070.410-Iom RXF 2014-08
070.410-Iom RXF 2014-08
070.410-Iom RXF 2014-08
RXF
ROTARY SCREW COMPRESSOR UNITS
MODELS 12 – 101
Table Of Contents
General Information OIL FILTER, SPIN-ON (RXF 12 – 50)..................................24
PREFACE.............................................................................3 OIL FILTER (OF-1) Cartridge Style (58 – 101)................24
DESIGN LIMITATIONS...........................................................3 COALESCER OIL RETURN STRAINER.................................. 25
JOB INSPECTION.................................................................3 LIQUID INJECTION STRAINER............................................ 25
TRANSIT DAMAGE CLAIMS.................................................3 OIL PUMP STRAINER (Optional)........................................ 25
UNIT IDENTIFICATION..........................................................3 SUCTION CHECK VALVE BYPASS.......................................26
COMPRESSOR IDENTIFICATION.......................................... 4 COALESCER FILTER ELEMENT............................................26
GEOMETRICAL SWEPT VOLUME TABLE.............................. 4 CHANGING OIL..................................................................26
SUCTION STRAINER CLEANING PROCEDURE..................... 27
Installation
DEMAND PUMP DISASSEMBLY.......................................... 27
FOUNDATION......................................................................5 DEMAND PUMP ASSEMBLY...............................................28
HANDLING and MOVING......................................................5 THRUST BEARING ADJUSTMENT....................................29
SKID REMOVAL...................................................................6 INSTALLATION OF CARBON GRAPHITE BUSHINGS.........29
COMPRESSOR/MOTOR COUPLINGS....................................6 TROUBLESHOOTING THE DEMAND PUMP.........................30
CH COUPLING......................................................................6 RECOMMENDED MAINTENANCE PROGRAM...................... 31
HOLDING CHARGE and STORAGE........................................7 VIBRATION ANALYSIS........................................................ 31
COMPRESSOR OIL...............................................................7 MAINTENANCE SCHEDULE................................................ 31
OIL CHARGE........................................................................7 OIL QUALITY and ANALYSIS..............................................32
OIL HEATER.........................................................................7 MOTOR BEARINGS............................................................32
OIL FILTER(S).......................................................................8 OPERATING LOG................................................................32
SUCTION ISOLATION VALVE MOUNTING.............................8 TROUBLESHOOTING GUIDE...............................................32
THERMOSYPHON OIL COOLING..........................................8 ABNORMAL OPERATION ANALYSIS and CORRECTION......32
WATER-COOLED OIL COOLING...........................................9 PRESSURE TRANSDUCERS ‑ TESTING...............................33
LIQUID INJECTION OIL COOLING.........................................9 PRESSURE TRANSDUCERS REPLACEMENT........................33
DUAL DIP TUBE METHOD...............................................10 SLIDE VALVE TRANSMITTER REPLACEMENT - SLIDE STOP...35
ECONOMIZER - HIGH STAGE (OPTIONAL).........................10 TEMPERATURE SENSOR REPLACEMENT............................35
ELECTRICAL....................................................................... 11 OIL LEVEL TRANSMITTER REPLACEMENT.........................35
VOLTAGE PROTECTION................................................... 11 TEMPERATURE and/or PRESSURE ADJUSTMENT..............35
MOTOR STARTER PACKAGE.............................................. 12 BARE COMPRESSOR MOUNTING.......................................35
MINIMUM BURDEN RATINGS............................................. 13 TROUBLESHOOTING THE COMPRESSOR...........................36
CONTROL POWER REGULATOR......................................... 13 OIL SEPARATOR.............................................................36
Operation LIQUID INJECTION OIL COOLING SYSTEM......................36
OPERATION and START‑UP INSTRUCTIONS......................14 HYDRAULIC SYSTEM.....................................................37
RXF COMPRESSOR............................................................14 COMPRESSOR PORT LOCATIONS - RXF 12 - 19................38
COMPRESSOR LUBRICATION SYSTEM...............................14 SAE STRAIGHT THREAD O-RING FITTINGS - ASSEMBLY
NO PUMP OIL SYSTEM...................................................14 PROCEDURE FOR RXF 58 - 101.................................... 40
COLD-START SYSTEM....................................................14 P & I DIAGRAMS................................................................41
DEMAND PUMP OIL SYSTEM.......................................... 15 RXF COOLING OPTIONS (See P & I Diagrams)
COMPRESSOR OIL SEPARATION SYSTEM......................... 15 PLATE OIL COOLER........................................................42
COMPRESSOR HYDRAULIC SYSTEM................................. 15 WIRING HARNESS - External for Analog Devices..............49
CAPACITY CONTROL...................................................... 15 WIRING HARNESS - AC to Heaters and Valves (External).50
VOLUMIZER II Vi CONTROL............................................16 Installation Of Electronic Equipment
SLIDE VALVE CALIBRATION............................................16 WIRE SIZING...................................................................... 51
COMPRESSOR OIL COOLING SYSTEMS............................. 17 VOLTAGE SOURCE............................................................. 51
SINGLE-PORT LIQUID INJECTION................................... 17 GROUNDING...................................................................... 52
DUAL-PORT LIQUID INJECTION...................................... 17 VFD APPLICATIONS........................................................... 52
QUANTUM™HD EZ-COOL™ LIQUID INJECTION CONDUIT...........................................................................53
ADJUSTMENT PROCEDURE........................................ 17 WIRING PRACTICES . ........................................................53
OPERATION OF DANFOSS COMMUNICATIONS........................................................... 55
LIQUID INJECTION VALVE...........................................18 UPS POWER AND QUANTUM™ HD PANELS........................ 55
THERMOSYPHON OIL COOLING..................................... 21
INITIAL START-UP PROCEDURE......................................... 21 Forms
NORMAL START-UP PROCEDURE......................................22 OPERATING LOG SHEET....................................................56
VFD SKIP FREQUENCIES....................................................22 RXF COMPRESSOR PRESTART CHECKLIST........................ 57
VIBRATION DATA SHEET....................................................62
MAINTENANCE
NORMAL MAINTENANCE OPERATIONS.............................23 INDEX................................................................................63
GENERAL MAINTENANCE..................................................23
COMPRESSOR SHUTDOWN and START-UP.......................23
COMPRESSOR/MOTOR SERVICING....................................24
GENERAL INSTRUCTIONS FOR REPLACING
COMPRESSOR UNIT COMPONENTS...............................24
RXF ROTARY SCREW COMPRESSOR UNITS 070.410-IOM (AUG 14)
GENERAL INFORMATION Page 3
UNIT IDENTIFICATION
CORRECT INSTALLATION
PROPER OPERATION Each compressor unit has two identification data plates. The
REGULAR, SYSTEMATIC PLANNED MAINTENANCE unit data plate containing unit model, serial number and Frick
sales order number is mounted on the control panel support
To ensure correct installation and application, the equipment bracket. The compressor data plate containing compressor
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 refrigerant controls are carefully selected
and in good operating condition; the piping is properly sized
and traps, if necessary, are correctly arranged; the suction
line has an accumulator or slugging protection; that load
surges are known and provisions made for control; operating
cycles and defrosting periods are reasonable; oil return is
controlled; and that high side condenser units control head
pressures and temperatures are within system and compres-
sor design limits.
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 070.410-SED.
NOTICE Indicates an operating procedure, practice, etc., or portion thereof which is essential to highlight.
070.410-IOM (AUG 14) RXF ROTARY SCREW COMPRESSOR UNITS
Page 4 GENERAL INFORMATION
COMPRESSOR IDENTIFICATION
The unit can be moved with a forklift by forking through unit mounting supports to the skid before lowering the unit
the base tubing. NEVER MOVE THE UNIT BY PUSHING onto the mounting surface.
OR FORKING AGAINST THE SEPARATOR SHELL OR ITS
MOUNTING SUPPORTS. If the unit is skidded into place, remove the cross members
from the skid and remove the nuts anchoring the unit to the
RXF 58 – 101 units can be moved with rigging, using a crane skid. Using a 10-ton jack under the separator, raise the unit
or forklift by hooking into three lifting points on the oil sepa- at the compressor end until it clears the two mounting bolts.
rator. See Figure 2. Spread the skid to clear the unit mounting support, then lower
the unit to the surface. Repeat procedure on opposite end.
WARNING
It is mandatory that the coupling center be removed and
the direction of motor rotation be confirmed before run-
ning the compressor. Proper rotation of the compressor
shaft is clockwise looking at the end of the compressor
shaft. Failure to follow this step could result in backward
compressor rotation which can cause compressor failure
or explosion of the suction housing.
Figure 2 - RXF 58 – 101 1. Inspect the shaft of the motor and compressor to ensure
that no nicks, grease, or foreign matter is present.
The unit can be moved with a forklift by forking under
the wooden skid (if provided), or it can be skidded into 2. Inspect the bores in the coupling hubs to make sure that
place with pinch bars by pushing against the skid. NEVER they are free of burrs, dirt, and grit.
MOVE THE UNIT BY PUSHING OR FORKING AGAINST THE
SEPARATOR SHELL OR ITS MOUNTING SUPPORTS. 3. Check that the keys fit the hubs and shafts properly.
4. Slide one hub onto each shaft as far as possible. It may
SKID REMOVAL be necessary to use a screwdriver as a wedge in the slot to
open the bore before the hubs will slide on the shafts.
CAUTION 5. Hold the elastomeric gear between the hubs and slide both
This screw compressor package may be top-heavy. Use hubs onto the gear to fully engage the mating teeth. Center
caution to prevent unit from turning over. the gear and hub assembly so there is equal engagement on
both shafts. Adjust the space between hubs as specified in
If the unit is rigged into place, the wooden skid can be re- the CH Coupling Data Table below. SEE NOTICE:
moved by taking off the nuts and bolts that are fastening the
NOTICE RXF
BASIC
CHARGE
ADDITIONAL FOR
OIL COOLER
MODEL (gallon) (gallon)
The center section will be a little loose between the
hubs. This allows for growth during operation. 12 – 19 10 1
24 – 50 11 1
6. Torque the clamping bolts in both hubs to the torque value 58, 68 25 3½
given in the CH Data Table. DO NOT USE ANY LUBRICANT 85, 101 36 3½
ON THESE BOLTS.
Add oil by attaching the end of a suitable pressure type
HOLDING CHARGE and STORAGE hose to the oil drain valve (see Figure 3), located under the
oil separator. Using a pressure-type pump and the recom-
Each compressor unit is pressure and leak tested at the John- mended Frick® oil, open the drain valve and pump oil into
son Controls-Frick factory and then thoroughly evacuated and the separator.
charged with dry nitrogen to ensure the integrity of the unit
during shipping and short term storage prior to installation.
NOTICE
CAUTION Evacuation of the oil separator will assist the flow of
oil into the unit. Also, fill slowly because oil will fill up
Care must be taken when entering the unit to ensure in the separator faster than it shows in the sight glass.
that the nitrogen charge is safely released.
Oil distillers and similar equipment which trap oil must be
filled prior to unit operation to normal design outlet levels.
WARNING The same pump used to charge the unit may be used for
filling these auxiliary oil reservoirs.
Holding charge shipping gauges on separator and
external oil cooler are rated for 30 PSIG and are for The sight glass located near the bottom of the separator shell
checking the shipping charge only. They must be re- at the discharge end should remain empty when the unit is
moved before pressure testing the system and before in operation. The presence of oil in this end of the vessel
charging the system with refrigerant. Failure to remove during operation indicates liquid carryover or malfunction
these gauges may result in catastrophic failure of the of the oil return.
gauge and uncontrolled release of refrigerant resulting
in serious injury or death.
All units must be kept in a clean, dry location to prevent
corrosion damage. Reasonable consideration must be given
to proper care for the solid-state components of the mi-
croprocessor.
Units which will be stored for more than two months must
have the nitrogen charge checked periodically. Contact
Johnson Controls-Frick for long term storage procedure.
COMPRESSOR OIL
WARNING
DO NOT MIX OILS of different brands, manufacturers, or
types. Mixing of oils may cause excessive oil foaming, Figure 3 - Oil Drain Valve
nuisance oil level cutouts, oil pressure loss, gas or oil
leakage and catastrophic compressor failure. OIL HEATER
Standard units are equipped with 500 watt oil heaters, which
NOTICE provide sufficient heat to maintain the oil temperature for
most indoor applications during shutdown cycles and to
The oil charge shipped with the unit is the best suited permit safe start‑up. RXF 12–50 use one heater while mod-
lubricant for the conditions specified at the time of els 58–101 use two. Should additional heating capacity be
purchase. If there is any doubt due to the refrigerant, required because of an unusual environmental condition,
operating pressures, or temperatures; refer to Frick contact Johnson Controls-Frick. The heater is energized only
publication 160.802-SPC for guidance. when the unit is not in operation.
OIL CHARGE
WARNING
The normal charging level is midway in the top sight
Do not energize the heater when there is no oil in the unit,
glass located midway along the oil separator shell. Normal
otherwise the heater will burn out. The oil heater will be
operating level is between the top sight glass and bottom
energized whenever 120 volt control power is applied to
sight glass. Oil charge quantities are as follows:
the unit and the compressor is not running, unless the 16
amp circuit breaker in micro enclosure is turned off (or 15
amp fuse (1FU) in the Plus panel is removed).
070.410-IOM (AUG 14) RXF ROTARY SCREW COMPRESSOR UNITS
Page 8 INSTALLATION
OIL FILTER(S) The liquid level in the refrigerant source must be 6 to 8 feet
above the center of the oil cooler.
CAUTION
After removing the suction sealing disc, confirm that
the check valve hinge pin is in the vertical position! If
the hinge pin is not in a vertical position, then failure
of the check valve may occur. Figure 5 - Thermosyphon Oil-Cooled System
1. Thermosyphon oil cooler is supplied with oil side piped to
INCORRECT! the compressor unit and socket weld ends supplied on the
refrigerant side.
2. A refrigerant-side safety valve is required when refriger-
ant isolation valves are installed between the cooler and
thermosyphon receiver. If no valves are used between the
cooler and thermosyphon receiver, the safety valve on the
thermosyphon receiver must be sized to handle the volume
of both vessels. Then, the safety valve on the cooler vent
(liquid refrigerant side) can be eliminated.
3. System receiver must be mounted below thermosyphon
receiver level in this arrangement.
4. The refrigerant source, thermosyphon or system receiver,
should be in close proximity to the unit to minimize piping
pressure drop.
5. The liquid level in the refrigerant source must not be less
than 6 feet above the center of the oil cooler.
6. An angle valve should be installed in the piping before the
CORRECT! thermosyphon oil cooler to balance the thermosyphon sys-
tem. Sight glasses should also be installed at the TSOC inlet
and outlet to aid in troubleshooting. The factory-mounted
Figure 4 - Suction Isolation Valve Mounting plate-type thermosyphon oil cooler requires a refrigerant-
side drain valve to be provided and installed by the customer.
THERMOSYPHON OIL COOLING
The component and piping arrangement shown in Figure 5 is
EQUIPMENT: The basic equipment required for a thermo intended only to illustrate the operating principles of thermo-
syphon system consists of: syphon oil cooling. Other component layouts may be better
suited to a specific installation. Refer to publication 070.900-E
1. A source of liquid refrigerant at condensing pressure and for additional information on Thermosyphon Oil Cooling.
temperature located in close proximity to the unit to minimize
piping pressure drop.
RXF ROTARY SCREW COMPRESSOR UNITS 070.410-IOM (AUG 14)
INSTALLATION Page 9
Intermediate, and 10°F suction superheat; R-507 unloaded tion. Because of this, an output from the microprocessor is
slide valve. generally used to turn off the supply of flashing liquid on a
shell and coil or DX economizer when the capacity falls below
High-stage compressor units may be supplied with single-port approximately 60%-70% (85%-90% slide valve position). This
(low Vi, side, or closed thread) or dual-port (low Vi and high Vi), is done to improve compressor operating efficiency. Please
liquid injection oil cooling. Single port will be furnished for low note however that shell and coil and DX economizers can be
compression ratio operation and dual port for high compres- used at low compressor capacities in cases where efficien
sion ratio operation. Booster compressor units use single-port cy is not as important as ensuring that the liquid supply is
(High Vi), liquid injection oil cooling due to the typically lower subcooled. In such cases, the economizer liquid solenoid can
compression ratios. be left open whenever the compressor is running.
The control system on high-stage units with dual-port, liquid Due to the tendency of the port pressure to fall with de
injection oil cooling switches the liquid refrigerant supply to creasing compressor capacity, a back-pressure regulator
the high port when the compressor is operating at higher valve (BPR) is generally required on a Flash Economizer
compression ratios (3.5 Vi and above) for best efficiency. System (Figure 11) in order to maintain some preset pressure
difference between the subcooled liquid in the flash vessel
Where low compression ratios (low condensing pressures)
and the evaporators. If the back-pressure regulator valve is
are anticipated, thermosyphon or water-cooled oil cooling
not used on a flash economizer, it is possible that no pressure
should be used.
difference will exist to drive liquid from the flash vessel to the
evaporators, since the flash vessel will be at suction pressure.
CAUTION In cases where wide swings in pressure are anticipated in
the flash economizer vessel, it may be necessary to add an
It is imperative that an uninterrupted high-pressure outlet pressure regulator to the flash vessel outlet to avoid
liquid refrigerant be provided to the injection system overpressurizing the economizer port, which could result
at all times. Two items of EXTREME IMPORTANCE are in motor overload. Example: A system feeding liquid to the
the design of the receiver/liquid injection supply and flash vessel in batches.
the size of the liquid line. It is recommended that the
receiver be oversized sufficiently to retain a 5-minute The recommended economizer systems are shown in Figures
supply of refrigerant for oil cooling. The evaporator 9 – 12. Notice that in all systems there must be a strainer
supply must be secondary to this consideration. Failure and a check valve between the economizer vessel and the
to follow these requirements causes wire draw which economizer port on the compressor. The strainer prevents
can result in damage to the expansion valve, loss of oil dirt from passing into the compressor and the check valve
cooling, and intermittant oil cooling. One method of prevents oil from flowing from the compressor unit to the
accomplishing this is described below. economizer vessel during shutdown.
Figure 8
VOLTAGE PROTECTION
NOTICE
Johnson Controls-Frick® does not advise nor support the
use of UPS power systems in front of the Quantum™HD
panel.
With a UPS power system providing shutdown protection
for the Quantum™HD, the panel may not see the loss of
the 3-phase voltage on the motor because the UPS could
prevent the motor starter contactor from dropping out. With
Figure 10 - Direct Expansion Economizer System the starter contactor still energized, the compressor auxiliary
will continue to feed an “Okay” signal to the panel. This will
allow the motor to be subjected to a fault condition on the
3-phase bus. Some fault scenarios are:
1. The 3-phase bus has power “on” and “off” in a continu-
ous cyclic manner which may cause the motor to overheat
due to repeated excessive in-rush currents.
2. Motor cycling may damage the coupling or cause other
mechanical damage due to the repeated high torque motor
“bumps”.
3. Prolonged low voltage may cause the motor to stall and
overheat before the motor contactor is manually turned off.
Figure 11 - Flash Economizer System
Under normal conditions, the loss of 3-phase power will shut
down the Quantum™HD panel, and it will restart upon power
return. If the panel was in:
• Auto – Compressor motor will return to running as pro-
grammed.
• Remote – The external controller would reinitialize the
panel and proceed to run as required.
• Manual – The compressor will have to be restarted
manually after the 3-phase bus fault has been cleared.
If the local power distribution system is unstable or prone
to problems, there are other recommendations to satisfy
these problems. If power spikes or low or high line voltages
Figure 12 - Multiple Compressor Flash Economizer System are the problem, then we recommend the use of a Sola®
constant voltage (CV) transformer with a line suppression
ELECTRICAL feature. If a phase loss occurs, then you will typically get a
high motor amp shutdown. If problems continue to exist, then
NOTICE an examination of the plant’s power factor may be in order.
Before beginning electrical installation, read the instruc- Unless careful design failure analysis is considered in the
tions in the section "Proper Installation of Electronic implementation of power systems, the alternative solutions
Equipment" at the back of this manual. provide a safer and less expensive implementation. In either
case, only one Sola® may be used per compressor. Each
RXF units are supplied with a Quantum™HD control system. compressor needs to be individually isolated from each other
Care must be taken that the controls are not exposed to through a dedicated control transformer. Sharing a common
physical damage during handling, storage, and installation. control power source is an invitation for ground loops and
The single-box control door must be kept tightly closed to the subsequent unexplainable problems.
prevent moisture and foreign matter from entry.
070.410-IOM (AUG 14) RXF ROTARY SCREW COMPRESSOR UNITS
Page 12 INSTALLATION
CAUTION
When starting at full voltage or across-the-line, a
shunting device must be installed or the Analog I/O
board in the Quantum™HD panel may be severely dam-
aged at start-up. See Figure 13.
Motor starter and interlock wiring requirements are shown
in the diagram, Figure 12. All of the equipment shown is sup-
plied by the installer unless a starter package is purchased
separately from Frick. Starter packages should consist of:
1. The compressor motor starter of the specified horse-
power and voltage for the starting method specified
(across‑the‑line, autotransformer, wye‑delta or solid-state).
NOTICE
If starting methods other than across‑the‑line are
desired, a motor/compressor torque analysis must be
done to ensure sufficient starting torque is available.
Contact Frick if assistance is required.
2. If specified, the starter package can be supplied as a com-
bination starter with circuit breaker disconnect. However,
the motor overcurrent protection/disconnection device can Figure 13 - Starter Wiring Diagram
be applied by others, usually as a part of an electrical power
distribution board.
3. A 3.0 KVA control power transformer (CPT) to supply 120
volt control power to the control system and separator oil
heaters is included. If environmental conditions require more
than 2000 watts of heat, an appropriately oversized control
transformer will be required.
4. One normally open compressor motor starter auxiliary
contact should be supplied and wired as shown on the starter
package wiring diagram. In addition, the compressor starter
coil and the CPT secondaries should be wired as shown on
the starter package wiring diagram, Figure 13.
NOTICE
The CT must see all the current on any one phase,
therefore in wye-delta applications BOTH leads of any
one phase must pass through the CT.
RXF ROTARY SCREW COMPRESSOR UNITS 070.410-IOM (AUG 14)
INSTALLATION Page 13
NOTICE
DO NOT operate unit with a CT more than one size
larger than recommended.
NOTICE
Do not install a compressor HAND/OFF/AUTO switch in
the starter package as this would bypass the compres-
sor safety devices.
070.410-IOM (AUG 14) RXF ROTARY SCREW COMPRESSOR UNITS
Page 14 OPERATION
6. Compressor housing suitable for 350 PSI pressure. For high-stage packages, the cold-start valve is equipped
with a large spring that creates 30 psi of pressure in the oil
7. Most bearing and control oil is vented to closed threads in separator (above suction pressure), for lubrication of the
the compressor instead of suction port to avoid performance compressor.
penalties from superheating suction gas.
8. The shaft seal is designed to maintain operating pressure CAUTION
on the seal well below discharge pressure for increased
DO NOT ATTEMPT TO SERVICE THE COLD-START
seal life.
VALVE. PLEASE CONTACT THE FRICK SERVICE
9. Oil is injected into the rotors to maintain good volumetric DEPARTMENT.
and adiabatic efficiency, even at very high compression ratios.
Once the compressor is running it will begin to force gas
to the condenser at connection P2. See Figure 15. As the
WARNING condenser heats up it will begin to rise in pressure as the
compressor suction pulls down in pressure. As soon as dif-
It is mandatory that the coupling center be removed and ferential pressure is developed between the condenser and
the direction of motor rotation be confirmed before run- suction, these pressures act across a piston inside the cold-
ning the compressor. Proper rotation of the compressor start valve to partially overcome the spring force. When the
shaft is clockwise looking at the end of the compressor differential pressure reaches and exceeds 30 psi, the piston
shaft. Failure to follow this step could result in backward fully overcomes the spring force and powers the valve fully
compressor rotation which can cause compressor failure open for very low operating pressure drop.
or explosion of the suction housing.
RXF ROTARY SCREW COMPRESSOR UNITS 070.410-IOM (AUG 14)
OPERATION Page 15
Figure 17
The sight glass located near the bottom of the coalescer
section of the oil separator should remain empty during
normal operation. If an oil level develops and remains in the
sight glass, a problem in the oil return separation system or
compressor operation has developed. Refer to Maintenance
for information on how to correct the problem.
COMMON
OUT
VENT COMMON
OUT
PRESSURE
YY4
Figure 18
VOLUMIZER II Vi CONTROL
The RXF compressor is equipped with a special internal
control that automatically adjusts the compressor volume
ratio to the most efficient of three available steps, (2.2, 3.5,
or 5.0 volume ratio). This gives the compressor the ability
to operate at varying operating conditions while minimizing
power consumption by avoiding over or undercompression.
Solenoid valves 3 and 4 (See Figures 19 - 21 and location
on P & I diagram represented by YY3 and YY4) control the
Volumizer II volume ratio control. Oil is internally ported to
apply hydraulic pressure to two stepping pistons in order
to move the moveable slide stop to the optimum position.
The following chart shows the logic of solenoid operation
to adjust the volume ratio.
COMPRESSOR OIL COOLING SYSTEMS liquid refrigerant is then supplied to the motorized expansion
valve. Refer to P & I DIAGRAMS section for piping and
The RXF unit can be equipped with one of several systems instrumentation drawings.
for controlling the compressor oil temperature. They are
single or dual-port liquid injection, thermosyphon, or water- DUAL-PORT LIQUID INJECTION
cooled oil coolers. Each system is automatically controlled,
independentof compressor loading or unloading. The dual-port liquid injection system is designed to obtain
the most efficient compressor performance at high and low
Oil cooling systems maintain oil temperature within the fol- compression ratios by permitting injection of liquid refrigerant
lowing ranges for R-717: into one of two ports optimally located on the compressor.
This minimizes the performance penalty incurred with liquid
Liquid Injection Oil Cooling: 130 to 150°F
injection oil cooling.
External* Oil Cooling: 120 to 140°F
* Thermosyphon Oil Cooling (TSOC) or Water-Cooled Oil The dual-port system contains all the components of the
Cooling (WCOC). single-port system with the addition of a double-acting
solenoid valve and operates as outlined.
SINGLE-PORT LIQUID INJECTION
The liquid injection solenoid valve is energized by the micro
The single-port liquid injection system is designed to permit processor when the temperature sensor, installed in the
liquid refrigerant injection into one port on the compressor compressor discharge, exceeds the setpoint. Liquid refriger-
at any given moment and operates as outlined. ant is then passed through the motorized expansion valve to
the 3-way motorized valve. Depending on the compressor’s
The liquid injection solenoid valve is energized by the micro operating volume ratio (Vi), the microprocessor will select the
processor when the temperature sensor, installed in the flow of the liquid refrigerant to the optimum compressor port.
compressor discharge, exceeds the setpoint. High-pressure
Figure 22
DESCRIPTION: This screen allows the user to enter and EZ COOL PI CONTROL
view the basic operating parameters related to EZ Cool
LIOC PI control. [Setpoint] - Enter the value that you wish to control to.
The following are the EZ Cool LIOC Setup screen selections [Proportional Band] – This setpoint determines the size of
available on this screen: a region either above or below the Control Setpoint. Within
this region, the Proportional component of the PI Output
value is the number between 0% and 100% that directly
070.410-IOM (AUG 14) RXF ROTARY SCREW COMPRESSOR UNITS
Page 18 OPERATION
corresponds to the difference between the Control Input •• “Down” arrow push button (Figures 23 and 24)
(Actual) and the Control Setpoint (Setpoint). Outside of this - Decreases parameter number by 1 at each activation.
region, the Proportional component is either 100% or 0%. •• “Up” arrow push button (Figures 23 and 24)
If the PI’s Action is Forward, the Proportional Band extends - Increases parameter number by 1 at each activation.
above the Control Setpoint. If the PID’s Action is Reverse,
the Proportional Band extends below the Control Setpoint.
High Limit - The highest value that the output can be.
Low Limit - The lowest value that the output can be.
•• None
•• Analog Board 1
•• Analog Board 2
OPERATION OF DANFOSS
LIQUID INJECTION VALVE
The Danfoss ICAD (Industrial Control Actuator with Display)
is equipped with an LED Interface from which it is possible
to monitor and change the setting of parameters to adapt
the ICAD and the corresponding ICM (Motorized Industrial Figure 25
Control Valve) to the actual refrigeration application.
- Gives access to change a value once the Parameter list
The setting of parameters is managed by means of the inte- has been accessed.
grated ICAD (Figures 23 and 24) and consists of: - Acknowledge and save change of value of a parameter.
RXF ROTARY SCREW COMPRESSOR UNITS 070.410-IOM (AUG 14)
OPERATION Page 19
- To exit from the Parameter list and return to the display 1. Ensure that there is power to the valve (24 VDC) and all
of Opening Degree (OD), keep the push button activated wiring is complete prior to configuring the motorized valve.
for 2 seconds. The ICAD 600 requires 1.2 amps for operation and the ICAD
•• Display (Figure 26) 900 requires 2.0 amps.
- Normally the Opening Degree (OD) 0 - 100% of the 2. Identify which actuator is being used (ICAD 600 or 900)
ICM valve is displayed. No activation of push buttons and which motorized valve is being used (ICM 20, 25, 32, 40,
for 20 seconds means that the display will always show 50, or 65). Ensure that the correct actuator is being used
0 (Figure 25). with the ICM valve as follows:
ICM20 with ICAD 600
ICM25 with ICAD 600
ICM32 with ICAD 600
ICM40 with ICAD 900
ICM50 with ICAD 900
ICM65 with ICAD 900
3. When the valve is initially powered, A1 and CA will be
flashing on the LED display. Hold the enter button down for
two seconds until these values stop flashing.
4. Push the down arrow button and scroll until j10 is displayed
Figure 26 and push the enter button. Using the up arrow, scroll until
j11 is displayed and push the enter button. This step must be
•• Displays the parameter.
completed within 20 seconds or the valve will reset.
•• Displays the actual value of a parameter.
5. Push the down arrow button again and scroll until j26 is
•• Displays the function status by means of text (Figure 23).
displayed and push the enter button. Identify the ICM valve
- Mod represents that ICAD is positioning the ICM valve being used and push the up arrow until the correct number is
according to an analog input signal (Current). displayed for the ICM valve and then push the enter button.
- Low represents that ICAD is operating the ICM valve like The values are as follows:
an ON/OFF solenoid valve with low speed according to 1 for ICM20
a digital input signal. 2 for ICM25
- Med represents that ICAD is operating the ICM valve like 3 for ICM32
an ON/OFF solenoid valve with medium speed according 4 for ICM40
to a digital Input signal. 5 for ICM50
6 for ICM65
- High represents that ICAD is operating the ICM valve like
an ON/OFF solenoid valve with high speed according to 6. The ICAD will store these parameters with the power
a digital input signal (Figure 27). removed.
Alarms - ICAD can handle and display different alarms.
ICM
Description Comments
Alarm Text
No valve type A1 At start-up A1 and CA will be
selected displayed
Controller fault A2 Internal fault inside electronics
All input error A3 When input amps are > 22 mA
Parameter list
Display Factory
Description Min. Max. Unit Comments
Name Setting
ICM OD ICM valve Opening Degree is displayed during normal operation.
- 0 100 - %
(Opening Degree) Running display value (see j01, j05).
Internal main switch
1: Normal operation
Main Switch j01 1 2 1 - 2: Manual operation. Valve Opening Degree will be flashing. With the
down arrow and the up arrow push buttons the OD can be entered
manually.
Operation mode
1: Modulating - ICM positioning according to Analogue input (see j03)
Mode jo2 1 2 1 -
2: ON/OFF - operating the ICM valve like an ON/OFF solenoid valve
controlled via Digital Input. See also j09.
Type of Analog input signal from external controller
1: 0-20mA
Analog Input signal j03 1 4 2 - 2: 4-20mA
3: 0-10V
4: 2-10V
Speed can be decreased. Max. speed is 100 %
Not active when j01 = 2
If j02 = 2, the display will indicate speed in display. Low, Med, and
Speed at ON/OFF
j04 1 100 100 % High also means ON/OFF operation.
and Modulating Mode
If j04 < = 33, Low is displayed
33 < If j04 < = 66, Med is displayed
If j04 > = 67, High is displayed
Not active before j26 has been operated.
Automatic calibration j05 0 1 0 - Always auto reset to 0.
CA will flash in the display during calibration.
Type of A0 signal for ICM valve position
0: No signal
Analog Output signal j06 0 2 2 -
1: 0 - 20mA
2: 4 - 20mA
Define condition at power cut when fail-safe is installed.
1: Close valve
Fail-safe j07 1 4 1 - 2: Open valve
3: Maintain valve position
4: Go to OD given by j12
Define function when Dl is ON (short circuited Dl terminals) when j02 = 2
Digital Input function j09 1 2 1 1: Open ICM valve (Dl = OFF = > Close ICM valve)
2: Close ICM valve (Dl = OFF = > Open ICM valve)
Enter number to access password protected parameters:
Password j10 0 199 0 -
j26
Old alarms will be listed with the latest shown first. Alarm list can be
Old Alarms j11 A1 A99 - - reset by means of activating down arrow and up arrow at the same
time for 2 seconds.
Only active if j07 = 4
OD at powercut j12 0 100 50 - If fail-safe supply is connected and powercut occurs, ICM will go to
entered OD.
NB: Password protected. Password = 11
At first start-up, A1 will flash in display. Enter valve type.
0: No valve selected. Alarm A1 will become active.
1: ICM20 with ICAD 600
ICM configuration j26 0 6 0 2: ICM25 with ICAD 600
3: ICM32 with ICAD 600
4: ICM40 with ICAD 900
5: ICM50 with ICAD 900
6: ICM65 with ICAD 900
OD% j50 0 100 - % ICM valve Opening Degree
AI [mA] j51 0 20 - mA Analog Input signal
AI [V] j52 0 10 - V Analog Input signal
AO [mA] j53 0 20 - mA Analog Output signal
DI j54 0 1 - - Digital Input signal
DO Close j55 0 1 - - Digital Output Closed status. ON when OD < 3%
DO Open j56 0 1 - - Digital Output Open status. ON when OD > 97%
DO Alarm j57 0 1 - - Digital Output alarm status. ON when an alarm is detected
MAS mP SW ver. j58 0 100 - - Software version for MASTER Microprocessor
SLA mP SW ver. j59 0 100 - - Software version for SLAVE Microprocessor
RXF ROTARY SCREW COMPRESSOR UNITS 070.410-IOM (AUG 14)
OPERATION Page 21
THERMOSYPHON OIL COOLING adequate oil flow. There is still an orifice installed in the
compressor to control maximum oil flow. At initial start-up
Thermosyphon oil cooling is an economical, effective method of the package the hand expansion valve must be fully open.
for cooling oil on screw compressor units. Thermosyphon After initial start-up of the package the hand expansion valve
cooling utilizes liquid refrigerant at condenser pressure and should be adjusted. There are two methods of determining
temperature which is partially vaporized at the condenser the correct adjustment of this valve.
temperature in a shell and tube or plate-type vessel, cooling
the oil. The vapor, at condensing pressure, is vented to the The best method to determine target discharge temperature
condenser inlet and reliquified. This method is the most cost is to run CoolWare™ with the operating conditions of the
effective of all currently applied cooling systems since no compressor. The program will give you a theoretical discharge
compressor capacity loss or compressor power penalties are temperature of the compressor. Once this temperature is
incurred. The vapor from the cooler need only be condensed, known, you may adjust the hand expansion valve. The ideal
not compressed. Refrigerant flow to the cooler is automa discharge temperature is within 5°F + or – of the theoretical
tic, driven by the thermosyphon principle, and cooling flow discharge temperature. Adjust the valve to achieve the theo-
increases as the oil inlet temperature rises. retical discharge temperature. If you do not have access to
CoolWare™, 180°F is a good target discharge temperature for
a high stage ammonia compressor. Booster applications and
compressors using HFC and HCFC refrigerants may run cooler.
Compressors with high discharge pressure may run hotter.
The first method is used for compressors with External Oil
Cooling (Thermosyphon, Water Cooled, and Glycol Cooled).
Before the initial startup of the compressor close the hand
expansion valve completely. Open the valve back up and
count the turns that it takes to fully open the valve. After the
initial startup close the valve to achieve approximately 180°F
discharge temperature or the theoretical temperature from
CoolWare. Do not fully close the valve at any time while the
compressor is running.
The second method is used for compressors with Liquid
Injection Oil Cooling. Because the discharge temperature is
controlled by the Liquid Injection Thermal Expansion Valve
Figure 28 you will not be able adjust for the correct oil flow by using
the discharge temperature. Before the initial startup of the
SYSTEM OPERATION: Liquid refrigerant fills the cooler. compressor close the hand expansion valve completely. Open
Warm or hot oil (above the liquid return temperature) flowing the valve back up and count the turns that it takes to fully
through the cooler will cause some of the refrigerant to boil open the valve. After the initial startup close the valve ½
and vaporize. The vapor rises in the return line. way. If it took 10 turns to open the valve completely, then
The density of the refrigerant liquid/vapor mixture in the turn it in 5 turns. If it took 7 turns to open, then close the
return line is considerably less than the density of the liquid valve 3½ turns. Do not close the valve any further than ½
in the supply line. This imbalance provides a differential the number of turns required to fully open it.
pressure which sustains a flow condition to the oil cooler.
This relationship involves: WARNING
1. Liquid height above the cooler. Failure to properly adjust this valve can lead to exces-
2. Oil heat of rejection. sive noise and vibration of the compressor and package,
premature failure of the bearings, liquid loading of the
3. Cooler size and piping pressure drops. rotors, liquid starvation of the rotors and catastrophic
failure of the compressor.
Current thermosyphon systems are using single-pass oil
coolers and flow rates based on 3:1 overfeed. 2. All Models! For proper and safe operation, the compres-
sor must be run at the proper speed and discharge pressure.
The liquid/vapor returned from the cooler is separated in Exceeding design conditions creates a potential hazard.
the receiver. The vapor is vented to the condenser inlet and
need only be reliquified since it is still at condenser pressure 3. Rotate and lubricate motor bearings according to manufac-
(see Figure 28). turer’s recommendations PRIOR to initial start-up as required.
4. After running the unit for approximately three hours, ad-
INITIAL START-UP PROCEDURE just liquid injection oil cooling if applicable. If unit has water
Having performed the checkpoints on the prestart check cooled oil cooling, adjust water control valve to cooler.
list (see FORMS section), the compressor unit is ready for 5. The compressor slide valve linear transmitter should be
start‑up. It is important that an adequate refrigerant load calibrated.
be available to load test the unit at normal operating condi-
tions. The following points should be kept in mind during 6. Perform vibration analysis if equipment is available.
initial start‑up. 7. Pull and clean suction strainer after 24 hours operation. If
1. Models 58 - 101 ONLY! It is imperative that during the it is excessively dirty, repeat every 24 hours until system is
initial start-up of the package that the hand expansion clean. Otherwise, follow the Maintenance Schedule. See the
valve on the main oil injection line is fully open to ensure RECOMMENDED MAINTENANCE PROGRAM section.
070.410-IOM (AUG 14) RXF ROTARY SCREW COMPRESSOR UNITS
Page 22 OPERATION
GENERAL MAINTENANCE 6. Shut off the cooling water supply valve to the oil cooler.
Drain water, if applicable. Attach CLOSED tags.
Proper maintenance is important in order to assure long and
trouble-free service from your screw compressor unit. Some 7. Protect oil cooler from ambient temperatures below
areas critical to good compressor operation are: freezing.
COMPRESSOR/MOTOR SERVICING 2. Isolate the package by closing all package valves to the
system. Tag all closed valves.
Before removing the motor from an RXF unit, it is criti-
cal that proper support be provided for the compressor to
prevent damage to the oil separator. Insert blocks or a jack CAUTION
between the separator shell and compressor casting. Make
Open any solenoid valves or other valves that may trap liquid
sure the weight is held safely by the separator shell. Loosen
between the isolation valves and other package valves
the compressor discharge flange bolts to relax any flange
to prevent injury or damage to components.
and pipe stress, then carefully remove the motor. Similarly,
before removing the compressor for servicing, the back end SLOWLY vent separator to low-side system pressure using
of the motor must be supported to prevent damage. Again, the suction check valve bypass.
insert either blocks or a jack between the rear of the motor
and the separator shell.
NOTICE
GENERAL INSTRUCTIONS FOR REPLACING Recover or transfer all refrigerant vapor, in accordance
COMPRESSOR UNIT COMPONENTS with local ordinances, before opening to atmosphere. The
separator MUST be equalized to atmospheric pressure.
When replacing or repairing components which are exposed
to refrigerant, proceed as follows:
1. Push [STOP] key to shut down the unit. CAUTION
2. Open disconnect switches for compressor motor starter Oil entrained refrigerant may vaporize, causing a sepa-
and oil pump motor starter (if applicable). rator pressure increase. Repeat transfer and recovery
procedure, if necessary.
3. Isolate the package by closing all package valves to the
system. Tag all closed valves. 3. Remove spin-on oil filter element and discard.
CAUTION NOTICE
Open any solenoid valves or other valves that may trap liquid Use of oil filters other than Frick may cause warranty
between the isolation valves and other package valves claim to be denied.
to prevent injury or damage to components.
4. Replace with new oil filter element. Make finger tight plus
4. SLOWLY vent separator to low-side system pressure using an additional half turn.
the suction check valve bypass. 5. Isolate the low pressure transducer, PE-4, to prevent dam-
age during pressurization and leak test.
NOTICE 6. Pressurize and leak test.
Recover or transfer all refrigerant vapor, in accordance 7. Evacuate unit to 29.88" Hg (1000 microns).
with local ordinances, before opening to atmosphere.
The separator MUST be equalized to atmospheric 8. Open the suction and discharge service valves, and the
pressure. low pressure transducer. Close disconnect switches for the
compressor. Start the unit.
12. Open the suction and discharge service valves, oil filter 6. When all entrapped refrigerant has been relieved, carefully
remove loosened capscrews (as liquid refrigerant is sometimes
isolation valves, and the low pressure transducer. Readjust
caught in the strainer), strainer cover, and strainer basket.
suction check valve bypass. Close disconnect switches for
the compressor and (if applicable) the oil pump motor start- 7. Wash the strainer basket and cover in solvent and blow
ers. Start the unit. clean with air.
1. Push [STOP] key to shut down the unit. Open disconnect 9. Open the service valve between the compressor and the
switches for the compressor. liquid injection thermal expansion valve, purge entrained air,
and check for leakage.
2. Isolate the package by closing all package valves to the
system. Tag all closed valves. 10. Screw out the manual solenoid valve stem.
11. Carefully open the liquid supply service valve.
CAUTION 12. Leak test.
Open any solenoid valves or other valves that may trap
13. Close disconnect switches for compressor starter.
liquid between the isolation valves and other package
valves to prevent injury or damage to components. 14. Start the unit.
SLOWLY vent separator to low-side system pressure
using the suction check valve bypass. OIL PUMP STRAINER (Optional)
To clean the full-lube oil pump strainer, the unit must be shut
NOTICE down. The procedure is as follows:
1. Push [STOP] key to shut down the unit, then open the
Recover or transfer all refrigerant vapor, in accordance
disconnect switches for the compressor and (if applicable)
with local ordinances, before opening to atmosphere. The the oil pump motor starters.
separator MUST be equalized to atmospheric pressure.
070.410-IOM (AUG 14) RXF ROTARY SCREW COMPRESSOR UNITS
Page 26 MAINTENANCE
2. Close strainer service valves. 6. Replace coalescer filter retainer and nut. Tighten the nut
to 21 ft-lb torque. DO NOT OVERTIGHTEN NUT. Excessive
3. Open the drain valve located in the strainer cover and torque can damage the element and result in oil carryover.
drain the oil into a container. Install jam nut and tighten.
4. Remove the capscrews securing the strainer cover, strainer 7. Install a new head gasket and replace the coalescer head.
cover gasket, and element. Retain the gasket.
8. Tighten the head bolts, first to finger tight, then 65 ft-lb,
5. Wash the element in solvent and blow it clean with air. then 130 ft-lb.
6. Wipe the strainer body cavity clean with a lint‑free clean cloth.
7. Replace the cleaned element and gasket, then reattach
NOTICE
the cover using the retained capscrews. WHEN THE COMPRESSOR UNIT IS REPRESSURIZED,
RETIGHTEN SINCE HEAD BOLTS WILL LOOSEN.
8. Reinstall the drain plug and open the strainer service valves.
9. Refer to CHANGING OIL, Steps 9 thru 14.
9. Check for leakage.
CHANGING OIL
10. Close the disconnect switches for the compressor and
(if applicable) the oil pump motor starters.
11. Start the unit.
WARNING
DO NOT MIX OILS of different brands, manufacturers, or
SUCTION CHECK VALVE BYPASS types. Mixing of oils may cause excessive oil foaming,
nuisance oil level cutouts, oil pressure loss, gas or oil
A 1/4" angle valve is installed between the compressor and
leakage and catastrophic compressor failure.
suction flange that can be used as a suction valve bypass.
This feature has several uses including reducing starting Shut down the unit when changing oil. At the same time all
torque, improving oil quality, and relieving the refrigerant oil filter cartridges must be changed and all oil strainer ele-
to low side for servicing. ments removed and cleaned. The procedure is as follows:
In most cases, the valve should be left open approximately 1 to 1. Push [STOP] key to shut down the unit.
2 turns at all times. If the compressor back-spins or too much
oil foaming is experienced while venting, partially close valve 2. Open disconnect switch for the compressor motor starter.
to slow speed of equalization. If system is on AUTO CYCLE and
short cycling occurs, the valve must be closed. 3. Close liquid injection service valves (if applicable).
To relieve refrigerant to low side, close separator discharge 4. Close discharge service valve. SLOWLY vent the separator
service valve. Slowly open bypass valve (if closed) and wait to low-side system pressure using the suction check valve
for pressure to equalize. Close bypass and suction service bypass. Close suction valve.
valves before evacuating the unit.
COALESCER FILTER ELEMENT
NOTICE
Recover or transfer all refrigerant vapor, in accordance
with local ordinances, before opening to atmosphere. The
CAUTION separator MUST be equalized to atmospheric pressure.
Use of coalescer filter elements other than Frick may
cause warranty claim to be denied.
When changing the coalescer filter element, it is recom
CAUTION
mended that the oil and oil filter be changed. Applicable Oil entrained refrigerant may vaporize, causing a separa
strainer elements should be removed and cleaned. tor pressure increase. Repeat transfer and recovery
procedure, if necessary.
1. Refer to CHANGING OIL, Steps 1 thru 8.
5. Open drain valve(s) located on the underside of the sepa-
2. Remove coalescer head and gasket. Discard the gasket. rator and drain the oil.
3. Remove and retain nut securing coalescer filter retainer. 6. Drain oil filter, strainers, and oil cooler, if applicable.
4. Remove retainer, coalescer filter element(s), and two 7. Remove and install new oil filter element.
O‑rings. Discard the filter element(s).
8. Remove, clean, and reinstall strainer elements in strainers.
5. Install new coalescer filter element(s).
9. Evacuate unit to 29.88" Hg (1000 microns).
NOTICE 10. Open suction service valve and pressurize the unit to
Frick SuperCoalescer™ element (with drain feature), on system suction pressure. Close the suction valve and leak test.
Models 24–101, must be installed with the "DRAIN DOWN"
11. Add oil by attaching a suitable pressure-type hose to
tag on the bottom at the 6 o'clock position.
the oil drain valve located on top of the separator. Using a
pressure-type oil pump and recommended Frick oil, open
CAUTION the drain valve and fill the separator until oil level is midway
in the top sight glass.
Seat element in center of locating tabs on separator
bulkhead.
RXF ROTARY SCREW COMPRESSOR UNITS 070.410-IOM (AUG 14)
MAINTENANCE Page 27
CAUTION
If the strainer is installed backwards, it will be damaged.
GG, HJ, HL: Remove outer snap ring from the bearing housing Once the rotary portion of the mechanical seal is installed on
and remove the ball bearing. See Figure 29. the rotor shaft, it is necessary to assemble parts as quickly
as possible to ensure that the seal does not stick to the shaft
AS, AK, AL: Loosen the two set screws in flange outside in the wrong axial position. The seal will stick to the shaft
diameter. Rotate end cap and lip seal counterclockwise and after several minutes setting time.
remove. Remove the ball bearing. See Figure 30.
Never touch sealing faces with anything except clean hands
The casing should be examined for wear, particularly in the or clean cloth. Minute particles can scratch the seal faces
area between ports. All parts should be checked for wear and cause leakage.
before the pump is put together.
1. Coat the idler pin with refrigeration oil and place idler
When making major repairs, such as replacing a rotor and and bushing on idler pin in the head. If replacing a carbon-
shaft, it is advisable to also install a new mechanical seal, graphite bushing, refer to "Installation of Carbon Graphite
head and idler pin, idler, and bushing. See INSTALLATION Bushings".
OF CARBON-GRAPHITE BUSHINGS.
2. Clean rotor hub and casing seal housing bore. Make sure
both are free from dirt and grit. Coat outer diameter of seal
Figure 31 Figure 32
RXF ROTARY SCREW COMPRESSOR UNITS 070.410-IOM (AUG 14)
MAINTENANCE Page 29
seat and inner diameter of seal housing bore with refrigera- 15. Pack the double row ball bearing with multipurpose
tion oil. grease, NLGI #2.
3. Start seal seat in seal housing bore. If force is necessary, GG, HJ, HL: Install the ball bearing into the bearing housing
protect seal face with a clean cardboard disc and gently tap it with shield side toward the coupling end of the shaft. See
in place with a piece of wood. Be sure seal seat is completely Figure 29. Install the snap ring into bearing housing to retain
seated in the bore. ball bearing. This snap ring has a tapered edge to fit tapered
groove in bearing housing. The tapered edge is located away
4. Place tapered installation sleeve on shaft. Refer to Figure from the ball bearing.
32. Sleeve is furnished with GG, AS, AK, and AL replacement
mechanical seals. Coat rotor shaft, tapered installation sleeve, AS, AK, AL: Install the ball bearing into the bearing housing.
and inner diameter of mechanical seal rotary member with Install the lip seal in the bearing housing end cap. The lip
a generous amount of refrigeration oil. Petrolatum may be should face towards the end of the shaft. Put the bearing
used but grease is not recommended. spacer collar in the lip seal and install in the bearing housing
and tighten the set screws securely. See Figure 30.
5. Place seal spring on the shaft against the rotor hub. Refer
to Figure 32. 16. Insert a brass bar or piece of hardwood through the
port opening between the rotor teeth to keep the shaft
6. Slide rotary member, with lapped contact surface facing from turning.
away from the spring, over installation sleeve on shaft until
just contacting the spring. Do not compress the spring. Re- 17. Start the thrust bearing assembly into casing. Turn by hand
move the installation sleeve. until tight. This forces the rotor against the head. Replace
and tighten the locknut or shaft.
7. Coat the rotor shaft with refrigeration oil. Install the rotor
and shaft into the casing, slowly pushing until the ends of 18. Remove the brass bar or hardwood from port opening.
the rotor teeth are just below the face of the casing. Take
care not to damage the seal seat. 19. Adjust pump end clearance, refer to “Thrust Bearing
Adjustment.”
8. Leave the rotor in this position. Withdrawal of rotor and
shaft may displace the carbon seal rotating face and result
in damage to the seal. DANGER
9. Place O‑ring gasket on the head and install head and idler BEFORE STARTING PUMP, ENSURE THAT ALL DRIVE
assembly on pump. Pump head and casing were marked EQUIPMENT GUARDS ARE IN PLACE. FAILURE TO
before disassembly to ensure proper reassembly. If not, be PROPERLY MOUNT GUARDS MAY RESULT IN SERIOUS
sure the idler pin, which is offset in pump head, is positioned INJURY OR DEATH.
up and equal distance between port connections to allow for
proper flow of liquid through the pump. THRUST BEARING ADJUSTMENT
10. Tighten the head capscrews evenly. Loosen two screws in face of thrust-bearing assembly. See
Figures 29 or 30.
11. If the pump was equipped with a relief valve and was
removed during disassembly, install on the head with new If shaft cannot be rotated freely, turn thrust-bearing assembly
O-Rings or gaskets. The relief valve adjusting screw cap must counterclockwise until shaft can be turned easily.
always point towards the suction port. 1. While turning rotor shaft, rotate thrust-bearing assembly
12. In 2005, the use of single seal bearings were phased out. clockwise until noticeable drag occurs. This is zero end
Pumps now use “Sealed for Life” bearings that have seals clearance.
on both sides. The new bearings can be installed either side 2. Mark position of bearing housing with respect to the casing.
first and do not need to be packed with grease. For older
models with single seal bearings, pack the inner ball bearing 3. Rotate thrust-bearing assembly counterclockwise the
with multi-purpose grease, NLGI #2. distance listed below as measured on outside of bearing
housing.
GG, HJ, HL: Drive the bearing into the bore. Tap the inner
race with a brass bar and lead hammer to position bearing. 4. Tighten two setscrews in face of bearing housing after
Install the inner snap ring. adjustment is made to secure thrust-bearing assembly
position.
AS, AK, AL: Install the bearing retainer washer over the shaft
before installing the ball bearing. Install the ball bearing in For viscosities above 2500 SSU, add additional end clearance
the casing with sealed side towards head end of the pump. (0.004" for GG, HJ and HL size pumps and 0.005" for AS,
Drive the bearing into the bore. Tap the inner race with a AK and AL size pumps).
brass bar and lead hammer to position the bearing.
Pump Distance (in.) on O.D. End Clearance
13. GG, HJ, HL: Install the shaft snap ring in groove in the
shaft. See Figure 29. Size of Bearing Housing (in.)
GG 7/16 .003
AS, AK, AL: Install the bearing spacer over the shaft and
HJ, HL 9/16 .003
against the single row ball bearing. See Figure 30.
AS, AK, AL 1/2 .003
14. Pack the lubrication chamber between the inner ball
bearing and double row ball bearing in the thrust bearing as- INSTALLATION OF CARBON GRAPHITE BUSHINGS
sembly approximately one-half full of multi-purpose grease, When installing carbon graphite bushings, extreme care must
NLGI #2. The thrust bearing assembly will take the remaining be taken to prevent breaking. Carbon graphite is a brittle
space. See Figures 29 or 30.
070.410-IOM (AUG 14) RXF ROTARY SCREW COMPRESSOR UNITS
Page 30 MAINTENANCE
material and easily cracked. If cracked, the bushing will e. Line partially plugged from buildup on inside of pipe.
quickly disintegrate. Using a lubricant and adding a chamfer f. Liquid in pipe not up to temperature.
on the bushing and the mating part will help in installation. g. Liquid in pipe has undergone a chemical reaction and
The additional precautions listed below must be followed has solidified.
for proper installation: h. Relief valve set too high.
1. A press must be used for installation. 2. Low reading would indicate:
a. Relief valve set too low
2. Be certain bushing is started straight. b. Relief valve poppet not seating properly.
c. Too much extra clearance.
3. Do not stop pressing operation until bushing is in proper d. Pump worn.
position. Starting and stopping will result in a cracked bushing.
3. Fluttering, jumping, or erratic reading:
4. Check bushing for cracks after installation. a. Cavitation.
b. Liquid coming to pump in slugs.
TROUBLESHOOTING THE DEMAND PUMP c. Air leak in suction line.
d. Vibrating from misalignment or mechanical problems.
DANGER Some of the following may also help pinpoint the problem:
1. Pump does not pump.
BEFORE OPENING ANY VIKING PUMP LIQUID CHAM-
a. Lost its prime - air leak, low level in tank.
BER (PUMPING CHAMBER, RESERVOIR, JACKET, ETC.)
b. Rotating in wrong direction.
ENSURE:
c. Motor does not come up to speed.
1. THAT ANY PRESSURE IN THE CHAMBER HAS BEEN d. Suction and discharge valves not open.
COMPLETELY VENTED THROUGH SUCTION OR DIS- e. Strainer clogged.
CHARGE LINES OR OTHER APPROPRIATE OPENINGS f. Relief valve set too low, relief valve poppet stuck open.
OR CONNECTIONS. g. Pump worn out.
2. THAT THE DRIVING MEANS (MOTOR, TURBINE, h. Any changes in the liquid system, or operation that
ENGINE, ETC.) HAS BEEN “LOCKED OUT” OR MADE would help explain the trouble, e.g. new source of
NONOPERATIONAL SO THAT IT CANNOT BE STARTED supply, added more lines, inexperienced operators,
WHILE WORK IS BEING DONE ON THE PUMP. etc.
i. Tighten end clearance.
FAILURE TO FOLLOW ABOVE LISTED PRECAUTIONARY
j. Head position incorrect.
MEASURES MAY RESULT IN SERIOUS INJURY OR DEATH.
2. Pump starts, then loses its prime.
Mark valve and head before disassembly to ensure proper a. Low level in tank.
reassembly. b. Liquid vaporizing in the suction line.
c. Air leaks or air pockets in the suction line; leaking air
If trouble does develop, one of the first steps toward find- through packing or mechanical seal.
ing the difficulty is to install a vacuum gauge in the suction d. Worn out.
port and a pressure gauge in the discharge port. Readings
on these gauges often will give a clue as to where to start 3. Pump is noisy
looking for the trouble. a. Pump is being starved (heavy liquid cannot get to pump
fast enough). Increase suction pipe size or reduce
Vacuum Gauge—Suction Port length.
1. High reading would indicate: b. Pump is cavitating (liquid vaporizing in the suction
a. Suction line blocked - foot valve stuck, gate valve line). Increase suction pipe size or reduce length; if
closed, strainer plugged. pump is above the liquid, raise the liquid level closer
b. Liquid too viscous to flow through the piping. to the pump; if the liquid is above the pump, increase
c. Lift too high. the head of liquid.
d. Line too small. c. Check alignment.
d. May have a bent shaft or rotor tooth. Straighten or
2. Low reading would indicate - replace.
a. Air leak in suction line. e. May be a foreign object trying to get into the pump
b. End of pipe not in liquid. through the suction port.
c. Pump is worn.
d. Pump is dry - should be primed. 4. Pump not up to capacity
a. Starving or cavitating - increase suction pipe size or
3. Fluttering, jumping, or erratic reading: reduce length.
a. Liquid vaporizing. b. Strainer partially clogged - clean.
b. Liquid coming to pump in slugs - possibly an air leak c. Air leak in suction piping or along pump shaft.
or insufficient liquid above the end of the suction pipe. d. Running too slowly - is motor the correct speed and
c. Vibrating from cavitation, misalignment, or damaged is it wired up correctly
parts. e. Relief valve set too low or stuck open.
Pressure Gauge - Discharge Port f. Pump worn out.
g. Tighten end clearance.
1. High reading would indicate: h. Head position incorrect.
a. High viscosity and small and/or long discharge line.
b. Gate valve partially closed. 5. Pump takes too much power.
c. Filter plugged. a. Running too fast - is correct motor speed, reducer
d. Vertical head did not consider a high specific gravity ratio, sheave size, etc. being used.
liquid.
RXF ROTARY SCREW COMPRESSOR UNITS 070.410-IOM (AUG 14)
MAINTENANCE Page 31
b. Liquid more viscous than unit sized to handle - heat RECOMMENDED MAINTENANCE PROGRAM
the liquid, increase the pipe size, slow the pump down,
In order to obtain maximum compressor unit performance
or get a bigger motor.
and ensure reliable operation, a regular maintenance program
c. Discharge pressure higher than calculated - check with
should be followed (see Maintenance Schedule):
pressure gauge. Increase size or reduce length of pipe,
reduce speed (capacity), or get bigger motor. The compressor unit should be checked daily for leaks, abnor-
d. Pump misaligned. mal vibration, noise, and proper operation. A daily log should
e. Extra clearance on pumping elements may not be also be maintained. There should be a continued monitoring
sufficient for operating conditions. Check parts for of oil quality and oil analysis testing. In addition, an analysis
evidence of drag or contact in pump and increase of the unit’s vibration should be made periodically.
clearance where necessary
6. Rapid Wear. VIBRATION ANALYSIS
Examination of a pump that has gradually lost its ability to Periodic vibration analysis can be useful in detecting bearing
deliver capacity or pressure would show a smooth wear pat- wear and other mechanical failures. If vibration analysis is
tern on all parts. Rapid wear shows up as heavy grooving, used as a part of your preventive maintenance program, take
galling, twisting, breaking, or similar severe signs of trouble. the following guidelines into consideration.
1. Always take vibration readings from exactly the same
places, at exactly the same percent of load.
MAINTENANCE SCHEDULE
This schedule should be followed to ensure trouble-free operation of the compressor unit.
FREQUENCY OR Hours of Operation (Maximum)
40,000
80,000
60,000
90,000
30,000
20,000
50,000
10,000
70,000
45,000
85,000
65,000
95,000
35,000
25,000
55,000
75,000
15,000
8000
5000
1000
200
Maintenance
4. Excessively high discharge pressure. 7. This result is the absolute suction pressure (PSIA). Subtract
14.7 to obtain PSIG which the Operating display will indicate.
5. Inadequate refrigerant charge or low receiver level.
8. Isolate the oil pressure transducers (PE‑1 & PE-2) from
6. Excessively high or low temperature coolant to the oil
the package and depressurize.
cooler.
7. Liquid return from system (carryover). NOTICE
8. Refrigerant underfeed or overfeed to evaporators. Recover or transfer all refrigerant vapor, in accordance
9. Blocked tubes or plates in water-cooled oil cooler from with local ordinances, before opening to atmosphere.
high mineral content of water. 9. Measure the voltage of (PE‑1 & PE-2) on connector (P5A)
10. Insufficient evaporator or condenser sizing. (terminals 5 and 6) on the analog board.
11. Incorrect refrigerant line sizing. 10. The voltage reading should be between 1.1 VDC and 1.29
12. Improper system piping. VDC at standard atmospheric pressure. (PE-1 & PE-2) and
(PE-3) have a span of 500 PSI as compared to (PE-4) with a
13. Problems in electrical service to compressor unit. span of 200 PSI. Therefore, atmospheric pressure changes
14. Air and moisture present in the system. have a lesser effect which is 0.0067 VDC per 1000 feet of
elevation and 0.00067 VDC per 0.1 inch Hg barometric de-
Make a list of all deviations from normal plant operation and viation.
normal compressor unit operation. Delete any items which
11. Subtract 1.2 from the voltage.
do not relate to the symptom and separately list those items
that might relate to the symptom. Use the list as a guide to 12. Multiply by 75, the result will be PSIG.
further investigate the problem.
13. Since the discharge pressure (PE-3) cannot be closed
The second step in problem solving is to decide which items off from its sensing point (code requirements), remove all
on the list are possible causes and which items are additional transducers from atmosphere and open them to their sensing
symptoms. High discharge temperature and high oil tempera- points so all transducers can equalize to separator pressure.
ture readings may both be symptoms of a problem and not
casually related. High suction superheat or a low receiver 14. Measure the voltage of (PE-3) on connector (P5B) (ter-
level, however, could cause both symptoms. minals 5 and 6) on the analog board.
The third step is to identify the most likely cause and take 15. Test complete.
action to correct the problem. If the symptoms are not
relieved, move to the next item on the list and repeat the PRESSURE TRANSDUCERS REPLACEMENT
procedure until you have identified the cause of the problem. 1. Shut off control power.
Once the cause has been identified and confirmed, make the
necessary corrections. 2. Close the applicable transducer isolation valve.
070.410-IOM (AUG 14) RXF ROTARY SCREW COMPRESSOR UNITS
Page 34 MAINTENANCE
NOTICE TRANSDUCER
Suction Pressure
CONNECTION
PE‑4
To change the discharge pressure transducer (PE-3), it Discharge Pressure PE‑3
will be necessary to depressurize the entire compressor Oil Pressure PE‑1 & PE-2
package. Follow "General Instructions For Replacing Com-
pressor Unit Components" section before going to step 3. 5. Unscrew the transducer using a wrench on the metal hex at
the base of the transducer. DO NOT ATTEMPT TO LOOSEN
OR TIGHTEN TRANSDUCERS BY THEIR TOP CASING.
CABLE COLOR CODE
6. Install new transducer, reconnect DIN connector, and
PIN 1 + SUPPLY
1
retighten DIN connector screw.
PIN 2 DC COMMON 7. Recalibrate.
3
2 PIN 3 SIGNAL
CASE GND
NOTICE
If replacing older hard-wired transducer, cut cable at
Figure 34 - Pressure Transducer Color Key back of old transducer and rewire to the Danfoss unit.
3. Refer to Figure 34 to identify wiring harness connectors. 8. Reopen the transducer isolation valve or compressor
package isolation valves.
4. Remove DIN connector screw, then remove DIN connector
from the transducer. 9. Turn on control power.
RXF ROTARY SCREW COMPRESSOR UNITS 070.410-IOM (AUG 14)
MAINTENANCE Page 35
SLIDE VALVE TRANSMITTER 3. Unscrew knurled ring and remove transmitter unit.
REPLACEMENT - SLIDE STOP 4. Apply thermal compound to new sensor assembly, insert
into thermal well, and tighten knurled ring.
The Slide Valve Transmitter (Figure 35) is located on the
right side of the compressor (facing shaft) at the inlet end. 5. Apply DIN connector plug to transmitter.
The linear transmitter with hermetic enclosure is based on 6. Turn on control power.
the inductive measuring principle. It features removable
electronics (from the sensor well) eliminating the need to
evacuate the compressor for replacement. This type of
NOTICE
transmitter is dedicated to volume ratio control and has no For calibration instructions, refer to Quantum™HD Op-
user adjustments. erator's Manual 090.040-O.
1. Shut off control power. OIL LEVEL TRANSMITTER
2. Remove DIN connector plug from transmitter. REPLACEMENT
3. Loosen set screws.
The Oil Level Transmitter is located on the front of the sepa-
4. Remove transmitter unit. rator near the bottom/center. See Figure 37.
5. Install new transmitter unit.
6. Tighten set screws.
7. Apply DIN connector plug to transmitter.
8. Turn on control power.
NOTICE
For calibration of the Slide Valve unit, refer to the Ana-
log Calibration instructions in publication 090.040-O.
RAPID LOSS WITH NO OIL Compressor unit suction check valve did not close on shutdown. Repair valve.
LEVEL IN THE COALESCER
SECTION SIGHT GLASS Bypass open around suction check valve. Close bypass valve.
Bypass valve opened too far. Tighten
Coalescer filter elements not seated properly. Replace oil charge and coalescers.
Oil viscosity too low. Verify correct oil, replace if incorrect.
High system CFM. System operating out of design conditions (High suction and Low discharge
pressures).
Refrigerant flood-back. Correct system problem.
Two or more compressors piped to a single economizer vapor port. Verify check valves are in
working order.
OIL TEMPERATURE System conditions rapidly fluctuate causing liquid injection system to overrespond. Stabilize
FLUCTUATES system operation.
Check calibration and operation of motor valve - Adjust P & ID setpoints for analog output.
RXF ROTARY SCREW COMPRESSOR UNITS 070.410-IOM (AUG 14)
MAINTENANCE Page 37
SLIDE VALVE WILL LOAD BUT YY1 solenoid coil burned out. Replace coil.
WILL NOT UNLOAD
Check valve in solenoid valve piston bad. Replace or repair.
Dirt inside solenoid valve preventing valve from operating both ways. Clean valve.
Solenoid may be mechanically actuated by inserting a piece of 3/16" rod against armature pin and pushing
spool to opposite end. Push YY1 valve to confirm unload capability. If valve works, problem is electrical.
Slipper seals worn out or damaged. Replace.
Check valve in slide valve piston sticking. Remove and clean check valve.
SLIDE VALVE WILL UNLOAD YY2 solenoid coil burned out. Replace coil.
BUT WILL NOT LOAD
Dirt inside solenoid valve preventing valve from operating both ways. Clean valve.
Solenoid may be mechanically actuated by inserting a piece of 3/16" rod against armature pin
and pushing spool to opposite end. If valve works, the problem is electrical.
SLIDE STOP WILL NOT FUNC- Solenoid coil burned out. Replace coils.
TION IN EITHER DIRECTION
Solenoid valve sticking. Replace valve.
SAE STRAIGHT THREAD O-RING FITTINGS - ASSEMBLY PROCEDURE FOR RXF 58 - 101
When performing maintenance or replacing the compres- 1. Inspect components to ensure that male and female port
sor, the hydraulic tubing may need to be removed and threads and sealing surfaces are free of burrs, nicks and
re-installed. The following procedure outlines the proper scratches or any foreign material.
installation of SAE straight thread fittings to SAE straight
thread ports. 2. If the O-ring is not pre-installed to the fitting on the male
end, install the proper size O-ring.
The male and female ends of SAE straight thread O-ring
ports have UN/UNF straight threads. An elastomeric O-ring 3. Lubricate the O-ring with a light coating of system oil or
is fitted to the male end. On assembly, the O-ring is firmly petroleum jelly.
sandwiched between the angular sealing surface of the fe-
4. Screw the fitting into the female port until the hex flat
male port and the shoulder of the male end. Sealing is thus
contacts the port face. Light wrenching may be necessary.
affected and maintained by the O-ring compression which
results from the clamping force generated by the tightening 5. Tighten to the appropriate torque value shown in the
action. The straight threads do not offer sealing action; they Assembly Torque Table.
provide the resistance (holding power) for service pressure.
NOTE: Compressor port locations for RXF 58 -101 are located on the following page.
RXF ROTARY SCREW COMPRESSOR UNITS 070.410-IOM (AUG 14)
MAINTENANCE Page 41
COMPRESSOR
DRIVE SHAFT
TUBING LINE
SIGHT
SOLENOID GLASS
VALVE MOTORIZED
STRAINER EXPANSION
S VALVE
LIQUID REFRIGERANT
FROM RECEIVER
LIQUID LINE
070.410-IOM (AUG 14) RXF ROTARY SCREW COMPRESSOR UNITS
Page 42 MAINTENANCE
3-WAY
MOTORIZED
VALVE
COMPRESSOR COMPRESSOR
LOW VI HIGH VI
M
TUBING LINE
SOLENOID
VALVE MOTORIZED
EXPANSION
STRAINER VALVE
S
LIQUID REFRIGERANT
FROM RECEIVER
LIQUID
LINE SIGHT
GLASS
YY
9
COMPRESSOR COMPRESSOR
SUCTION PRESS. S
LOW VI
COMPRESSOR
HIGH VI TUBING LINE
TO SEPARATOR
SOLENOID
VALVE MOTORIZED
EXPANSION
STRAINER VALVE
S
LIQUID REFRIGERANT
FROM RECEIVER
LIQUID
LINE SIGHT GLASS
RXF MODELS 12 through 19 without OIL PUMP (See OIL COOLING ADDITIONS)
LEGEND*
C COMPRESSOR PE PRESSURE ELEMENT XE VIBRATION ELEMENT
CV CHECK VALVE PI PRESSURE INDICATOR XAH VIBRATION HIGH ALARM
F FILTER OR FILTER DRIER PIC/TIC PRESS./TEMP. INDICATING CONTROLLER XAHH VIBRATION HIGH SHUTDOWN
HTR HEATER PM PUMP MOTOR ZT POSITION TRANSMITTER
LG SIGHT OR LEVEL GLASS PSV PRESSURE SAFETY VALVE ZI POSITION INDICATOR
LSL OIL LEVEL SWITCH LOW PV PRESSURE VESSEL
LSLL LOW OIL LEVEL SHUTDOWN STR STRAINER * Continued following page
M MOTOR TAH HIGH TEMPERATURE ALARM
NV NEEDLE VALVE TAHH HIGH TEMP. SHUTDOWN
P PUMP TAL LOW TEMPERATURE ALARM
PAH HIGH PRESSURE ALARM TALL LOW TEMPERATURE SHUTDOWN
PAHH HIGH PRESSURE SHUTDOWN TCV TEMPERATURE CONTROL VALVE
PAL LOW PRESSURE ALARM TE TEMPERATURE ELEMENT
PALL LOW PRESSURE SHUTDOWN YY SOLENOID VALVE/EVENT VALVE
070.410-IOM (AUG 14) RXF ROTARY SCREW COMPRESSOR UNITS
Page 44 MAINTENANCE
RXF MODELS 12 through 19 with OIL PUMP (See OIL COOLING ADDITIONS)
LEGEND (Cont.)
CONNECTIONS ** NOTES:
1 MAIN OIL SUPPLY 1. PRESSURE TRANSDUCERS INDICATE:
2 SLIDE VALVE PISTON PE-1 OIL PRESSURE
7 SUCTION PRESSURE PE-3 DISCHARGE PRESSURE
10 DISCHARGE PRESSURE PE-4 SUCTION PRESSURE
11 LIQ. INJ. BLEED LINE 2. TEMPRERATURE PROBES INDICATE:
12 COALESCER BLEED LINE TE-1 SUCTION GAS TEMPERATURE
16 THERMOWELL TE-2 DISCHARGE GAS TEMPERATURE
18 MAIN OIL INJECTION TE-3 LUBE OIL TEMPERATURE
22 CAPACITY VALVE VENT TO SUCTION TE-4 SEPARATOR OIL TEMPERATURE
3. TERMINATIONS "A" THROUGH "C" REFER TO
** N
ot all ports are shown. See COMPRESSOR CONNECTION POINTS FOR VARIOUS OPTIONS.
PORT LOCATIONS for all ports.
RXF ROTARY SCREW COMPRESSOR UNITS 070.410-IOM (AUG 14)
MAINTENANCE Page 45
RXF MODELS 24 throughy 50 without OIL PUMP (See OIL COOLING ADDITIONS)
LEGEND*
C COMPRESSOR PE PRESSURE ELEMENT ZT POSITION TRANSMITTER
CV CHECK VALVE PI PRESSURE INDICATOR ZI POSITION INDICATOR
F FILTER OR FILTER DRIER PIC/TIC PRESS./TEMP. INDICATING CONTROLLER
HTR HEATER PM PUMP MOTOR * Continued following page
LG SIGHT OR LEVEL GLASS PSV PRESSURE SAFETY VALVE
LSL OIL LEVEL SWITCH LOW PV PRESSURE VESSEL
LSLL LOW OIL LEVEL SHUTDOWN STR STRAINER
M MOTOR TAH HIGH TEMPERATURE ALARM
NV NEEDLE VALVE TAHH HIGH TEMP. SHUTDOWN
P PUMP TAL LOW TEMPERATURE ALARM
PAH HIGH PRESSURE ALARM TALL LOW TEMPERATURE SHUTDOWN
PAHH HIGH PRESSURE SHUTDOWN TCV TEMPERATURE CONTROL VALVE
PAL LOW PRESSURE ALARM TE TEMPERATURE ELEMENT
PALL LOW PRESSURE SHUTDOWN YY SOLENOID VALVE/EVENT VALVE
070.410-IOM (AUG 14) RXF ROTARY SCREW COMPRESSOR UNITS
Page 46 MAINTENANCE
RXF MODELS 24 through 50 with OIL PUMP (See OIL COOLING ADDITIONS)
LEGEND (Cont.)
CONNECTIONS ** NOTES:
1 MAIN OIL SUPPLY 1. PRESSURE TRANSDUCERS INDICATE:
2 SLIDE VALVE PISTON PE-1 OIL PRESSURE
7 SUCTION PRESSURE PE-3 DISCHARGE PRESSURE
10 DISCHARGE PRESSURE PE-4 SUCTION PRESSURE
11 LIQ. INJ. BLEED LINE 2. TEMPRERATURE PROBES INDICATE:
12 COALESCER BLEED LINE TE-1 SUCTION GAS TEMPERATURE
16 THERMOWELL TE-2 DISCHARGE GAS TEMPERATURE
19 SUCTION PRESSURE TE-3 LUBE OIL TEMPERATURE
22 CAPACITY VALVE VENT TO SUCTION TE-4 SEPARATOR OIL TEMPERATURE
3. TERMINATIONS "A" THROUGH "C" REFER TO
** N
ot all ports are shown. See COMPRESSOR CONNECTION POINTS FOR VARIOUS OPTIONS.
PORT LOCATIONS for all ports.
RXF ROTARY SCREW COMPRESSOR UNITS 070.410-IOM (AUG 14)
MAINTENANCE Page 47
RXF MODELS 58, 68, 85, & 101 without OIL PUMP (See OIL COOLING ADDITIONS)
LEGEND *
C COMPRESSOR PE PRESSURE ELEMENT TE TEMPERATURE ELEMENT
CV CHECK VALVE PI PRESSURE INDICATOR TI TEMPERATURE INDICATOR
HTR HEATER PIC/TIC PRESS./TEMP. INDICATING CONTROLLER YY SOLENOID VALVE/EVENT VALVE
LG SIGHT OR LEVEL GLASS PM PUMP MOTOR
M MOTOR PSV PRESSURE SAFETY VALVE * See additional Legend items on opposite
OF OIL FILTER STR STRAINER
P PUMP TAH HIGH TEMPERATURE ALARM page.
PAH HIGH PRESSURE ALARM TAHH HIGH TEMP. SHUTDOWN
PAHH HIGH PRESSURE SHUTDOWN TAL LOW TEMPERATURE ALARM
PAL LOW PRESSURE ALARM TALL LOW TEMPERATURE SHUTDOWN
PALL LOW PRESSURE SHUTDOWN TCV TEMPERATURE CONTROL VALVE
070.410-IOM (AUG 14) RXF ROTARY SCREW COMPRESSOR UNITS
Page 48 MAINTENANCE
RXF Models 58, 68, 85, & 101 with OIL PUMP and DUAL OIL FILTERS (See OIL COOLING ADDITIONS)
LEGEND (Cont.)
CONNECTIONS NOTES:
1 MAIN OIL SUPPLY 16 OIL PRESSURE 1. PRESSURE TRANSDUCERS INDICATE:
2 SLIDE VALVE PISTON 18 CAPACITY VENT VALVE TO SUCTION PE-1 OIL PRESSURE
6 SUCTION PRESSURE PE-3 DISCHARGE PRESSURE
8 DISCHARGE PRESSURE ** N
ot all ports are shown. See COMPRESSOR PE-4 SUCTION PRESSURE
9 LIQ. INJ. BLEED LINE PORT LOCATIONS for all ports. 2. TEMPRERATURE PROBES INDICATE:
10 COALESCER BLEED LINE TE-1 SUCTION GAS TEMPERATURE
11 THERMOWELL (SUCT. TEMP.) TE-2 DISCHARGE GAS TEMPERATURE
12 MAIN OIL INJECTION TE-3 LUBE OIL TEMPERATURE
13 SUCTION PRESSURE TE-4 SEPARATOR OIL TEMPERATURE
3. TERMINATIONS "A" THROUGH "C" REFER TO CONNEC-
TION POINTS FOR VARIOUS OPTIONS.
RXF ROTARY SCREW COMPRESSOR UNITS 070.410-IOM (AUG 14)
MAINTENANCE Page 49
NOTICE
It is very important to read the installation instructions
thoroughly before beginning the project. Make sure you
have drawings and instructions with your equipment.
If not, call the manufacturer and request the proper
instructions and drawings. Every manufacturer of elec-
tronic equipment should have a knowledgeable staff,
willing to answer your questions or provide additional
information. Following correct wiring procedures will
ensure proper installation and consequently, proper
operation of your electronic equipment.
WIRE SIZING
Control power supply wires should be sized one size
larger than required for amperage draw to reduce instanta-
neous voltage dips caused by large loads such as heaters,
contactors, and solenoids. These sudden dips in voltage can
cause the electronic control panel, whether it is a micropro- Figure 38
070.410-IOM (AUG 14) RXF ROTARY SCREW COMPRESSOR UNITS
Page 52 PROPER INSTALLATION OF ELECTRICAL EQUIPMENT
GROUNDING NEC size ratings are for safety purposes and not necessarily
for adequate relaying of noise (EMI) to earth ground to avoid
Grounding is the most important factor for successful opera- possible interference with sensitive equipment. Therefore
tion and is typically the most overlooked. The NEC states that sizing this conductor 1 – 2 sizes larger than required by code
control equipment may be grounded by using the rigid conduit will provide better transfer of this noise.
as a conductor. This worked for the earlier relay systems, but
it is in no way acceptable for electronic control equipment. Frick requirements for the ground conductor are:
Conduit is made of steel and is a poor conductor relative • Stranded Copper
to an insulated stranded copper wire. Electronic equipment • Insulated
reacts to very small currents and must have a proper ground
in order to operate properly; therefore, stranded copper • One size larger than NEC requirements for conventional
starters
grounds are required for proper operation.
• Two sizes larger than NEC requirements for VFD starters
For proper operation, the control power ground circuit must
• Conduit must be grounded at each end
be a single continuous circuit of the proper sized insulated
stranded conductor, from the electronic control panel to the • This circuit must be complete from the motor to the
plant supply transformer (Figure 39). Driving a ground stake starter continuing in a seamless manner back to the plant
supply transformer (power source).
at the electronic control may also cause additional problems
since other equipment in the plant on the same circuits may For Direct Coupled, Package Mounted Starters, the ground
ground themselves to the ground stake causing large ground between the motor and the starter may need to be made
flow at the electronic control panel. Also, running multiple externally (Figure 40). The connection on the starter end
ground conductors into the electronic control panel from must be on the starter side of the vibration isolators. Be
various locations can create multiple potentials resulting in certain the connection is metal to metal. Paint may need
ground loop currents. A single ground wire (10 AWG or 8 to be removed to ensure a proper conductive circuit. The
AWG) from the electronic control panel, that is bonded to the use of counter-sunk star washers at the point of connec-
control power neutral at the secondary side of the control tion at each end will maximize metal to metal contact.
power transformer in the starter and then to the 3-phase
ground point, will yield the best results.
Figure 40
Figure 39
VFD APPLICATIONS
To install correctly, run a separate, properly sized (10 or 8 electrical ducts carrying 3-phase power to starters/vfd or
AWG typically) insulated ground along with and taken to motors.
ground with, the 3-phase ground at the 3-phase supply • Control power, communications, analog, or signal wiring
transformer (plant). This will require that the 3-phase ground should be run overhead (preferred) or in a separate trench.
and the control power ground be electrically isolated except If these lines are not in threaded metallic or threaded PVC-
for the connection at the plant supply transformer. coated metallic, abiding by the separation requirements
This style of grounding should steer the noise (EMI/RFI) noted above is necessary.
to earth ground, reducing the potential for it to affect the • Though not recommended, if cable trays are used, metallic
sensitive equipment, which could occur if the grounds were dividers must be used for separation of conductors of
left coupled. unlike voltages and types (AC or DC).
NOTICE NOTICE
If all other recommendations for grounding are followed, When in doubt contact the factory or use threaded
this process should not be necessary. metallic or threaded PVC coated metallic conduit.
Do not drill into an electronic control panel to locate conduit If the electronic control panel has a starter built into the
connections. You are probably not entering the panel where same panel, be sure to run the higher voltage wires where
the manufacturer would like you to since most manufactur- indicated by the manufacturer. EMI from the wires can
ers recommend or provide prepunched conduit connections. interfere with the electronics if run too close to the circuitry.
You may also be negating the NEMA rating of the enclosure.
Drilling can cause metal filings to land on the electronics and Never daisy-chain or parallel-connect power or ground
create a short circuit when powered is applied. If you must wires to electronic control panels. Each electronic control
drill the panel, take the following precautions: panel must have its own control power supply and ground
wires back to the power source (Plant Transformer). Multiple
• First, call the panel manufacturer before drilling into the electronic control panels on the same power wires create
panel to be sure you are entering the panel at the right current surges in the supply wires, which may cause control-
place. ler malfunctions. Daisy-chaining ground wires, taking them
• Take measures to avoid ESD (electrostatic discharge) to the to ground at each device, allows ground loop currents to
electronics as you prep the inside of the Electronic control flow between electronic control panels which also causes
panel. This can be done by employing an antistatic wrist malfunctions. See Figure 42.
band and mat connected to ground.
• Cover the electronics with plastic and secure it with
masking or electrical tape.
• Place masking tape or duct tape on the inside of the panel
where you are going to drill. The tape will catch most of
the filings.
• Clean all of the remaining filings from the panel before
removing the protective plastic.
When routing conduit to the top of an electronic control
panel, condensation must be taken into consideration. Water
can condense in the conduit and run into the panel causing
catastrophic failure. Route the conduit to the sides or bottom
of the panel and use a conduit drain. If the conduit must be
routed to the top of the panel, use a sealable conduit fitting
which is poured with a sealer after the wires have been
pulled, terminated, and the control functions have been
checked. A conduit entering the top of the enclosure must
have a NEMA-4 hub type fitting between the conduit and
the enclosure so that if water gets on top of the enclosure
it cannot run in between the conduit and the enclosure. This
is extremely important in outdoor applications.
NOTICE
It is simply NEVER a good practice to enter through the
top of an electronic control panel or starter panel that
does not already have knockouts provided. If knockouts
are not provided for this purpose it is obvious this is not
recommended and could VOID WARRANTY. Figure 42
Never add relays, starters, timers, transformers, etc. in-
side an electronic control panel without first contacting
the manufacturer. Contact arcing and EMI emitted from
these devices can interfere with the electronics. Relays and
timers are routinely added to electronic control panels by the
manufacturer, but the manufacturer knows the acceptable
device types and proper placement in the panel that will
keep interference to a minimum. If you need to add these
devices, contact the manufacturer for the proper device
types and placement.
NOTICE
It is very important to read the installation instructions thoroughly before
beginning the project. Make sure you have drawings and instructions for the
equipment being installed. If not, call the manufacturer to receive the proper
instructions and drawings. Every manufacturer of electronic equipment should
have a knowledgeable staff, willing to answer your questions or provide additional
information. Following correct wiring procedures will ensure proper installation
and consequently, proper operation of your electronic equipment.
070.410-IOM (AUG 14) RXF ROTARY SCREW COMPRESSOR UNITS
Page 56 FORMS
Forms
OPERATING LOG SHEET
RXF ROTARY SCREW COMPRESSOR UNITS 070.410-IOM (AUG 14)
FORMS Page 57
RXF COMPRESSOR PRESTART CHECKLIST
READ THIS FIRST: COMPRESSOR PRESTART CHECKLIST
The following items MUST be checked and completed by the installer prior to the arrival of the Frick Field
Service Supervisor. Details on the checklist can be found in this manual. Certain items on this checklist will
be reverified by the Frick Field Service Supervisor prior to the actual start-up.
Note: Customer connections are to be made per the electrical diagram for the motor starter listed under
the installation section and per the wiring diagram listed under the maintenance section of the IOM.
Please complete and sign this form & fax to 717-762-8624 as confirmation of completion.
Shaft Side Delay Opposite Shaft Side Delay Step Up Dead Band _________ PSI
High Warning________ F______ Sec High Warning_ ______ F______ Sec Step Up Delay ________ Sec
High Shutdown______ F______ Sec High Shutdown______ F______ Sec Step Down Dead Band _________ PSI
Step Down Delay ________ Sec
Motor Stator_ _________________ High Pressure Override _________ PSI
High Pressure Override Delay_ _____ Sec
Stator 1 Delay Stator 2 Delay
High Warning_______F_ ______ Sec High Warning_ _____F_ ______ Sec Analog Controls Analog Output A ____________
High Shutdown_____F_ ______ Sec High Shutdown_____F_ ______ Sec Analog Output B ____________
Proportional Band _________ PSI
Stator 3 Delay Integration Time ________ Sec
High Warning_______F_ ______ Sec High Limit _________ PSI
High Shutdown_____F_ ______ Sec Low Limit ________ Sec
Miscellaneous
Remote Capacity Deadband________ % Max Slide Valve Timer________ 1/10 Sec
High Compressor Oil Pressure _________________ Max Discharge Pressure ____________ PSI
Shutdown______PSI Delay _____ Sec Max Discharge and Oil Temp_ ________°F
RXF ROTARY SCREW COMPRESSOR UNITS 070.410-IOM (AUG 14)
FORMS Page 61
Compressor Inboard
Compressor Outboard (Coupling End Center) Motor Inboard (Coupled End)
(Noncoupled End) Vertical Direction Horizontal _______ . ______ IPS Overall
Axial Direction ____.____ IPS Overall Vertical _______ . ______ IPS Overall
____.____ IPS Overall Axial _______ . ______ IPS Overall
Compressor
Outboard Compressor Inboard
(Jackshaft) Motor Outboard (Noncoupled End)
Vertical Direction
Horizontal Direction Horizontal _______ . ______ IPS Overall
____.____ IPS (Male)
____.____ IPS Overall Vertical _______ . ______ IPS Overall
____.____ IPS (Female)
Axial _______ . ______ IPS Overall
RXF ROTARY SCREW COMPRESSOR UNITS 070.410-IOM (AUG 14)
INDEX Page 63
Index
Symbols idler, 27 E
3-phase ground, 53 idler pin, 27 Economizer
3-phase supply, 53 locknut, 27 back-pressure regulator valve, 10
O‑ring gasket, 29 balancing load, 10
B pump, 28 check valve, 10
back flushing, 9 pump head, 27 DX economizer, 10
bleed valve, 25 Pump head, 29 economizer port, 10
booster applications, 15 refrigeration oil, 28 flashing liquid, 10
brownouts, 13 rotor, 28, 29 flash vessel, 10
rotor hub, 28 isolation valve, 10
C rotor shaft, 29 microprocessor, 10
cable trays, 53 rotor teeth, 29 outlet pressure regulator, 10
chemical cleaning process, 9 seal, 28 strainer, 10
CH Coupling Data Table, 6 seal housing bore, 29 subcooling liquid, 10
clamping bolts, 7 seal seat, 28 elastomeric gear, 6
closed-loop fluids, 9 seal spring, 29 EMI, 53
closed-loop system, 9 snap ring, 27 external controller, 11
coalescer, 15 spring, 28, 29 External Oil Cooling, 21
coalescer filter element, 8 tapered installation sleeve, 29
codes, 53 thrust-bearing assembly, 28 F
cold-start valve, 14 Troubleshooting, 30 filter elements, 8
comm port, 55 Air leak, 30 flexible drive coupling, 6
Comm Port Protection, 55 alignment, 30 forklift, 6
Communications, 55 cavitation, 30 Foundation, 5, 14
Compressor Cavitation, 30 Anchor bolts, 5
discharge, 15 discharge port, 30 grout, 5
motor, 11 Discharge Port, 30 housekeeping pads, 5
motor starter, 12 Discharge pressure, 31 I-beams, 5
Port Locations end clearance, 30 pipe supports, 5
RXF 12 - 19, 38 Filter, 30 reinforced concrete, 5
RXF 24 - 50, 39 foot valve, 30 vibration expert, 5
RXF 58 - 101, 41 gate valve, 30
Compressor Prestart Checklist, 57 Gate valve, 30 H
compressor shaft, 6, 14 head, 30 hand expansion valve, 21
Compressor Unloading, 15 misalignment, 30 Handling and Moving, 5
compressor volume ratio, 15, 16 Motor, 30 crane, 5
Conduit, 53 motor speed, 30 forklift, 5
cone/button, 8 pressure gauge, 30 lifting ring, 6
constant speed starters, 53 Pressure Gauge, 30 rigging, 5
constant voltage (CV) transformer, 55 Pump, 30 hard water conditions, 9
control power regulator, 13 Relief valve, 30 heat exchanger, 9
cooling tower water, 9 sheave size, 30 Heat-sink paste, 9
cooling water, 9 Strainer, 30 high-stage operation, 14
CoolWare™, 21 Suction line, 30 hydraulic system, 15
coupling, 11 suction pipe, 30
Current Transformer, 12 suction port, 30 I
cutout parameters, 15 vacuum gauge, 30 initial start-up, 21
valve, 30 inlet service valve, 24
D vaporizing, 30
Daisy-chaining, 55 Vibrating, 30 J
Demand Pump differential pressure, 14 jack, 6
bearing retainer washer, 28 Direct Expansion Economizer System,
bearings, 28 11 L
bearing spacer, 27 direct motor drive, 6 liquid carryover, 7
carbon-graphite bushing, 28 discharge temperature, 21 liquid injection, 9, 17
carbon graphite bushings, 29 double-acting solenoid valve, 17 Alarms, 19
Carbon Graphite Bushings, 27 drive hubs, 6 analog input signal, 19
casing, 27, 29 dry nitrogen, 7 Danfossliquid Injection Valve, 18
end clearance, 29 DX economizer, 10 digital Input signal, 19
head, 27 Display, 19
dual dip tube method, 10
070.410-IOM (AUG 14) RXF ROTARY SCREW COMPRESSOR UNITS
Page 64 INDEX
CoolWare™, 21 W
discharge temperature, 21 water control valve, 21
hand expansion valve, 21 Water-Cooled Oil Cooling, 17
initial start‑up, 21 water- cooled oil coolers, 17
prestart checklist, 21 water treatment, 9
theoretical discharge temperature, welding, 9
21
water control valve, 21
starter package wiring diagram, 12
static forces, 9
strainer, 9, 27
stub connections, 9
suction check valve, 8
suction check valve bypass, 15, 27
suction housing, 6, 14
suction isolation valve, 8
suction strainer, 21
Surge suppression, 55
T
temperature sensor, 17
Thermosyphon oil cooling, 21
condensing pressure, 21
refrigerant-side safety valve, 8
vapor mixture, 21
Thermosyphon Oil Cooling, 17
Thermosyphon oil cooling, 8
drain valve, 8
liquid refrigerant, 8
thermostatically controlled mixing
valve, 8
Welding, 9
threaded metallic, 53
threaded PVC-coated metallic, 53
Troubleshooting, 36
Excessive Noise And Vibration, 36
High Oil Temperature, 36
Low Oil Temperature, 36
Oil Temperature Fluctuates, 36
Rapid Oil Loss, 36
Slide Valve, 37
U
uninterrupted power supply, 55
Unit Data Plate, 3
unshielded, 53
UN/UNF straight threads, 40
UPS, 11, 55
UPS Power, 55
UPS power system, 11
V
variable frequency drives, 53
vessel, 21
VFD, 22
VFD Applications, 52
VFD output, 52
vibration analysis, 21
Vibration Data Sheet, 62
voltage isolation, 55
070.410-IOM (AUG 14) RXF ROTARY SCREW COMPRESSOR UNITS
Page 66 NOTES
RXF ROTARY SCREW COMPRESSOR UNITS 070.410-IOM (AUG 14)
NOTES Page 67
070.410-IOM (AUG 14) RXF ROTARY SCREW COMPRESSOR UNITS
Page 68 INSTALLATION - OPERATION - MAINTENANCE