070.610-IOM (APR 2016)
Page 2
RWF II ROTARY SCREW COMPRESSOR UNITS
INSTALLATION - OPERATION - MAINTENANCE
Contents
GENERAL INFORMATION
Preface ..............................................................................3
Design Limitations .............................................................3
Job Inspection ................................................................... 3
Transit Damage Claims ......................................................3
Unit Identication ..............................................................3
Compressor Identication ................................................. 4
INSTALLATION
Foundation ........................................................................5
Rigging And Handling ........................................................ 5
Skid Removal ....................................................................5
Checking Motor/Compressor Rotation...............................6
Compressor/Motor Coupling Installation ........................... 6
Oil Pump Coupling .............................................................7
Holding Charge And Storage ............................................. 7
Oil Charge .........................................................................7
Oil Heater(s) ......................................................................8
Oil Filter(s) ........................................................................8
Suction Valve Mounting ....................................................8
Thermosyphon Oil Cooling ................................................8
Liquid Injection Oil Cooling (Optional) ............................... 9
Water-Cooled Oil Cooling (Optional) ...............................10
Economizer – High Stage (Optional) ...............................10
Economizer Load Balancing .............................................11
Economizer vi control .....................................................12
Electrical .........................................................................12
Motor Starter Package .................................................... 12
Current Transformer (CT) Ratios .....................................14
Minimum Burden Ratings ................................................ 14
Control Power Regulator ................................................. 14
OPERATION
Operation And Startup Instructions .................................15
SGC Compressor ............................................................. 15
Compressor Lubrication System ......................................15
No Pump Oil System .......................................................15
Demand Pump Oil System ...............................................16
Compressor Oil Separation System ................................. 16
Cold-Start System ...........................................................16
Compressor Hydraulic System .........................................17
Volume Ratio Control ......................................................17
Compressor Oil Cooling Systems .................................... 17
Single-Port Liquid Injection ............................................. 18
Dual-Port Liquid Injection ...............................................18
Quantum™HD EZ-COOL™ Liquid Injection Adjustment
Procedure ................................................................ 19
Operation Of Danfoss Liquid Injection Valve ...................20
Suction Check Valve Bypass ............................................ 23
Low Ambient Operation .................................................. 23
Suction Check Valve Power Assist Kit ............................. 23
Balance Piston Pressure Regulator .................................. 23
Initial Start-Up ................................................................24
Initial Start-Up Procedure ...............................................24
VFD Skip Frequencies .....................................................24
Normal Start-Up Procedure ............................................24
MAINTENANCE
General Information ........................................................25
Normal Maintenance Operations .....................................25
General maintenance ......................................................25
Compressor Shutdown And Start-Up .............................. 25
General Instructions For Replacing
Compressor Unit Components ................................. 25
Oil Filter (OF-1) Cartridge Style ......................................26
Strainer – Demand Oil Pump...........................................27
Strainer – Liquid Injection ............................................... 27
Coalescer Filter Element(s) ..............................................27
Changing Oil ....................................................................27
Demand Pump Disassembly ............................................28
Demand Pump Assembly .................................................29
Thrust Bearing Adjustment .............................................30
Installation Of Carbon Graphite Bushings ........................30
Troubleshooting The Demand Pump ...............................30
Preventive Maintenance .................................................. 31
Maintenance Schedule ....................................................32
Recommended Maintenance Program .............................32
Vibration Analysis ...........................................................32
Oil Quality And Analysis .................................................. 33
Oil Sampling Procedure ................................................... 33
Operating Log .................................................................33
Motor Bearings ...............................................................33
Grease Compatibility .......................................................34
Troubleshooting Guide ....................................................34
Abnormal Operation Analysis And Correction ................. 34
Servicing The Cold-Start Valve .......................................35
Pressure Transducers – Testing ....................................... 36
Pressure Transducers – Replacement .............................. 36
Capacity Linear Transmitter – Slide Valve ....................... 37
Volume Ratio Control Transmitter – Slide Stop ............... 37
Temperature Sensor ........................................................38
Oil Level Transmitter .......................................................38
Troubleshooting the RWF II Compressor .........................39
Troubleshooting The Demand Pump System ................... 39
Troubleshooting The Oil Separation System....................40
Troubleshooting The Hydraulic System ........................... 40
Motor And Bare Compressor Replacement .....................41
Shutdown Due To Improper Oil Pressure
(High Stage And Booster) ........................................41
SAE Straight Thread O-Ring Fittings
Assembly Procedure ................................................41
Compressor Port Locations .............................................42
P & I Diagram ..................................................................50
INSTALLATION OF ELECTRONIC EQUIPMENT
Wire Sizing ......................................................................53
Voltage Source ................................................................ 53
Grounding .......................................................................54
VFD Applications .............................................................54
Conduit ...........................................................................55
Wiring Practices ..............................................................55
Communications .............................................................57
UPS Power and Quantum™HD Panels ..............................57
FORMS
Operating Log Sheet .......................................................58
RWF II Compressor Prestart Checklist ............................. 59
Vibration Data Sheet .......................................................64
INDEX
Alphabetical Listing ......................................................... 65