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Johnson Controls SGC 2824 - User Manual

Johnson Controls SGC 2824
68 pages
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ROTARY SCREW COMPRESSOR UNITS
ALL REFRIGERANTS
MODELS
100 through 1080
RWF II
Form 070.610-IOM (JUN 2011)
INSTALLATION - OPERATION - MAINTENANCE
File: SERVICE MANUAL - Section 70
Replaces: 070-610 IOM (MAR 2011)
Dist: 3, 3a, 3b, 3c
Please check www.johnsoncontrols.com/frick for the latest version of this publication.
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.

Table of Contents

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Johnson Controls SGC 2824 Specifications

General IconGeneral
BrandJohnson Controls
ModelSGC 2824
CategoryAir Compressor
LanguageEnglish

Summary

Preface and Safety Precautions

Safety Precaution Definitions

Definitions for DANGER, WARNING, and CAUTION safety levels.

Installation - Foundation and Handling

Foundation Requirements

Guidelines for compressor unit foundation and anchoring.

Motor and Coupling Installation Procedures

Checking Motor;Compressor Rotation

Procedure to verify correct motor and compressor rotation direction.

BP Coupling Installation Procedure

Steps for installing the BP coupling assembly.

CH Coupling Installation Procedure

Details on installing the T. B. Woods Elastomeric Type CH Coupling.

Economizer System Operation and Diagrams

Economizer - High Stage System Diagrams

Diagrams of Shell/Coil, DX, Flash, and Multi-Compressor economizer systems.

Economizer Load Balancing and Electrical Considerations

Economizer Load Balancing Strategies

Methods for efficient operation with multiple compressors.

Electrical Installation and Voltage Protection

Proper installation of electrical components and voltage protection.

Motor Starter Package and Wiring Diagram

Motor Starter Package Components

Components included in the motor starter package.

Operation and Compressor Features

Operation and Start-Up Instructions Overview

Introduction to unit subsystems and start-up procedures.

SGC Compressor Features and Rotation Warning

Key features of the SGC compressor and rotation warning.

Compressor Lubrication System Functions

Functions of the compressor lubrication system.

Demand Pump, Oil Separation, and Cold-Start Systems

Demand Pump Oil System Function

How the demand pump provides adequate lubrication.

Compressor Oil Separation System

Oil separation and return process in the compressor.

Cold-Start System Operation

Function of the cold-start discharge check valve.

Compressor Hydraulic and Oil Cooling Systems

Compressor Hydraulic System Operation Modes

Single-acting and double-acting modes of the hydraulic system.

Volume Ratio Control and Oil Cooling Systems

Control of volume ratio and overview of oil cooling systems.

Liquid Injection System Types

Single-Port Liquid Injection Operation

How the single-port system injects liquid refrigerant.

QuantumLX EZ-Cool LIOC Adjustment Procedure

PID Control Setpoint Descriptions

Explanation of PID parameters like Proportional Band and Gain.

PID Setup and Danfoss Liquid Injection Valve Operation

PID Setup Screen Details

Configuration parameters for PID control setup.

ICAD Parameter List and Alarms

ICAD Parameter List Details

Initial Start-Up Procedures

Initial Start-Up Requirements

Importance of authorized start-up and prestart checks.

Normal Start-Up and Restart Procedures

Steps for normal start-up and after power interruptions.

Maintenance - General Information and Procedures

General Maintenance Safety Precautions

Essential safety measures before performing maintenance.

Oil Filter and Strainer Maintenance

Coalescer Filter and Oil Change Procedures

Demand Pump Disassembly and Carbon Graphite Bushing Installation

Demand Pump Assembly and Mechanical Seal

Thrust Bearing Adjustment and Demand Pump Troubleshooting

Demand Pump Troubleshooting Guide

Troubleshooting steps using vacuum and pressure gauges.

Demand Pump System Troubleshooting and Preventative Maintenance

Demand Pump System Troubleshooting Steps

Common issues and solutions for the demand pump system.

Oil Quality Analysis and Maintenance Schedule

Lubrication Schedule and Troubleshooting Guide

Abnormal Operation Analysis and Correction

Four logical steps to analyze and correct abnormal operation.

Servicing the Cold-Start Valve

Pressure Transducer Testing and Replacement

Transmitter Operation and Troubleshooting

Temperature and Oil Level Transmitter Procedures

Troubleshooting Compressor and Oil Separation Systems

Troubleshooting the RWF II Compressor

Common compressor issues and their causes/corrections.

Hydraulic System Troubleshooting

Troubleshooting the Hydraulic System

Common issues and solutions for the hydraulic system.

Demand Pump, Motor, and Oil Pressure Troubleshooting

Troubleshooting the Demand Pump System

Common issues and solutions for the demand pump system.

P & I Diagram

Proper Installation of Electronic Equipment

Electronic Equipment Installation in Industrial Environment

General guidelines for installing electronic equipment.

Grounding and VFD Applications

Grounding Requirements for Control Equipment

Critical factors for successful grounding of control equipment.

Conduit and Wiring Practices

Electronic Equipment Installation Precautions

Panel Drilling and Component Addition Precautions

Precautions for drilling panels and adding components.

Communications and UPS Power Considerations

Compressor Prestart Checklist and Start-up Supervisor Tasks

Mechanical and Electrical Prestart Checks

List of essential mechanical and electrical checks before start-up.

Control System Setpoints and Safeties

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