Johnson Controls Frick RWF II 177 User Manual

RWF II ROTARY SCREW COMPRESSOR UNITS
INSTALLATION - OPERATION - MAINTENANCE
070.610-IOM (JUN 11)
Page 2
PREFACE ..........................................................................3
DESIGN LIMITATIONS ......................................................3
JOB INSPECTION .............................................................3
TRANSIT DAMAGE CLAIMS ............................................3
COMPRESSOR and UNIT IDENTIFICATION ...................3
COMPRESSOR IDENTIFICATION ..................................4
INSTALLATION
FOUNDATION ...................................................................5
RIGGING and HANDLING ................................................5
SKID REMOVAL ................................................................5
CHECKING MOTOR/COMPRESS OR ROTA TION ...............6
COMPRESSOR/MOTOR COUPLING
INSTALLATION ...........................................................6
BP SERIES COUPLING DATA TABLE ..............................6
OIL PUMP COUPLING ......................................................7
HOLDING CHARGE AND STORAGE ...............................7
OIL CHARGE ....................................................................7
OIL HEATER(S) .................................................................7
OIL FILTER(S) ...................................................................7
SUCTION ISOLATION VALVE MOUNTING ......................8
THERMOSYPHON OIL COOLING ....................................8
LIQUID INJECTION OIL COOLING (Optional) ...................9
LIQUID LINE SIZES/RECEIVER VOLUME .......................9
WATER-COOLED OIL COOLING (OPTION AL) ................9
ECONOMIZER - HIGH STAGE (OPTIONAL) ..................10
ECONOMIZER LOAD BALANCING ................................11
ELECTRICAL ..................................................................11
MOTOR STARTER PACKAGE ........................................12
CURRENT TRANSFORMER (CT) RATIOS ....................13
MINI MUM BURDEN RATINGS ........................................13
CONTROL POWER REGULATOR ..................................13
OPERATION
OPERATION and START-UP INSTRUCTIONS ...............14
SGC COMPRESSOR ......................................................14
COMPRESSOR LUBRICATION SYSTEM ......................14
NO PUMP OIL SYSTEM .................................................14
DEMAND PUMP OIL SYSTEM .......................................15
COMPRESSOR OIL SEPARATION SYSTEM .................15
COLD-START SYSTEM ..................................................15
COMPRESSOR HYDRAULIC SYSTEM .........................16
VOLUME RATIO CONTROL ...........................................16
COMPRESSOR OIL COOLING SYSTEMS ....................16
SINGLE-PORT LIQUID INJECTION ...............................17
DUAL-PORT LIQUID INJECTION ...................................17
QUANTUM
™
LX EZ-COOL
™
LIQUID INJECTION
ADJUSTMENT PROCEDURE .................................18
OPERATION OF DANFOSS
LIQUID INJECTION VALVE ......................................19
SUCTION CHECK VALVE BYPASS ................................22
LOW AMBIENT OPERATION ..........................................22
SUCTION CHECK VALVE
POWER ASSIST KIT ...............................................22
BALANCE PISTON PRESSURE REGULATOR ..............22
INITIAL START-UP ..........................................................23
INITIAL START-UP PROCEDURE ..................................23
NORMAL START-UP PROCEDURE ...............................23
MAINTENANCE
GENERAL INFORMATION ..............................................24
NORMAL MAINTENANCE OPERATIONS ......................24
GENERAL MAINTENANCE ............................................24
COMPRESSOR SHUTDOWN and START-UP ................24
GENERAL INSTRUCTIONS FOR REPLACING
COMPRESSOR UNIT COMPONENTS ...................24
OIL FILTER (OF-1) MAIN SINGLE/DUAL........................25
STRAINER - DEMAND OIL PUMP .................................25
STRAINER - LIQUID INJECTION ...................................25
COALESCER FILTER ELEMENT(S) ...............................26
CHANGING OIL ..............................................................26
DEMAND PUMP DISASSEMBLY ....................................27
DEMAND PUMP ASSEMBLY ..........................................28
THRUST BEARING ADJUSTMENT ................................29
INSTALLATION OF CARBON GRAPHITE BUSHINGS ....29
TROUBLESHOOTING THE DEMAND PUMP .................29
PREVENTATIVE MAINTENANCE ..................................30
RECOMMENDED MAINTENANCE PROGRAM .............30
VIBRATION ANALYSIS ...................................................30
OIL QUALITY AND ANALYSIS ........................................31
MAINTENANCE SCHEDULE ..........................................31
OIL SAMPLING PROCEDURE .......................................32
OPERATING LOG ...........................................................32
MOTOR BEARINGS ........................................................32
GREASE COMPATIBILITY ..............................................32
NLGI GREASE COMPATIBILITY CHART .......................32
TROUBLESHOOTING GUIDE ........................................33
ABNORMAL OPERATION
ANALYSIS and CORRECTION ................................33
SERVICING THE COLD-START VALVE ..........................34
PRESSURE TRANSDUCERS - TESTING ......................35
PRESSURE TRANSDUCERS - REPLACEMENT ..........35
VOLUME RATIO CONTROL TRANSMITTER -
SLIDE STOP ............................................................36
TEMPERATURE SENSOR ..............................................36
CAPACITY LINEAR TRANSMITTER - SLIDE VALVE .....36
OIL LEVEL TRANSMITTER ............................................37
TROUBLESHOOTING THE RWF II COMPRESSOR......38
THE OIL SEPARATION SYSTEM ............................38
THE HYDRAULIC SYSTEM .....................................39
THE DEMAND PUMP SYSTEM ..............................40
MOTOR and BARE COMPRESSOR REPLACEMENT ...40
SHUTDOWN DUE TO IMPROPER OIL PRESSURE......40
COMPRESSOR PORT LOCATIONS ..............................41
P & I DIAGRAM ...............................................................49
PROPER INSTALLATION OF ELECTRONIC EQUIPMENT
IN AN INDUSTRIAL ENVIRONMENT ......................52
FORMS ............................................................................57
Contents

Johnson Controls Frick RWF II 177 Specifications

General

Brand	Johnson Controls
Model	Frick RWF II 177
Category	Air Compressor
Language	English