Johnson Controls Frick RWB II User Manual

RWB II ROTARY SCREW COMPRESSOR UNITS
INSTALLATION - OPERATION - MAINTENANCE
070.200-IOM (DEC 11)
Page 2
Contents
INITIAL START‑UP ..........................................................25
INITIAL START‑UP PROCEDURE ..................................25
NORMAL START‑UP PROCEDURE ...............................25
MAINTENANCE
GENERAL INFORMATION ..............................................26
NORMAL MAINTENANCE OPERATIONS ......................26
GENERAL MAINTENANCE ............................................26
COMPRESSOR SHUTDOWN and START‑UP ................26
GENERAL INSTRUCTIONS FOR REPLACING
COMPRESSOR UNIT COMPONENTS. ........................27
OIL FILTER (OF‑1) MAIN SINGLE/DUAL........................27
STRAINER ‑ DEMAND OIL PUMP .................................27
STRAINER ‑ LIQUID INJECTION ...................................28
COALESCER FILTER ELEMENT(S) ...............................28
CHANGING OIL ..............................................................28
DEMAND PUMP DISASSEMBLY ....................................29
TROUBLESHOOTING THE DEMAND PUMP .................31
RECOMMENDED MAINTENANCE PROGRAM .............33
VIBRATION ANALYSIS ...................................................33
MOTOR BEARINGS ........................................................33
OIL QUALITY and ANALYSIS .........................................33
OPERATING LOG ...........................................................34
MAINTENANCE SCHEDULE ..........................................34
TROUBLESHOOTING GUIDE ........................................35
ABNORMAL OPERATION
ANALYSIS and CORRECTION ....................................35
SERVICING THE COLD‑START VALVE ..........................35
PRESSURE TRANSDUCERS ‑ TESTING ......................35
PRESSURE TRANSDUCERS ‑ REPLACEMENT ..........36
SV POSITION POTENTIOMETER
REPLACEMENT AND ADJUST MENT ........................37
VOLUMIZER POTENTIOMETER
REPLACEMENT AND ADJUSTMENT ........................37
TEMPERATURE and/or PRESSURE ADJUSTMENT .....38
OIL LEVEL TRANSMITTER REPLACEMENT ................38
TROUBLESHOOTING RWB II COMPRESSOR .............38
THE OIL SEPARATION SYSTEM ................................39
THE HYDRAULIC SYSTEM ........................................39
THE LIQUID INJECTION OIL COOLING SYSTEM .....40
THE DEMAND PUMP SYSTEM ..................................40
THERMAL EXPANSION VALVES ....................................41
JORDAN TEMPERATURE REGULATOR VALVE ............42
BARE COMPRESSOR MOUNTING ...............................43
SHUTDOWN DUE TO IMPROPER OIL PRESSURE......43
GREASE COMPATIBILITY ..............................................43
NLGI Grease Compatibility Chart ....................................43
P & I DIAGRAMS ............................................................44
PROPER INSTALLATION OF ELECTRONIC EQUIPMENT
IN AN INDUSTRIAL ENVIRONMENT .........................48
FORMS ............................................................................53
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.
PREFACE ..........................................................................3
DESIGN LIMITATIONS ......................................................3
JOB INSPECTION .............................................................3
TRANSIT DAMAGE CLAIMS ............................................3
COMPRESSOR and UNIT IDENTIFICATION ...................3
INSTALLATION5
FOUNDATION ...................................................................4
RIGGING and HANDLING ................................................5
SKID REMOVAL ................................................................5
MOTOR MOUNTING .........................................................6
CHECKING MOTOR/COMPRESS OR ROTA TION ..............6
COMPRESSOR/MOTOR COUPLINGS INSTALLATION ...6
COUPLING ALIGNMENT PROCEDURE ..........................8
HOT ALIGNMENT OF COMPRESSOR/MOTOR ..............10
OIL PUMP COUPLING ....................................................10
HOLDING CHARGE AND STORAGE .............................10
COMPRESSOR UNIT OIL ..............................................10
OIL CHARGE ..................................................................10
OIL HEATER(S) ...............................................................10
OIL FILTER(S) .................................................................11
THERMOSYPHON OIL COOLING ..................................11
LIQUID INJECTION OIL COOLING (OPTIONAL) ...........12
LIQUID LINE SIZES/RECEIVER VOLUME .....................13
WATER‑COOLED OIL COOLING (Optional) ...................13
ECONOMIZER ‑ HIGH STAGE (OPTIONAL) ..................13
ECONOMIZER LOAD BALANCING ................................15
ELECTRICAL ..................................................................15
MOTOR STARTER PACKAGE ........................................15
MINI MUM BURDEN RATINGS ........................................16
CONTROL POWER REGULATOR ..................................17
OPERATION
OPERATION and START‑UP INSTRUCTIONS ...............18
TDSH COMPRESSOR ....................................................18
COMPRESSOR LUBRICATION SYSTEM ......................18
NO PUMP OIL SYSTEM .................................................18
COLD‑START SYSTEM ..................................................18
DEMAND PUMP OIL SYSTEM .......................................19
COMPRESSOR OIL SEPARATION SYSTEM .................19
COMPRESSOR HYDRAULIC SYSTEM .........................20
VOLUMIZER VOLUME RATIO CONTROL ......................20
COMPRESSOR OIL COOLING SYSTEMS ....................21
SINGLE‑PORT LIQUID INJECTION ...............................21
RWB II BOOSTER OR SWING DUTY APPLICATION ....21
DUAL‑PORT LIQUID INJECTION ...................................21
QUANTUM™ EZ‑COOL
™
LIQUID INJECTION
ADJUSTMENT PROCEDURE .....................................22
SUCTION CHECK VALVE ...............................................23
SUCTION CHECK VALVE BYPASS ................................24
LOW AMBIENT OPERATION ..........................................24
SUCTION CHECK VALVE POWER ASSIST KIT ............24

Johnson Controls Frick RWB II Specifications

General

Brand	Johnson Controls
Model	Frick RWB II
Category	Air Compressor
Language	English