Design and Selection Manual RWK II-CM ROTARY SCREW COMPRESSOR UNITS

Design and Selection Manual RWK II-CM ROTARY SCREW COMPRESSOR UNITS

Suary RWKII-CM rotary screw compressor units are designed for R717 and completely assembled in factory to assure reliability and highly energy efficient. The units are composed with Compressor, Control panel, Electrical motor, Oil separator, Oil cooler, Lube system include piping and wiring works. Design Features Continuous capacity control precisely matches load requirements. Smart View II Controller for user friendly, worry-free operation. Flange-Mounted Motors eliminate the need for coupling alignment. Cold-Start Valve ensures a quick start at any condition. Super Filter II keeps your oil clean down to 5 microns. Antifriction Bearings provide the highest reliability available. Easy to Service All critical components for service and maintenance are easily accessible. External Oil Cooling Shell & tube thermosyphon oil cooler or refrigerant liquid injection expansion valve with electrical motor applied. Super Coalescer Significantly reduced condensing pressures delivering maximum energy efficiency. Dual Oil Filters (Option) Ensure continuous operation during service of the primary filter, Isolation valves included. Nomenclature 2

Configuration Compressor The rotary screw compressors has been designed utilizing the latest technology to offer the most reliable and energy efficient unit currently available. Setup is easy due to the flange connection on low noise motor that is standard for the RWK II-CM. Casing: The compressor with gray cast iron housing, precision machining, to ensure that the rotor in a variety of pressure ratio, to maintain precise positioning, reduce wear, prevent leakage, longer life. Rotor: Forged steel rotor, non-syetrical sections with minute rotor engagement gap, four-separate roller antifriction bearing design, radial load, reduce power consumption and increase reliability. Antifriction Bearings: Cylindrical roller bearings handle radial loads, and four-point angular contact ball bearings, aided by balance pistons, absorb thrust loads. No preloading is required. At design conditions, L10 life is in excess of 100,000 hours. Roller bearings also maintain superior rotor positioning to minimize internal leakage and provide excellent performance. System differential pressure is normally sufficient as the driving force to supply oil to the bearings, thereby eliminating the need for an oil pump. Antifriction bearings have lower frictional horsepower requirements for lower power consumption. Compressor housings are machined to provide static oil reservoirs for the bearings. Oil Injection: Injected oil serves to lubricate the bearings, balance piston, and seal, fill any leakage paths between and around the rotors to prevent gas bypassing, and maintain superior efficiencies. Oil injection minimizes noise and vibration. It keeps the compressor cool to prevent overheating by absorbing much of the heat from compression. Oil Passages: Internally machined oil passages reduce the risk of leaks inherent in external piping. Capacity Control: Effective capacity control is achieved by use of a slide valve, which provides infinite adjustment from 100% down to 25% of full load for model RWKII 20/25/30-CM and down to 10% of full load for model RWKII 40/55/65/100-CM. Oil separator The oil separator is a horizontal, three-stage design with integral sump with replaceable coalescent separator elements are provided for final gas/oil separation of particles down to less than 1 micron. The separator DWP is 2.1MPa. Oil Heaters: The iersion oil heater to keep the oil temperature that the refrigerant could be effectively separated from the oil. Power supply: 220V-1PH-50HZ, from the control panel. Exhaust Muffler: It could effectively reduce the noise, and optimize discharge flow for improving performance. Oil Level Switch: To protect the compressor avoiding damage due to lube losing. Level Sight Glass: The sight glasses setting at position of oil tank and coalescer end can easily observe the oil level, find the unit working status. Lubrication system The compressor is designed specifically for operation without an oil pump. All oil required for main oil injection and lubrication is provided by positive gas differential pressure. The Cold Start TM valve mounted at the discharge side of oil separator as a check valve could help the package build the differential pressure quickly. Oil Filter: All oil passes through the Super-Filter II TM, specifically designed filter for increased particle capture and cleaner oil and compressor operation. Oil Cooling: Cooling the compressor oil is achieved by shell & tube thermosyphon oil cooler. Motor A factory mounted flange motor is close-coupled to the compressor. The compressor/motor assembly requires no field coupling alignment. The motor enclosure is IP23 or IP54 and has class F insulation. Built-In Suction Strainer: All models have integrated suction strainer with side access on left or right. 3

Options Dual Oil Filter With this option, one of the oil filter as standby, could switch each other to replace filter element when unit is operating. Demand Oil Pump Booster and some low-pressure differential, high-stage applications will require the demand oil pump option. Automatic Oil Temperature Control The packages can also be equipped with an oil temperature control valve (mechanical automatic), and keep the oil injection temperature at an optimal range. Oil Cooling Cooling the compressor oil may also be achieved by liquid refrigerant injection with motorized expansion valve controlled by the Smart View II control panel for optimum discharge temperature control. Economizer The package mounted PHE economizer is optional with compact structure and efficiency improvement, it will improve the capacity and COP. Suction Stop Valve The shipped loose suction stop valve is the option for the customer. The RWKII-CM compressor units complete with the previously described components. The package is dried and pressurized with nitrogen charged. The initial charge of lubricating oil is provided by service and shipped loose. The package is covered with Caribbean blue painting, anticorrosive and durable. 4

Parameters for Compressor Units Standard Configuration Model RWKII20-CM RWKII25-CM RWKII30-CM RWKII40-CM RWKII55-CM RWKII65-CM RWKII100-CM Compressor XJF151M XJF151L XJF151N YFG1918 YFG2313 YFG2317 YFG2321 Capacity Control 25% ~ 100% 10% ~ 100% Units Refrigerant Lube Oil R717 FRICK #3 Oil in Separator L 125 160 160 190 380 380 465 Oil in Cooler L 75 105 105 110 140 140 205 Total Oil Charge 1 L 200 265 265 300 520 520 670 Voltage V 380 Motor Frequency RPM Hz r/min 50 / 60 / Rated Power kw According to application conditions Length 3590 3640 3640 3890 4530 4530 4530 Dimension 2 Width 1325 1383 1383 1443 1532 1532 1758 Height 1750 1860 1860 2156 2502 2550 2640 Unit Weight 3 Shipping Operating kg kg 2965 3185 3050 3350 3300 3600 4600 5000 6700 7200 6800 7500 8000 8900 Suction Φ140 6.5 Φ140 6.5 Φ140 6.5 Φ168 7 Φ168 7 Φ219 8 Φ219 8 Connection Size Discharge TSOC Liquid In TSOC Vapor Out Φ89 6 Φ114 6 Φ114 6 Φ114 6 Φ114 6 Φ114 6 Φ140 6.5 Φ48 5 Φ60 4 Φ60 4 Φ60 4 Φ73 5 Φ73 5 Φ73 5 Φ89 6 Φ114 6 Φ114 6 Φ140 6.5 Φ140 6.5 Φ140 6.5 Φ168 7 Options Voltage V 380 Oil Pump Frequency RPM Hz r/min SQ 6 50 / 60 1450 / 1750 Rated Power kw 1.1 1.1 1.1 2.2 Connection Size LIOC Liquid In 4 Econ. Liquid In 5 Φ34 4.5 Φ27 4 Φ34 4.5 Econ. Vapor Out 5 Φ34 4.5 Φ34 4.5 Notes: 1. Total oil charge = Oil in separator + Oil in cooler (Oil in cooler is zero when LIOC); TSOC: Thermosyphon oil cooler, LIOC: Liquid injection oil cooling. 2. Unit dimensions will be different due to different configuration. 3. The unit shipping weight and operating weight will be different due to different configuration, data above is approximated. 4. LIOC liquid piping dimension=liquid injection valves connection dimension. Customer side connection pipe dimensions should be designed according to pipe pressure drop. 5. Economizer inlet/outlet connection size = PHE inlet/outlet dimensions, customer side connection pipe size should be designed according to pipeline pressure drop. 6. SQ means the application needs to be evaluated by JCI factory. 5

Selection Guide Performance Data, RWKII-CM at rpm Model Compressor Displacement Single W/O Econ. R717 Booster Single W/ Econ. -10/35 C -40/-10 C -30/35 C m 3 /hr rpm Capacity kw Power kw Capacity kw Power kw Capacity kw Power kw RWKII-20CM 570 361 104 112 31 169 85 RWKII-25CM 706 458 129 142 38 215 106 RWKII-30CM 844 554 156 172 46 260 128 RWKII-40CM 1113 702 192 222 54 339 158 RWKII-55CM 1468 955 249 292 73 451 207 RWKII-65CM 1849 1194 313 365 90 567 261 RWKII-100CM 2284 1487 387 455 111 705 323 Performance Data, RWKII-CM at rpm Model Compressor Displacement Single W/O Econ. R717 Booster Single W/ Econ. -10/35 C -40/-10 C -30/35 C m 3 /hr rpm Capacity kw Power kw Capacity kw Power kw Capacity kw Power kw RWKII-20CM 686 443 125 137 37 208 103 RWKII-25CM 849 558 157 173 47 261 129 RWKII-30CM 1015 673 191 208 57 315 157 RWKII-40CM 1339 862 232 267 68 403 191 RWKII-55CM 1767 1159 303 355 88 536 249 RWKII-65CM 2225 1452 381 444 111 672 313 RWKII-100CM 2749 1806 472 552 138 835 387 1. The performance data considered 5 C superheat for suction line and economizer gas line. 2. The economizer with same model for rpm and rpm package, consideration of 5 C approach temperature across the economizer for compressor running at 2,950 rpm, and 5 C to 10 C approach temperature for compressor running at rpm. 6

Package Dimensions RWKII20/25/30-CM with TSOC RWKII40/55/65/100-CM with TSOC Model Oil Cooler Code L W H A B C D E F G I J K M N RWKII20-CM TJ 3590 1325 1750 181 25 1605 492 340 1140 190 360 140 1183 1006 718 RWKII25-CM TK 3640 1383 1860 181 152 1716 562 301 1293 202 363 142 1204 1035 743 RWKII30-CM TK 3640 1383 1860 181 152 1716 562 301 1293 202 363 142 1204 1035 743 RWKII40-CM TA/TD 3890 1443 2156 543 94 1897 425 371 1364 224 384 187 1017 1017 710 RWKII55-CM TG/TH 4530 1532 2502 492 152 2266 369 451 1615 240 400 198 1242 1280 849 RWKII65-CM TB/TE 4530 1532 2550 452 133 2262 369 451 1615 240 400 198 1242 1280 849 RWKII100-CM TC/TF 4530 1758 2640 309 168 2358 628 464 1693 227 387 203 1275 1305 1127 7

Base Dimensions / Service Space ANCHOR BOLT DETAILS G-G NOT TO SCALE 4-130X130 STEEL BASE EPOXY GROUT ANCHOR BOLT STEEL LEVELING SHIMS GROUT COMPRESSOR SIDE MOTOR SIDE Base Dimensions () Model A B C D E F H Anchor Bolt RWKII20- CM 1400 860 2000 1260 300 200 550 M27 X 500 RWKII25/30- CM 1400 1000 2000 1400 300 200 550 M27 X 500 RWKII40- CM 1857 812 2457 1312 300 350 550 M27 X 500 RWKII55/65- CM 2011 812 2611 1412 300 450 550 M27 X 500 RWKII100- CM 1950 1372 2550 1772 300 250 550 M27 X 500 D C Service Space B A Model A B C D Space Func2on Opera&on Maintenance Opera&on Maintenance RWKII20- CM 800 950 800 900 RWKII25/30- CM 800 950 800 900 RWKII40- CM 800 900 800 950 RWKII55/65- CM 800 900 800 950 RWKII100- CM 800 900 800 950 8

Smart View II Control Panel Software Full touch screen operator interface What you see is what you get. Easy to understand. The UI is user-level driven, each level is designed for different operator ability. Software diagnostics Numerous diagnostic features have been incorporated to assist in troubleshooting, they include: sensor short/open, set point input out of sensing range. Override controls All safety and controller functions can be prograed to unload the compressor when maximum safety and control parameters are exceeded. Hardware ARM based industrial Controller High-Speed processor provides speed and processing capability far surpassing competitive microprocessors. 7 WVGA graphic display with touch panel Full touch screen, high contact, clear display of unit information and status with a superior viewing angle. Serial counication ports Support RS-485 counication ports. On-screen calibrations Sensor, slide valve and slide stop are easy calibrated on screen. Real-time trending Selected data can be viewed in an X-Y trending chart. Foreign language Language include: English and simplified Chinese. Industry standard counication protocols Modbus ASCII, Modbus RTU Ethernet counication port Support 10/100M Ethernet counication port. Flexible analog inputs design Easily to support 0-20mA, 0-10V outputs. RTC Support high precision real time clock NAND Flash memory All set points are stored on an internal NAND Flash memory, which requires no battery backup, you will never lose any set point or have to reenter set points due to power-lossing. 9

Johnson Controls (JCI) is a global diversified technology and industrial leader serving customers in more than 150 countries. Our 150,000 employees create quality products, services and solutions to optimize energy and operational efficiencies of buildings; lead-acid automotive batteries and advanced batteries for hybrid and electric vehicles; and seating components and systems for automobiles. Our coitment to sustainability dates back to our roots in 1885, with the invention of the first electric room thermostat. Johnson Controls Building Efficiency delivers products, services and solutions that increase energy efficiency and lower operating costs in buildings for more than one million customers worldwide. Operating from 500 locations globally, the company is coitted to growing the BE business. In 2014, we acquired Air Distribution Technologies and in 2015, we obtained a majority stake in the joint venture with Hitachi Appliances. Australia (Melbourne) Tel : +61 (2) 9805 8300 Fax: +61 (2) 9889 3016 China (Shanghai) Tel : +86 (21) 6276 6509 Fax: +86 (21) 6277 3543 Hong Kong Tel : +852 2590 0012 Fax: +852 2516 5648 India (Mumbai) Tel : +91 (22) 6683 7000 Fax: +91 (22) 6683 7002 Indonesia (Jakarta) Tel : +62 (21) 5366 8500 Fax: +61 (21) 5366 8300 Japan (Tokyo) Tel : +81 (3) 5738 6100 Fax: +81 (3) 5738 6298 Korea (Seoul) Tel : +822 554 5935 Fax: +822 554 5739 Macau Tel : +853 2875 1820 Fax: +853 2875 1825 Malaysia (Kuala Lumpur) Tel : +60 (3) 7628 4300 Fax: +60 (3) 7874 1180 New Zealand (Auckland) Tel : +64 (9) 444 6434 Fax: +64 (9) 444 2092 Singapore Tel : +65 6748 0202 Fax: +65 6743 4420 Thailand (Bangkok) Tel : +66 (2) 717 1260-80 Fax: +66 (2) 717 1325-8 2016 Johnson Controls, Inc. www.johnsoncontrols.com PUBL-8021(0516) Printed on recycled paper