replacement - Slide Valve

Procedure for replacing the capacity linear transmitter for the slide valve.

Volumizer Transmitter Replacement - Slide Stop

Procedure for replacing the Volumizer transmitter for the slide stop.

Bare Compressor Replacement Procedure

Steps required for replacing a bare compressor in the field.

Shutdown Due to Improper Oil Pressure

Critical information on compressor shutdown due to incorrect oil pressure.

Drive Train Alignment Procedures

Operating Log Sheet

Vibration Data Sheet

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