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Johnson Controls Frick RWB II - User Manual

Johnson Controls Frick RWB II
60 pages
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RWB II
ROTARY SCREW COMPRESSOR UNITS
ALL REFRIGERANTS
MODELS
60 through 480
Form 070.200-IOM (NOV 2011)
INSTALLATION - OPERATION - MAINTENANCE
File: SERVICE MANUAL - Section 70
Replaces: 070-200 IOM (JAN 2009)
Dist: 3, 3a, 3b, 3c
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 RWB II Specifications

General IconGeneral
ModelRWB II
ManufacturerJohnson Controls Frick
RefrigerantR717 (Ammonia)
TypeScrew Compressor
Power SourceElectric
Control SystemMicroprocessor-based
Operating PressureVaries by model

Summary

PREFACE

GENERAL INFORMATION

COMPRESSOR and UNIT IDENTIFICATION

Identifies compressor and unit data plates for inquiries and ordering parts.

DESIGN LIMITATIONS

JOB INSPECTION

TRANSIT DAMAGE CLAIMS

INSTALLATION

FOUNDATION

Requirements for proper foundation support and anchoring of the compressor package.

RIGGING and HANDLING

Procedures and safety precautions for moving the compressor unit safely.

SKID REMOVAL

Instructions for removing the skid from the compressor package.

MOTOR MOUNTING

CHECKING MOTOR;COMPRESSOR ROTATION

Procedure to verify correct compressor rotation before coupling.

COMPRESSOR;MOTOR COUPLINGS INSTALLATION

Instructions for installing flexible drive couplings between compressor and motor.

COUPLING ALIGNMENT PROCEDURE

ANGULAR ALIGNMENT

Steps to measure and correct angular shaft misalignment using dial indicators.

PARALLEL ALIGNMENT

Steps to measure and correct parallel shaft misalignment using dial indicators.

HOT ALIGNMENT OF COMPRESSOR;MOTOR

COMPRESSOR UNIT OIL

OIL CHARGE

Instructions for filling the compressor with the correct type and quantity of oil.

OIL HEATER(S)

Information on oil heaters for maintaining oil temperature during shutdown.

OIL FILTER(S)

THERMOSYPHON OIL COOLING

SYSTEM OPERATION

Explanation of how thermosyphon oil cooling functions with refrigerant.

OIL TEMPERATURE CONTROL

Guidelines for maintaining optimal oil temperature using thermosyphon cooling.

INSTALLATION

Customer responsibilities for installing thermosyphon oil cooling system components.

LIQUID INJECTION OIL COOLING (OPTIONAL)

SYSTEM OPERATION

How liquid injection oil cooling operates on the unit.

LIQUID LINE SIZES;RECEIVER VOLUME

WATER-COOLED OIL COOLING (Optional)

ECONOMIZER - HIGH STAGE (OPTIONAL)

ECONOMIZER SYSTEMS

SHELL and COIL Economizer System

Diagram and description of a shell and coil economizer system.

FLASH Economizer System

Diagram and description of a flash economizer system.

DIRECT EXPANSION Economizer System

Diagram and description of a direct expansion economizer system.

MULTIPLE COMPRESSOR Economizer System

Considerations for economizer systems with multiple compressors.

ECONOMIZER LOAD BALANCING

ELECTRICAL

VOLTAGE PROTECTION

Information on protecting electronic controls from voltage fluctuations and spikes.

MOTOR STARTER PACKAGE

Components and wiring for motor starter packages.

CURRENT TRANSFORMER (CT) RATIOS

MINIMUM BURDEN RATINGS

CONTROL POWER REGULATOR

RECOMMENDED REGULATOR INSTALLATION

Instructions for installing the Sola control power regulator.

BATTERY BACKUP

OPERATION and START-UP INSTRUCTIONS

TDSH COMPRESSOR

Features and specifications of the TDSH rotary screw compressor.

COMPRESSOR LUBRICATION SYSTEM

Functions of the compressor lubrication system.

NO PUMP OIL SYSTEM

Explanation of units designed for self-lubrication without a pump.

COLD-START SYSTEM

Description of the cold start discharge check valve system.

DEMAND PUMP OIL SYSTEM

COMPRESSOR OIL SEPARATION SYSTEM

OIL SEPARATION SYSTEM

Diagram showing the oil separation system components.

COMPRESSOR HYDRAULIC SYSTEM

VOLUMIZER VOLUME RATIO CONTROL

How to control compressor volume ratio (Vi) using solenoids and hydraulics.

MSV and MSS HYDRAULIC CYLINDER and SOLENOID VALVES

Diagram and function of solenoids controlling slide valve and volume ratio.

COMPRESSOR OIL COOLING SYSTEMS

SINGLE-PORT LIQUID INJECTION

Operation of the single-port liquid injection system for oil cooling.

RWB II BOOSTER OR SWING DUTY APPLICATION

Specific considerations for booster or swing duty applications.

DUAL-PORT LIQUID INJECTION

Operation of the dual-port liquid injection system for optimized performance.

LIQUID INJECTION ADJUSTMENT PROCEDURE

Procedure for adjusting liquid injection oil cooling systems.

QUANTUM LX EZ-COOL LIQUID INJECTION ADJUSTMENT PROCEDURE

PID Setup

Setting up PID parameters for the EZ-Cool liquid injection system.

SUCTION CHECK VALVE BYPASS

LOW AMBIENT OPERATION

SUCTION CHECK VALVE POWER ASSIST KIT

INITIAL START-UP

INITIAL START-UP PROCEDURE

Steps to follow for a safe and proper initial start-up of the compressor unit.

NORMAL START-UP PROCEDURE

Steps for starting the compressor under normal operating conditions.

RESTARTING COMPRESSOR UNIT AFTER CONTROL POWER INTERRUPTION (PLANT POWER FAILURE)

Procedure for restarting the compressor after a power interruption.

MAINTENANCE

GENERAL INFORMATION

Overview of maintenance procedures and safety precautions.

NORMAL MAINTENANCE OPERATIONS

General safety precautions to follow during maintenance.

GENERAL MAINTENANCE

Key areas for maintaining compressor unit longevity and reliability.

COMPRESSOR SHUTDOWN and START-UP

Procedure for safely shutting down and restarting the compressor after prolonged periods.

GENERAL INSTRUCTIONS FOR REPLACING COMPRESSOR UNIT COMPONENTS

OIL FILTER (OF-1) MAIN SINGLE;DUAL

STRAINER - DEMAND OIL PUMP

STRAINER - LIQUID INJECTION

COALESCER FILTER ELEMENT(S)

CHANGING OIL

DEMAND PUMP DISASSEMBLY

INSTALLATION OF CARBON GRAPHITE BUSHINGS

Procedures for installing carbon graphite bushings, emphasizing care due to brittleness.

DEMAND PUMP ASSEMBLY

DEMAND PUMP ASSEMBLY

Step-by-step instructions for reassembling the demand pump, focusing on mechanical seal installation.

THRUST BEARING ADJUSTMENT

TROUBLESHOOTING THE DEMAND PUMP

Vacuum Gauge - Suction Port

Interpreting vacuum gauge readings on the suction port for pump diagnostics.

Pressure Gauge - Discharge Port

Interpreting pressure gauge readings on the discharge port for pump diagnostics.

PREVENTATIVE MAINTENANCE

RECOMMENDED MAINTENANCE PROGRAM

VIBRATION ANALYSIS

MOTOR BEARINGS

OIL QUALITY and ANALYSIS

LUBRICATION SCHEDULE; INSTRUCTIONS

MAINTENANCE SCHEDULE

TDSH Flange Bolt Torque

Torque specifications for TDSH compressor flange bolts.

TROUBLESHOOTING GUIDE

ABNORMAL OPERATION ANALYSIS and CORRECTION

Four logical steps to analyze and correct operational problems.

SERVICING THE COLD-START VALVE

PRESSURE TRANSDUCERS - TESTING

PRESSURE TRANSDUCERS - REPLACEMENT

SV POSITION POTENTIOMETER REPLACEMENT AND ADJUSTMENT

VOLUMIZER POTENTIOMETER REPLACEMENT AND ADJUSTMENT

TEMPERATURE and;or PRESSURE ADJUSTMENT

OIL LEVEL TRANSMITTER REPLACEMENT

TROUBLESHOOTING THE RWB II COMPRESSOR

TROUBLESHOOTING THE OIL SEPARATION SYSTEM

TROUBLESHOOTING THE HYDRAULIC SYSTEM

TROUBLESHOOTING THE LIQUID INJECTION OIL COOLING SYSTEM

TROUBLESHOOTING THE DEMAND PUMP SYSTEM

THERMAL EXPANSION VALVES

JORDAN TEMPERATURE REGULATOR VALVE

Adjustment

How to adjust the temperature regulator valve spring tension.

Action

How to check and change the valve's operating action (direct/reverse).

BARE COMPRESSOR MOUNTING

SHUTDOWN DUE TO IMPROPER OIL PRESSURE (HIGH STAGE and BOOSTER)

GREASE COMPATIBILITY

P & I DIAGRAM

LEGEND (Covers all P & I diagrams in this manual)

P & I DIAGRAM, LIQUID INJECTION - SINGLE PORT

P & I DIAGRAM, LIQUID INJECTION - DUAL PORT

P & I DIAGRAM, LIQUID INJECTION - BOOSTER

PROPER INSTALLATION OF ELECTRONIC EQUIPMENT IN AN INDUSTRIAL ENVIRONMENT

WIRE SIZING

Guidelines for sizing control power supply wires to minimize voltage dips.

VOLTAGE SOURCE

Importance of providing a clean, isolated voltage source for electronic equipment.

GROUNDING

VFD APPLICATIONS

Grounding requirements for VFD applications due to EMI generation.

CONDUIT

WIRING PRACTICES

PROPER INSTALLATION OF ELECTRONIC EQUIPMENT

PROPER INSTALLATION OF ELECTRONIC EQUIPMENT

General precautions for installing electronic controls, avoiding drilling and ensuring proper conduit routing.

COMMUNICATIONS

UPS POWER AND QUANTUM PANELS

SCREW COMPRESSOR Operating Log Sheet

RWB II COMPRESSOR PRESTART CHECKLIST

Mechanical Checks

List of mechanical checks to be completed by the installer before service supervisor arrival.

Electrical Checks

List of electrical checks to be completed by the installer before service supervisor arrival.

Start-up Report

Unit General Information

Details about the unit, compressor, and operating conditions.

Micro Information

Serial numbers and software versions for microprocessors and boards.

Compressor Motor Starter; Drive Information

Details about the motor starter and drive specifications.

Oil Pump Information

Information pertaining to the oil pump.

Cooling Fan Information

Information regarding cooling fan specifications.

Special Options

Details on optional features for the compressor unit.

Capacity Control Setpoints

Compressor Safeties

Package Safeties

Compressor Motor Setpoints and Information

VFD

Setpoints and information related to Variable Frequency Drive operation.

Vyper Coolant Setpoints

Setpoint values for the Vyper coolant system.

PHD Monitoring Setpoints

Setpoint values for PHD monitoring.

Condenser Control

Setpoints for condenser control.

Analog Controls

Setpoints for analog control inputs/outputs.

Miscellaneous

Other miscellaneous setpoints and information.

P&ID Setpoints

Setpoints related to Process and Instrumentation Diagrams.

Communications

Drive Train Alignment

Compressor Operating Log Sheet

Starter Operating Log Sheet

VIBRATION DATA SHEET

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