Johnson Controls Frick RXF 12 User Manual

RXF ROTARY SCREW COMPRESSOR UNITS
INSTALLATION - OPERATION - MAINTENANCE
070.410-IOM (JAN 12)
Page 2
TABLE OF CONTENTS
PREFACE.............................................................................3
DESIGN LIMITATIONS ..........................................................3
JOB INSPECTION ................................................................3
TRANSIT DAMAGE CLAIMS ................................................3
UNIT IDENTIFICATION .........................................................3
GEOMETRICAL SWEPT VOLUME TABLE ............................. 4
INSTALLATION
FOUNDATION .....................................................................5
HANDLING and MOVING .....................................................5
SKID REMOVAL...................................................................6
COMPRESSOR/MOTOR COUPLINGS ...................................6
CH COUPLING .....................................................................6
HOLDING CHARGE and STORAGE .......................................6
COMPRESSOR OIL ..............................................................7
OIL CHARGE .......................................................................7
OIL HEATER ........................................................................7
OIL FILTER(S) ......................................................................7
SUCTION ISOLATION VALVE MOUNTING ............................7
THERMOSYPHON OIL COOLING .........................................8
WATER-COOLED OIL COOLING ..........................................8
LIQUID INJECTION OIL COOLING ........................................9
DUAL DIP TUBE METHOD ..............................................10
ECONOMIZER - HIGH STAGE (OPTIONAL) ........................10
ELECTRICAL ......................................................................11
VOLTAGE PROTECTION .................................................. 11
MOTOR STARTER PACKAGE ............................................. 11
MINI MUM BURDEN RATINGS ............................................12
CONTROL POWER REGULATOR ........................................12
OPERATION
OPERATION and START-UP INSTRUCTIONS ..................... 13
RXF COMPRESSOR ...........................................................13
COMPRESSOR LUBRICATION SYSTEM ..............................13
NO PUMP OIL SYSTEM ..................................................13
COLD-START SYSTEM ...................................................13
DEMAND PUMP OIL SYSTEM .........................................14
COMPRESSOR OIL SEPARATION SYSTEM ........................14
COMPRESSOR HYDRAULIC SYSTEM ................................14
CAPACITY CONTROL .....................................................14
VOLUMIZER
®
II Vi CONTROL .......................................... 15
SLIDE VALVE CALIBRATION............................................ 15
COMPRESSOR OIL COOLING SYSTEMS ............................16
SINGLE-PORT LIQUID INJECTION...................................16
DUAL-PORT LIQUID INJECTION .....................................16
QUANTUM
™
LX EZ-COOL
™
LIQUID
INJECTION ADJUSTMENT PROCEDURE .....................16
OPERATION OF DANFOSS
LIQUID INJECTION VALVE ..........................................18
THERMOSYPHON OIL COOLING ....................................21
INITIAL START-UP PROCEDURE ........................................21
NORMAL START-UP PROCEDURE .....................................21
VFD SKIP FREQUENCIES ...................................................21
MAINTENANCE
NORMAL MAINTENANCE OPERATIONS ............................22
GENERAL MAINTENANCE .................................................22
COMPRESSOR SHUTDOWN and START-UP ......................22
COMPRESSOR/MOTOR SERVICING ...................................22
GENERAL INSTRUCTIONS FOR REPLACING
COMPRESSOR UNIT COMPONENTS ..............................23
OIL FILTER, SPIN-ON (RXF 12 – 50) .................................23
OIL FILTER, SINGLE ELEMENT (58 – 101) ..........................23
COALESCER OIL RETURN STRAINER .................................24
LI Q UID INJECTION STRAINER ...........................................24
OIL PUMP STRAINER (Optional) .......................................24
SUCTION CHECK VALVE BYPASS ......................................24
COALESCER FILTER ELEMENT ...........................................24
CHANGING OIL .................................................................25
SUCTION STRAINER CLEANING PROCEDURE ....................25
DEMAND PUMP DISASSEMBLY .........................................26
DEMAND PUMP ASSEMBLY ..............................................27
TROUBLESHOOTING THE DEMAND PUMP ........................28
RECOMMENDED MAINTENANCE PROGRAM .....................29
VIBRATION ANALYSIS .......................................................29
OIL QUALITY and ANALYSIS .............................................29
MAINTENANCE SCHEDULE ...............................................30
MOTOR BEARINGS ...........................................................31
OPERATING LOG ...............................................................31
TROUBLESHOOTING GUIDE ..............................................31
ABNORMAL OPERATION ANALYSIS and CORRECTION .....31
PRESSURE TRANSDUCERS - TESTING ..............................32
PRESSURE TRANSDUCERS REPLACEMENT .......................33
SLIDE VALVE TRANSMITTER REPLACEMENT ....................33
TEMPERATURE SENSOR REPLACEMENT ...........................33
OIL LEVEL TRANSMITTER REPLACEMENT ........................34
TEMPERATURE and/or PRESSURE ADJUSTMENT..............34
BARE COMPRESSOR MOUNTING ......................................34
TROUBLESHOOTING THE COMPRESSOR ..........................35
OIL SEPARATOR ............................................................35
LIQUID INJECTION OIL COOLING SYSTEM .....................35
HYDRAULIC SYSTEM ....................................................36
COMPRESSOR PORT LOCATIONS .....................................37
SAE STRAIGHT THREAD O-RING FITTINGS -
ASSEMBLY PROCEDURE ............................................... 39
P & I DIAGRAM .................................................................41
WIRING HARNESS ............................................................46
PROPER INSTALLATION OF ELECTRONIC EQUIPMENT IN
AN INDUSTRIAL ENVIRONMENT ...................................48
WIRE SIZING .................................................................48
VOLTAGE SOURCE .........................................................48
GROUNDING .................................................................49
VFD APPLICATIONS ......................................................49
CONDUIT ......................................................................50
WIRING PRACTICES .....................................................50
COMMUNICATIONS .......................................................52
UPS POWER AND QUANTUM
™
LX PANELS ....................52
FORMS .............................................................................53

Johnson Controls Frick RXF 12 Specifications

General

Brand	Johnson Controls
Model	Frick RXF 12
Category	Air Compressor
Language	English