ROTARY SCREW COMPRESSOR UNITS - Johnson Controls

1 Form (NOV 2014). INSTALLATION - OPERATION - MAINTENANCE. File: SERVICE MANUAL - Section 70. Replaces: (AUG 2014). Dist: 3, 3a, 3b, 3c RXF. ROTARY SCREW COMPRESSOR UNITS . MODELS 12 101. 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 for the latest version of this publication. (NOV 14) RXF ROTARY SCREW COMPRESSOR UNITS . Page 2 INSTALLATION - OPERATION - MAINTENANCE. Table Of Contents General Information OIL FILTER, SPIN-ON (RXF 12 50)..24. OIL FILTER (OF-1) Cartridge Style (58 101)..24. DESIGN COALESCER OIL RETURN 25. JOB LIQUID INJECTION 25. TRANSIT DAMAGE OIL PUMP STRAINER (Optional).. 25. UNIT SUCTION CHECK VALVE COMPRESSOR 4 COALESCER FILTER GEOMETRICAL SWEPT VOLUME 4 CHANGING SUCTION STRAINER CLEANING 27. Installation DEMAND PUMP 27. DEMAND PUMP HANDLING and THRUST BEARING SKID Installation Of Carbon Graphite COMPRESSOR /MOTOR TROUBLESHOOTING THE DEMAND CH RECOMMENDED MAINTENANCE 31.

2 HOLDING CHARGE and MAINTENANCE 31. COMPRESSOR VIBRATION OIL OIL QUALITY and OIL MOTOR OIL FILTER(S)..8 OPERATING SUCTION ISOLATION VALVE TROUBLESHOOTING THERMOSYPHON OIL ABNORMAL OPERATION. WATER-COOLED OIL ANALYSIS and LIQUID INJECTION OIL PRESSURE TRANSDUCERS DUAL DIP TUBE PRESSURE TRANSDUCERS ECONOMIZER - HIGH STAGE (OPTIONAL)..10 SLIDE VALVE TRANSMITTER. 11 REPLACEMENT - SLIDE VOLTAGE 11 TEMPERATURE SENSOR MOTOR STARTER 12 OIL LEVEL TRANSMITTER MINIMUM BURDEN 13 TEMPERATURE and/or PRESSURE control POWER 13 BARE COMPRESSOR Operation TROUBLESHOOTING THE OPERATION and START UP OIL RXF LIQUID INJECTION OIL COOLING COMPRESSOR LUBRICATION HYDRAULIC NO PUMP OIL COMPRESSOR PORT LOCATIONS - RXF 12 - COLD-START SAE STRAIGHT THREAD O-RING FITTINGS - ASSEMBLY. DEMAND PUMP OIL 15 PROCEDURE FOR RXF 58 - 40. COMPRESSOR OIL SEPARATION 15 P & I DIAGRAM, LIQUID INJECTION SINGLE COMPRESSOR HYDRAULIC 15 RXF COOLING OPTIONS (See P & I Diagrams). CAPACITY 15 PLATE OIL VOLUMIZER II Vi WIRING HARNESS - External for Analog SLIDE VALVE WIRING HARNESS - AC to Heaters and Valves (External).

3 50. COMPRESSOR OIL COOLING 17 Installation Of Electronic Equipment SINGLE-PORT LIQUID 17 WIRE 51. DUAL-PORT LIQUID 17 VOLTAGE 51. QUANTUM HD EZ-COOL LIQUID INJECTION ADJUST- 52. MENT 17 VFD 52. OPERATION OF DANFOSS LIQUID INJECTION WIRING PRACTICES ..53. THERMOSYPHON OIL 21 55. INITIAL START-UP 21 UPS POWER AND QUANTUM HD 55. NORMAL START-UP VFD SKIP Forms OPERATING LOG Maintenance RXF COMPRESSOR PRESTART 57. NORMAL MAINTENANCE VIBRATION DATA GENERAL COMPRESSOR SHUTDOWN and COMPRESSOR /MOTOR GENERAL INSTRUCTIONS FOR REPLACING. COMPRESSOR UNIT RXF ROTARY SCREW COMPRESSOR UNITS (NOV 14). GENERAL INFORMATION Page 3. General Information JOB INSPECTION. PREFACE Immediately upon arrival examine all crates, boxes, and exposed COMPRESSOR and component surfaces for damage. This manual has been prepared to acquaint the owner and Unpack all items and check against shipping lists for any service person with the INSTALLATION, OPERATION, and possible shortage. Examine all items for damage in transit.

4 MAINTENANCE procedures as recommended by Frick for RXF ROTARY SCREW Compres sor UNITS . TRANSIT DAMAGE CLAIMS. It is most important that these UNITS be properly applied to an All claims must be made by consignee. This is an ICC re . adequately controlled refrigeration system. Your author ized quirement. Request immediate inspec tion by the agent of Frick repre sentative should be consulted for expert guidance the carrier and be sure the proper claim forms are executed. in this determination. Contact Johnson Controls -Frick, Sales Administration Proper performance and continued satisfaction with these Depart ment, in Waynesboro, PA to report dam age or short- UNITS is dependent upon: age claims. UNIT IDENTIFICATION. CORRECT INSTALLATION. PROPER OPERATION Each COMPRESSOR unit has two identifica tion data plates. The REGULAR, SYSTEMATIC PLANNED MAIN TENANCE unit data plate containing unit model, serial number and Frick sales order number is mount ed on the control panel support To ensure correct installation and application, the equipment bracket.

5 The COMPRESSOR data plate containing compres sor must be properly selected and connected to a properly de- model and serial number is mounted on the COMPRESSOR body. signed and installed system. The Engineering plans, piping layouts, etc. must be detailed in accordance with the best practices and local codes, such as those outlined in ASHRAE. NOTICE. literature. When inquiring about the COMPRESSOR or unit, or order- ing repair parts, provide the MODEL, SERIAL, and FRICK. A refrigeration COMPRESSOR is a VAPOR PUMP. To be certain SALES ORDER NUMBERS from these data plates. that it is not being subjected to liquid refrigerant carryover, it is necessary that refriger ant Controls are carefully selected and in good operating condition; the piping is properly sized and traps, if necessary, are correctly arrang ed; the suction line has an accumulator or slugging protec tion; that load surges are known and provisions made for control ; operating cycles and defrosting periods are reason able; oil return is controlled; and that high side condenser UNITS control head pressures and temperatures are within system and compres- sor design limits.

6 It is recommended that the entering vapor temperature to the COMPRESSOR be superheated to 10 F above the refrigerant saturation temperature to ensure that all refrigerant at the COMPRESSOR suction is in the vapor state. DESIGN LIMITATIONS. The COMPRESSOR UNITS are designed for operation within the pressure and temperature limits as shown in Frick Publica- tion UNIT DATA PLATE. SAFETY PRECAUTION DEFINITIONS. Indicates an imminently hazardous situation which, if not avoided, will result in death or serious DANGER injury. Indicates a potentially hazardous situation or practice which, if not avoided, will result in death or WARNING serious injury. Indicates a potentially hazardous situation or practice which, if not avoided, will result in damage CAUTION to equipment and/or minor injury. NOTICE Indicates an operating procedure, practice, etc., or portion thereof which is essential to highlight. (NOV 14) RXF ROTARY SCREW COMPRESSOR UNITS . Page 4 GENERAL INFORMATION.

7 COMPRESSOR IDENTIFICATION. COMPRESSOR DATA PLATE. ROTARY SCREW COMPRESSOR serial numbers are defined by the following information: EXAMPLE: 10240A90000015Z. GLOBAL ADDITIONAL. PLANT DECADE MONTH YEAR SEQ NO. REMARKS. 1024 0 A 9 0000015 Z. Month: A = JAN, B = FEB, C = MAR, D = APR, E = MAY, F =. JUN, G = JUL, H = AUG, K = SEP, L = OCT, M = NOV, N = DEC. Additional Remarks: R = Remanufactured; Z = Deviation from Standard Configuration. GEOMETRICAL SWEPT VOLUME TABLE. Geometrical Rotor Max Swept Volume COMPRESSOR Diameter Rotor Speed Drive Shaft End Cfm M /H. Model mm L/D Rpm Ft / Rev M /Rev 3550 Rpm 2950 Rpm XJS/XJF 95M 95 5,772 89 126. XJS/XJF 95L 95 4,661 110 156. XJS/XJF 95S 95 3,600 145 205. XJS/XJF 120M 120 5,772 180 254. XJS/XJF 120L 120 4,661 223 314. XJS/XJF 120S 120 3,600 292 412. XJF 151A 151 6,297 342 482. XJF 151M 151 5,332 403 569. XJF 151L 151 4,306 500 705. XJF 151N 151 3,600 598 843. RXF ROTARY SCREW COMPRESSOR UNITS (NOV 14). INSTALLATION Page 5.

8 Disconnected from the COMPRESSOR . See table for Allowable Installation Flange Loads. FOUNDATION ALLOWABLE FLANGE LOADS. NOZ. MOMENTS (ft-lbf) LOAD (lbf). NOTICE SIZE. NPS. AXIAL VERT. LAT. AXIAL VERT. LAT. MR MC ML P VC VL. Allow space for servicing the unit per factory drawings. 1 25 25 25 50 50 50. 25 25 25 50 50 50. The first requirement of the COMPRESSOR foundation is that 50 40 40 100 75 75. it must be able to support the weight of the COMPRESSOR 2 100 70 70 150 125 125. package including coolers, oil, and refrigerant charge. SCREW 3 250 175 175 225 250 250. compressors are capable of converting large quantities of 4 400 200 200 300 400 400. shaft power into gas compression in a relatively small space and a mass is required to effectively dampen these relatively 5 425 400 400 400 450 450. high frequency vibrations. 6 1,000 750 750 650 650 650. 8 1,500 1,000 1,000 1,500 900 900. Firmly anchoring the COMPRESSOR package to a suitable 10 1,500 1,200 1,200 1,500 1,200 1,200.

9 Foundation by proper application of grout and elimination of 12 1,500 1,500 1,500 1,500 1,500 1,500. piping stress imposed on the COMPRESSOR is the best insur- 14 2,000 1,800 1,800 1,700 2,000 2,000. ance for a trouble free installation. Use only the certified general arrangement drawings from Frick to determine the Proper foundations and proper installation methods are vital;. mounting foot locations and to allow for recommended clear- and even then, sound attenuation or noise curtains may be ances around the unit for ease of operation and servicing. required to reduce noise to desired levels. Foundations must be in compliance with local building codes For more detailed information on SCREW COMPRESSOR Founda- and materials should be of industrial quality. tions, please request Frick publication The floor shall be a minimum of 6 inches of reinforced con- crete and housekeeping pads are recommended. Anchor HANDLING and MOVING. bolts are required to firmly tie the unit to the floor.

10 Once the unit is rigged into place (See HANDLING and MOVING), the feet must then be shimmed in order to level the unit. The WARNING. shims should be placed to position the feet roughly one inch This SCREW COMPRESSOR package may be top-heavy. Use above the housekeeping pad to allow room for grouting. An caution in rigging and handling. expansion-type epoxy grout must be worked under all areas of the base with no voids and be allowed to settle with a RXF 12 50 UNITS can be moved with a forklift or with rigging slight outward slope so oil and water can run off of the base. and a crane. The recommended method is to insert lengths of 2" pipe through the base tubing (see Figure 1 below). When installing on a steel base, the following guidelines should be implemented to properly design the system base: 1. Use I-beams in the skid where the SCREW COMPRESSOR will CAUTION. be attached to the system base. They shall run parallel to Spreader bars should be used on both the length and the package feet and support the feet for their full length.