Compressor Manual

Form 070.
410-IOM (NOV 2014)

INSTALLATION - OPERATION - MAINTENANCE
File:
Replaces:
Dist:
SERVICE MANUAL - Section 70

070.410-IOM (AUG 2014)
3, 3a, 3b, 3c
RXF
ROTARY SCREW COMPRESSOR UNITS

MODELS 12 101
THIS MANUAL CONTAINS RIGGING, ASSEMBLY, START-UP,

AND MAINTENANCE INSTRUCTIONS. READ THOROUGHLY
BEFORE BEGINNING INSTALLATION. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR DEATH,
DAMAGE TO THE UNIT, OR IMPROPER OPERATION.
Please check www.jci.com/frick for the latest version of this publication.
070.410-IOM (NOV 14)

Page 2
RXF ROTARY SCREW COMPRESSOR UNITS

INSTALLATION - OPERATION - MAINTENANCE
Table Of Contents
General Information
PREFACE.............................................................................3
DESIGN LIMITATIONS...........................................................3
JOB INSPECTION.................................................................3
TRANSIT DAMAGE CLAIMS.................................................3
UNIT IDENTIFICATION..........................................................3
COMPRESSOR IDENTIFICATION.......................................... 4
GEOMETRICAL SWEPT VOLUME TABLE.............................. 4
Installation
FOUNDATION......................................................................5
HANDLING and MOVING......................................................5
SKID REMOVAL...................................................................6
COMPRESSOR/MOTOR COUPLINGS....................................6
CH COUPLING......................................................................6
HOLDING CHARGE and STORAGE........................................7
COMPRESSOR OIL...............................................................7
OIL CHARGE........................................................................7
OIL HEATER.........................................................................7
OIL FILTER(S).......................................................................8
SUCTION ISOLATION VALVE MOUNTING.............................8
THERMOSYPHON OIL COOLING..........................................8
WATER-COOLED OIL COOLING...........................................9
LIQUID INJECTION OIL COOLING.........................................9
DUAL DIP TUBE METHOD...............................................10
ECONOMIZER - HIGH STAGE (OPTIONAL).........................10
ELECTRICAL....................................................................... 11
VOLTAGE PROTECTION................................................... 11
MOTOR STARTER PACKAGE.............................................. 12
MINIMUM BURDEN RATINGS............................................. 13
CONTROL POWER REGULATOR......................................... 13
Operation
OPERATION and STARTUP INSTRUCTIONS......................14
RXF COMPRESSOR............................................................14
COMPRESSOR LUBRICATION SYSTEM...............................14
NO PUMP OIL SYSTEM...................................................14
COLD-START SYSTEM....................................................14
DEMAND PUMP OIL SYSTEM.......................................... 15
COMPRESSOR OIL SEPARATION SYSTEM......................... 15
COMPRESSOR HYDRAULIC SYSTEM................................. 15
CAPACITY CONTROL...................................................... 15
VOLUMIZER II Vi CONTROL............................................16
SLIDE VALVE CALIBRATION............................................16
COMPRESSOR OIL COOLING SYSTEMS............................. 17
SINGLE-PORT LIQUID INJECTION................................... 17
DUAL-PORT LIQUID INJECTION...................................... 17
QUANTUMHD EZ-COOL LIQUID INJECTION ADJUSTMENT PROCEDURE..................................................... 17
OPERATION OF DANFOSS
LIQUID INJECTION VALVE...........................................18
THERMOSYPHON OIL COOLING..................................... 21
INITIAL START-UP PROCEDURE......................................... 21
NORMAL START-UP PROCEDURE......................................22
VFD SKIP FREQUENCIES....................................................22
Maintenance
NORMAL MAINTENANCE OPERATIONS.............................23
GENERAL MAINTENANCE..................................................23
COMPRESSOR SHUTDOWN and START-UP.......................23
COMPRESSOR/MOTOR SERVICING....................................24
GENERAL INSTRUCTIONS FOR REPLACING
COMPRESSOR UNIT COMPONENTS................................24
OIL FILTER, SPIN-ON (RXF 12 50)..................................24

OIL FILTER (OF-1) Cartridge Style (58 101)................24
COALESCER OIL RETURN STRAINER.................................. 25
LIQUID INJECTION STRAINER............................................ 25
OIL PUMP STRAINER (Optional)........................................ 25
SUCTION CHECK VALVE BYPASS.......................................26
COALESCER FILTER ELEMENT............................................26
CHANGING OIL..................................................................26
SUCTION STRAINER CLEANING PROCEDURE..................... 27
DEMAND PUMP DISASSEMBLY.......................................... 27
DEMAND PUMP ASSEMBLY...............................................28
THRUST BEARING ADJUSTMENT....................................29
Installation Of Carbon Graphite Bushings.........29
TROUBLESHOOTING THE DEMAND PUMP.........................30
RECOMMENDED MAINTENANCE PROGRAM...................... 31
MAINTENANCE SCHEDULE................................................ 31
VIBRATION ANALYSIS........................................................32
OIL QUALITY and ANALYSIS..............................................32
MOTOR BEARINGS............................................................32
OPERATING LOG................................................................32
TROUBLESHOOTING GUIDE...............................................32
ABNORMAL OPERATION
ANALYSIS and CORRECTION.............................................33
PRESSURE TRANSDUCERS TESTING...............................33
PRESSURE TRANSDUCERS REPLACEMENT........................33
SLIDE VALVE TRANSMITTER
REPLACEMENT - SLIDE STOP............................................35
TEMPERATURE SENSOR REPLACEMENT............................35
OIL LEVEL TRANSMITTER REPLACEMENT.........................35
TEMPERATURE and/or PRESSURE ADJUSTMENT..............35
BARE COMPRESSOR MOUNTING.......................................35
TROUBLESHOOTING THE COMPRESSOR...........................36
OIL SEPARATOR..............................................................36
LIQUID INJECTION OIL COOLING SYSTEM.......................36
HYDRAULIC SYSTEM.......................................................37
COMPRESSOR PORT LOCATIONS - RXF 12 - 19................38
SAE STRAIGHT THREAD O-RING FITTINGS - ASSEMBLY
PROCEDURE FOR RXF 58 - 101...................................... 40
P & I DIAGRAM, LIQUID INJECTION SINGLE PORT..........41
RXF COOLING OPTIONS (See P & I Diagrams)
PLATE OIL COOLER.........................................................42
WIRING HARNESS - External for Analog Devices..............49
WIRING HARNESS - AC to Heaters and Valves (External).50
Installation Of Electronic Equipment
WIRE SIZING...................................................................... 51
VOLTAGE SOURCE............................................................. 51
GROUNDING...................................................................... 52
VFD APPLICATIONS........................................................... 52
CONDUIT...........................................................................53
WIRING PRACTICES . ........................................................53
COMMUNICATIONS........................................................... 55
UPS POWER AND QUANTUM HD PANELS........................ 55
Forms
OPERATING LOG SHEET....................................................56
RXF COMPRESSOR PRESTART CHECKLIST........................ 57
VIBRATION DATA SHEET....................................................62
Index................................................................................65

GENERAL INFORMATION
070.410-IOM (NOV 14)

Page 3
General Information
JOB INSPECTION
PREFACE
Immediately upon arrival examine all crates, boxes, and

exposed compressor and component surfaces for damage.
Unpack all items and check against shipping lists for any
possible shortage. Examine all items for damage in transit.
This manual has been prepared to acquaint the owner and

service person with the INSTALLATION, OPERATION, and
MAINTENANCE procedures as recommended by Frick for
RXF Rotary Screw Compressor Units.
It is most important that these units be properly applied to an
adequately controlled refrigeration system. Your authorized
Frick representative should be consulted for expert guidance
in this determination.
Proper performance and continued satisfaction with these
units is dependent upon:
CORRECT INSTALLATION
PROPER OPERATION
REGULAR, SYSTEMATIC PLANNED MAINTENANCE
To ensure correct installation and application, the equipment
must be properly selected and connected to a properly designed 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
literature.
A refrigeration compressor is a VAPOR PUMP. To be certain
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 compressor design limits.
TRANSIT DAMAGE CLAIMS

All claims must be made by consignee. This is an ICC re
quirement. Request immediate inspection by the agent of
the carrier and be sure the proper claim forms are executed.
Contact Johnson Controls-Frick, Sales Administration
Department, in Waynesboro, PA to report damage or shortage claims.
UNIT IDENTIFICATION
Each compressor unit has two identification data plates. The
unit data plate containing unit model, serial number and Frick
sales order number is mounted on the control panel support
bracket. The compressor data plate containing compressor
model and serial number is mounted on the compressor body.
NOTICE
When inquiring about the compressor or unit, or ordering repair parts, provide the MODEL, SERIAL, and FRICK
SALES ORDER NUMBERS from these data plates.
It is recommended that the entering vapor temperature to

the compressor be superheated to 10F 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 Publication 070.410-SED.
UNIT DATA PLATE
SAFETY PRECAUTION DEFINITIONS
WARNING
Indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
Indicates a potentially hazardous situation or practice which, if not avoided, will result in death or
serious injury.
CAUTION
Indicates a potentially hazardous situation or practice which, if not avoided, will result in damage
to equipment and/or minor injury.
DANGER
NOTICE
Indicates an operating procedure, practice, etc., or portion thereof which is essential to highlight.
070.410-IOM (NOV 14)

Page 4

GENERAL INFORMATION
COMPRESSOR IDENTIFICATION
COMPRESSOR DATA PLATE

Rotary screw compressor serial numbers are defined by the
following information:
EXAMPLE: 10240A90000015Z
PLANT
1024
DECADE
0
MONTH
A
YEAR
9
GLOBAL
SEQ NO.
0000015
ADDITIONAL
REMARKS
Z
Month: A = JAN, B = FEB, C = MAR, D = APR, E = MAY, F =

JUN, G = JUL, H = AUG, K = SEP, L = OCT, M = NOV, N = DEC.
Additional Remarks: R = Remanufactured; Z = Deviation from
Standard Configuration.
GEOMETRICAL SWEPT VOLUME TABLE

Compressor
Model
XJS/XJF 95M
XJS/XJF 95L
XJS/XJF 95S
XJS/XJF 120M
XJS/XJF 120L
XJS/XJF 120S
XJF 151A
XJF 151M
XJF 151L
XJF 151N
Rotor
Diameter
mm
95
95
95
120
120
120
151
151
151
151
Rotor
L/D
1.4
1.4
1.4
1.4
1.4
1.4
1.6
1.6
1.6
1.6
Max
Speed
Rpm
5,772
4,661
3,600
5,772
4,661
3,600
6,297
5,332
4,306
3,600
Geometrical
Swept Volume
Drive Shaft End
Ft/ Rev
0.02513
0.03112
0.04086
0.05065
0.06272
0.08234
0.09623
0.11366
0.14075
0.16833
M/Rev
0.000711
0.000881
0.001156
0.001433
0.001775
0.002330
0.002723
0.003217
0.003983
0.004764
Cfm
3550 Rpm
89
110
145
180
223
292
342
403
500
598
M/H
2950 Rpm
126
156
205
254
314
412
482
569
705
843

INSTALLATION
070.410-IOM (NOV 14)

Page 5
disconnected from the compressor. See table for Allowable

Flange Loads.
Installation
FOUNDATION
NOTICE
Allow space for servicing the unit per factory drawings.
The first requirement of the compressor foundation is that
it must be able to support the weight of the compressor
package including coolers, oil, and refrigerant charge. Screw
compressors are capable of converting large quantities of
shaft power into gas compression in a relatively small space
and a mass is required to effectively dampen these relatively
high frequency vibrations.
Firmly anchoring the compressor package to a suitable
foundation by proper application of grout and elimination of
piping stress imposed on the compressor is the best insurance for a trouble free installation. Use only the certified
general arrangement drawings from Frick to determine the
mounting foot locations and to allow for recommended clearances around the unit for ease of operation and servicing.
Foundations must be in compliance with local building codes
and materials should be of industrial quality.
The floor shall be a minimum of 6 inches of reinforced concrete and housekeeping pads are recommended. Anchor
bolts are required to firmly tie the unit to the floor. Once the
unit is rigged into place (See HANDLING and MOVING), the
feet must then be shimmed in order to level the unit. The
shims should be placed to position the feet roughly one inch
above the housekeeping pad to allow room for grouting. An
expansion-type epoxy grout must be worked under all areas
of the base with no voids and be allowed to settle with a
slight outward slope so oil and water can run off of the base.
When installing on a steel base, the following guidelines
should be implemented to properly design the system base:
1. Use I-beams in the skid where the screw compressor will
be attached to the system base. They shall run parallel to
the package feet and support the feet for their full length.
2. The compressor unit feet shall be continuously welded to
the system base at all points of contact.
3. The compressor unit shall not be mounted on vibration
isolators in order to hold down package vibration levels.
4. The customers foundation for the system base shall fully
support the system base under all areas, but most certainly
under the I-beams that support the compressor package.
NOZ.
SIZE
NPS
1
1.25
1.5
2
3
4
5
6
8
10
12
14
ALLOWABLE FLANGE LOADS

MOMENTS (ft-lbf)
LOAD (lbf)
AXIAL VERT. LAT. AXIAL VERT. LAT.
MC
ML
P
VC
VL
MR
25
25
25
50
50
50
25
25
25
50
50
50
50
40
40
100
75
75
100
70
70
150
125
125
250
175
175
225
250
250
400
200
200
300
400
400
425
400
400
400
450
450
1,000
750
750
650
650
650
1,500 1,000 1,000 1,500
900
900
1,500 1,200 1,200 1,500 1,200 1,200
1,500 1,500 1,500 1,500 1,500 1,500
2,000 1,800 1,800 1,700 2,000 2,000
Proper foundations and proper installation methods are vital;

and even then, sound attenuation or noise curtains may be
required to reduce noise to desired levels.
For more detailed information on Screw Compressor Foundations, please request Frick publication 070.210-IB.
HANDLING and MOVING
WARNING
This screw compressor package may be top-heavy. Use
caution in rigging and handling.
RXF 1250 units can be moved with a forklift or with rigging
and a crane. The recommended method is to insert lengths
of 2" pipe through the base tubing (see Figure 1 below).
CAUTION
Spreader bars should be used on both the length and
width of the package to prevent bending oil lines and
damage to the package. CAUTION must also be used in
locating the lifting ring. Appropriate adjustment in the
lifting point should be made to compensate for motor
weight. Adjustment of the lifting point must also be
made for any additions to the standard package such
as an external oil cooler, etc., as the center of balance
will be affected.
When installing on the upper floors of buildings, extra precautions should be taken to prevent normal package vibration
from being transferred to the building structure. It may be
necessary to use rubber or spring isolators, or a combination
of both, to prevent the transmission of compressor vibration
directly to the structure. However, this may increase package
vibration levels because the compressor is not in contact with
any damping mass. The mounting and support of suction
and discharge lines is also very important. Rubber or spring
pipe supports may be required to avoid exciting the building structure at any pipe supports close to the compressor
package. It is best to employ a vibration expert in the design
of a proper mounting arrangement.
In any screw compressor installation, suction and discharge
lines shall be supported in pipe hangers (preferably within
2 feet of vertical pipe run) so that the lines wont move if
Figure 1 - RXF 12 50
070.410-IOM (NOV 14)

Page 6

INSTALLATION
The unit can be moved with a forklift by forking through

the base tubing. NEVER MOVE THE UNIT BY PUSHING
OR FORKING AGAINST THE SEPARATOR SHELL OR ITS
MOUNTING SUPPORTS.
RXF 58 101 units can be moved with rigging, using a crane
or forklift by hooking into three lifting points on the oil separator. See Figure 2.
unit mounting supports to the skid before lowering the unit

onto the mounting surface.
If the unit is skidded into place, remove the cross members
from the skid and remove the nuts anchoring the unit to the
skid. Using a 10-ton jack under the separator, raise the unit
at the compressor end until it clears the two mounting bolts.
Spread the skid to clear the unit mounting support, then lower
the unit to the surface. Repeat procedure on opposite end.
CAUTION
COMPRESSOR/MOTOR COUPLINGS
Spreader bars may be required on both the length and

width of the package to prevent bending oil lines and
damage to the package. CAUTION must also be used in
locating the lifting ring. Appropriate adjustment in the
lifting point should be made to compensate for motor
weight. Adjustment of the lifting point must also be
made for any additions to the standard package such
as an external oil cooler, etc., as the center of balance
will be affected.
RXF units are arranged for direct motor drive and include a
flexible drive coupling to connect the compressor to the motor.
CH COUPLING
The T. B. Woods Elastomeric Type CH
Coupling is used in most applications. This coupling consists of
two drive hubs and a geartype Hytrel, EDPM, or neoprene drive spacer. The split
hub is clamped to the shaft by
tightening the clamp screws.
Torque is transmitted from the
motor through the elastomeric
gear which floats freely between the
hubs. Because of the use of the motor/compressor adapter
housing on the RXF, no field alignment is necessary.
WARNING
It is mandatory that the coupling center be removed and
the direction of motor rotation be confirmed before running 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
The unit can be moved with a forklift by forking under
the wooden skid (if provided), or it can be skidded into
place with pinch bars by pushing against the skid. NEVER
MOVE THE UNIT BY PUSHING OR FORKING AGAINST THE
SEPARATOR SHELL OR ITS MOUNTING SUPPORTS.
1. Inspect the shaft of the motor and compressor to ensure

that no nicks, grease, or foreign matter is present.
2. Inspect the bores in the coupling hubs to make sure that
they are free of burrs, dirt, and grit.
3. Check that the keys fit the hubs and shafts properly.
4. Slide one hub onto each shaft as far as possible. It may
be necessary to use a screwdriver as a wedge in the slot to
open the bore before the hubs will slide on the shafts.
SKID REMOVAL
CAUTION
This screw compressor package may be top-heavy. Use
caution to prevent unit from turning over.
If the unit is rigged into place, the wooden skid can be removed by taking off the nuts and bolts that are fastening the
5. Hold the elastomeric gear between the hubs and slide both
hubs onto the gear to fully engage the mating teeth. Center
the gear and hub assembly so there is equal engagement on
both shafts. Adjust the space between hubs as specified in
the CH Coupling Data Table below. SEE NOTICE:
CH Coupling Data Table

CH
Series
Size
6
7
8
9
10
Between Shaft Spacing

Min.
Max.
In.
mm
In.
mm
2
50.8
2
69.9
2B\zn 58.7 3M\zn 87.3
4
101.6
2>\zn 65.1
3Z\zn 77.8
4B\, 117.5
5 133.4
3>\zn 90.5
Coupling Hub
Shaft Engagement
Face
Spacing
Min.
Max.
In.
mm
In.
mm
In.
mm
1
25.4 1ZB\zn 49.2
7/8
22.2
1
25.4 2C\zn 55.6 1Z\zn 27.0
2
63.5
28.6
1Z\zn 27.0
1Z\,
3
76.2 1M\zn 36.5
1M\zn 36.5
3
88.9 1ZZ\zn 42.9
1ZZ\zn 42.9
Clamp Bolt
Keyway
Torque (Dry)
Setscrew Torque
Size
Ft-Lb Nm
Ft-Lb
Nm
15
20.3 1/4-20 UNC
13
17.6
30
40.7 5/16-24 UNF
13
17.6
55
74.6 3/8-24 UNF
13
17.6
55
74.6 3/8-24 UNF
13
17.6
130 176.3 1/2-20 UNF
13
17.6
Size
UNC
5/16-18
5/16-18
5/16-18
5/16-18
5/16-18

INSTALLATION
NOTICE
The center section will be a little loose between the
hubs. This allows for growth during operation.
6. Torque the clamping bolts in both hubs to the torque value
given in the CH Data Table. DO NOT USE ANY LUBRICANT
ON THESE BOLTS.
HOLDING CHARGE and STORAGE

Each compressor unit is pressure and leak tested at the Johnson Controls-Frick factory and then thoroughly evacuated and
charged with dry nitrogen to ensure the integrity of the unit
during shipping and short term storage prior to installation.
CAUTION
Care must be taken when entering the unit to ensure
that the nitrogen charge is safely released.
WARNING
Holding charge shipping gauges on separator and
external oil cooler are rated for 30 PSIG and are for
checking the shipping charge only. They must be removed before pressure testing the system and before
charging the system with refrigerant. Failure to remove
these gauges may result in catastrophic failure of the
gauge and uncontrolled release of refrigerant resulting
in serious injury or death.
070.410-IOM (NOV 14)

Page 7
RXF
MODEL
BASIC
CHARGE
(gallon)
ADDITIONAL FOR
OIL COOLER
(gallon)
12 19
24 50
58, 68
85, 101
10
11
25
36
1
1
3
3
Add oil by attaching the end of a suitable pressure type

hose to the oil drain valve (see Figure 3), located under the
oil separator. Using a pressure-type pump and the recommended Frick oil, open the drain valve and pump oil into
the separator.
NOTICE
Evacuation of the oil separator will assist the flow of
oil into the unit. Also, fill slowly because oil will fill up
in the separator faster than it shows in the sight glass.
Oil distillers and similar equipment which trap oil must be
filled prior to unit operation to normal design outlet levels.
The same pump used to charge the unit may be used for
filling these auxiliary oil reservoirs.
The sight glass located near the bottom of the separator shell
at the discharge end should remain empty when the unit is
in operation. The presence of oil in this end of the vessel
during operation indicates liquid carryover or malfunction
of the oil return.
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 microprocessor.
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,
nuisance oil level cutouts, oil pressure loss, gas or oil
leakage and catastrophic compressor failure.
NOTICE
The oil charge shipped with the unit is the best suited
lubricant for the conditions specified at the time of
purchase. If there is any doubt due to the refrigerant,
operating pressures, or temperatures; refer to Frick
publication 160.802-SPC for guidance.
OIL CHARGE
The normal charging level is midway in the top sight
glass located midway along the oil separator shell. Normal
operating level is between the top sight glass and bottom
sight glass. Oil charge quantities are as follows:
Figure 3 - Oil Drain Valve
OIL HEATER
Standard units are equipped with 500 watt oil heaters, which
provide sufficient heat to maintain the oil temperature for
most indoor applications during shutdown cycles and to
permit safe startup. RXF 1250 use one heater while models 58101 use two. Should additional heating capacity be
required because of an unusual environmental condition,
contact Johnson Controls-Frick. The heater is energized only
when the unit is not in operation.
WARNING
Do not energize the heater when there is no oil in the unit,
otherwise the heater will burn out. The oil heater will be
energized whenever 120 volt control power is applied to
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 (NOV 14)

Page 8

INSTALLATION
OIL FILTER(S)
NOTICE
Use of filter elements other than Frick may cause warranty claim to be denied.
The oil filter(s) and coalescer filter element(s) shipped with
the unit are best suited to ensure proper filtration and operation of the system.
SUCTION ISOLATION VALVE MOUNTING

The suction isolation valve is shipped loose from the factory,
so it can be installed at various positions within the suction
line piping to the compressor. DO NOT install the valve at
the compressor suction with flow against the cone/button
(see Figure 4 TOP). When the isolation valve is installed in
this position, uneven flow is generated across the suction
check valve which is mounted at the inlet to the compressor.
This uneven flow causes the disks in the check valve to strike
against the stop pin, and eventually damage the internals
of the check valve. If the isolation valve is mounted at the
compressor suction, DO INSTALL with flow across the cone/
button (see Figure 4 BOTTOM). Please design your system
piping accordingly.
The liquid level in the refrigerant source must be 6 to 8 feet

above the center of the oil cooler.
2. A shell and tube or plate-type oil cooler with a minimum
300 psi design working pressure on both the oil and refrigerant sides.
Due to the many variations in refrigeration system design
and physical layout, several systems for assuring the above
two criteria are possible.
INSTALLATION: The plate-type thermosyphon oil cooler with
oil side piping and a thermostatically controlled mixing valve
are factory mounted and piped. See Figure 5.
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
the compressor unit and socket weld ends supplied on the
refrigerant side.
INCORRECT!
2. A refrigerant-side safety valve is required when refrigerant 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.
CORRECT!
Figure 4 - Suction Isolation Valve Mounting
THERMOSYPHON OIL COOLING

EQUIPMENT: The basic equipment required for a thermo
syphon system consists of:
1. A source of liquid refrigerant at condensing pressure and
temperature located in close proximity to the unit to minimize
piping pressure drop.
6. An angle valve should be installed in the piping before the

thermosyphon oil cooler to balance the thermosyphon system. Sight glasses should also be installed at the TSOC inlet
and outlet to aid in troubleshooting. The factory-mounted
plate-type thermosyphon oil cooler requires a refrigerantside drain valve to be provided and installed by the customer.
The component and piping arrangement shown in Figure 5 is
intended only to illustrate the operating principles of thermosyphon oil cooling. Other component layouts may be better
suited to a specific installation. Refer to publication 070.900-E
for additional information on Thermosyphon Oil Cooling.

INSTALLATION
WATER-COOLED OIL COOLING

The plate-type water-cooled oil cooler is mounted on the
unit complete with all oil piping. The customer must supply
adequate water to the oil cooler.
ANHP52
ANHP76
Fx
(lbf)
202
292
070.410-IOM (NOV 14)

Page 9
Fy
(lbf)
13
22
Fz
(lbf)
13
22
Mx
(lbfft)
57
103
My
(lbfft)
32
58
Mz
(lbfft)
32
58
Johnson Controls-Frick recommends a closed-loop system

for the waterside of the oil cooler. Careful attention to water
treatment is essential to ensure adequate life of the cooler
if cooling tower water is used. It is imperative that the condition of cooling water and closed-loop fluids be analyzed
regularly and as necessary and maintained at a pH of 7.4, but
not less than 6.0 for proper heat exchanger life. After initial
start-up of the compressor package, the strainer at the inlet
of the oil cooler should be cleaned several times in the first
24 hours of operation.
In some applications, the plate-type oil cooler may be subjected to severe water conditions, including high temperature
and/or hard water conditions. This causes accelerated scaling rates which will penalize the performance of the heat
exchanger. A chemical cleaning process will extend the life
of the heat exchanger. It is important to establish regular
cleaning schedules.
Figure 6 - Application of heat-sink paste before welding
Cleaning: A 3% solution of Phosphoric or Oxalic Acid is recommended. Other cleaning solutions can be obtained from
your local distributor, but they must be suitable for stainless
steel. The oil cooler may be cleaned in place by back flushing
with recommended solution for approximately 30 minutes.
After back flushing, rinse the heat exchanger with fresh water
to remove any remaining cleaning solution.
FIELD WELDING INSTRUCTIONS FOR TSOC AND WCOC:
The heat exchanger body is constructed in stainless steel,
while the stub connections are carbon steel. The highly
polished stub connections can give the appearance of stainless steel. The following are requirements for welding to the
socket weld fittings on Plate heat exchangers:
1. Use a heat-sink paste around the base of the connection.
These are available from a number of suppliers of welding
materials.
CAUTION
Heat-sink paste must be applied around the base of
the connection prior to welding. See Figure 6.
2. Two-pass welding is required; stagger start/stop region;
welding procedure in accordance with ASME Section 9.
3. If possible use gas protection, when welding, to avoid
oxidation of the surface. As it is rarely possible to clean the
root side of the weld by grinding or brushing to remove the
root oxide, it is optimal to use root gas.
4. Welding should occur in two segments, from 6:00 to 12:00.
The maximum intersegment temperature should be 350F.
Temperature should be verified with temperature indicating
crayon or equivalent.
5. The fitting may be cooled with forced air to reduce the
temperature of the fitting to 350F or lower, prior to welding
the second segment.
The maximum connection static forces and moments for Alfa
Nova heat exchangers are listed in the following table.Keep
these values in mind when designing your system. It is also
recommended to minimize connection loads when designing
piping systems. Also see Figure 7.
Figure 7 - Maximum static forces and moments
LIQUID INJECTION OIL COOLING

The liquid injection system provided on the unit is selfcon
tained but requires the connection of the liquid line. Liquid
line sizes and the additional receiver volume (quantity of
refrigerant required for 5 minutes of liquid injection oil cooling) are given in the following table:
REFRIG
R-717
HIGH
STAGE
R-507
HIGH
STAGE
R-717
BOOSTER
R-507
BOOSTER
RXF
MODEL
12-19
24-50
58-101
12-19
24-50
58-101
12-19
24-50
58-101
12-19
24-50
58-101
LIQ. LINE SIZE*

PIPE
SCH 80
3/8
1/2
3/4
3/8
3/8
1/2
3/8
3/8
3/8
LIQUID
5 MIN
TUBING SUPPLY VOLUME
POUNDS CU. FT
OD
1/2
1/2
5/8
12
33
65
24
60
99
3
8
14
0.3
0.9
1.8
0.4
1.0
1.6
0.1
0.2
0.4
No oil heat of rejection

at this condition
* 100 ft. liquid line. For longer runs, increase line size accordingly.
CONDITIONS: High Stage at 0F Evap, and 95F Cond, 10F

suction superheat; Booster at -40F Evap, 95F Cond, 20F
070.410-IOM (NOV 14)

Page 10

INSTALLATION
Intermediate, and 10F suction superheat; R-507 unloaded

slide valve.
High-stage compressor units may be supplied with single-port
(low Vi, side, or closed thread) or dual-port (low Vi and high Vi),
liquid injection oil cooling. Single port will be furnished for low
compression ratio operation and dual port for high compression ratio operation. Booster compressor units use single-port
(High Vi), liquid injection oil cooling due to the typically lower
compression ratios.
The control system on high-stage units with dual-port, liquid
injection oil cooling switches the liquid refrigerant supply to
the high port when the compressor is operating at higher
compression ratios (3.5 Vi and above) for best efficiency.
Where low compression ratios (low condensing pressures)
are anticipated, thermosyphon or water-cooled oil cooling
should be used.
CAUTION
It is imperative that an uninterrupted high-pressure
liquid refrigerant be provided to the injection system
at all times. Two items of EXTREME IMPORTANCE are
the design of the receiver/liquid injection supply and
the size of the liquid line. It is recommended that the
receiver be oversized sufficiently to retain a 5-minute
supply of refrigerant for oil cooling. The evaporator
supply must be secondary to this consideration. Failure
to follow these requirements causes wire draw which
can result in damage to the expansion valve, loss of oil
cooling, and intermittant oil cooling. One method of
accomplishing this is described below.
DUAL DIP TUBE METHOD

The dual dip tube method uses two dip tubes in the receiv
er. The liquid injection tube is below the evaporator tube to
assure continued oil cooling when the receiver level is low.
See Figure 8.
tion. Because of this, an output from the microprocessor is

generally used to turn off the supply of flashing liquid on a
shell and coil or DX economizer when the capacity falls below
approximately 60%-70% (85%-90% slide valve position). This
is done to improve compressor operating efficiency. Please
note however that shell and coil and DX economizers can be
used at low compressor capacities in cases where efficien
cy is not as important as ensuring that the liquid supply is
subcooled. In such cases, the economizer liquid solenoid can
be left open whenever the compressor is running.
Due to the tendency of the port pressure to fall with de
creasing compressor capacity, a back-pressure regulator
valve (BPR) is generally required on a Flash Economizer
System (Figure 11) in order to maintain some preset pressure
difference between the subcooled liquid in the flash vessel
and the evaporators. If the back-pressure regulator valve is
not used on a flash economizer, it is possible that no pressure
difference will exist to drive liquid from the flash vessel to the
evaporators, since the flash vessel will be at suction pressure.
In cases where wide swings in pressure are anticipated in
the flash economizer vessel, it may be necessary to add an
outlet pressure regulator to the flash vessel outlet to avoid
overpressurizing the economizer port, which could result
in motor overload. Example: A system feeding liquid to the
flash vessel in batches.
The recommended economizer systems are shown in Figures
9 12. Notice that in all systems there must be a strainer
and a check valve between the economizer vessel and the
economizer port on the compressor. The strainer prevents
dirt from passing into the compressor and the check valve
prevents oil from flowing from the compressor unit to the
economizer vessel during shutdown.
CAUTION
Other than the isolation valve needed for strainer cleaning, it
is essential that the strainer be the last device in the
economizer line before the compressor. The strainer
must be strong enough to handle the gas pulsations from
the compressor. Johnson Controls-Frick recommends an
R/S or Hansen strainer. Also, piston-type check valves
are recommended for installation in the economizer
line, as opposed to disc-type check valves. The latter
are more prone to gas-pulsation-induced failure. The
isolation and check valves and strainer should be located
as closely as possible to the compressor, preferably
within a few feet.
Figure 8
ECONOMIZER - HIGH STAGE (OPTIONAL)

The economizer option provides an increase in system capacity and efficiency by subcooling liquid from the condenser
through a heat exchanger or flash tank before it goes to the
evaporator. The subcooling is provided by flashing liquid in
the economizer cooler to an intermediate pressure level.The
intermediate pressure is provided by a port located part way
down the compression process on the screw compressor.
As the screw compressor unloads, the economizer port will
drop in pressure level, eventually being fully open to suc-
Figure 9 - Shell And Coil Economizer System

For refrigeration plants employing multiple compressors on
a common economizing vessel, regardless of economizer
type, each compressor must have a back-pressure regulat
ing valve in order to balance the economizer load, or gas
flow, between compressors. The problem of balancing load

INSTALLATION
becomes most important when one or more compressors
run at partial load, exposing the economizer port to suction
pressure. In the case of a flash vessel, there is no need for
the redundancy of a back-pressure regulating valve on the
vessel and each of the multiple compressors. Omit the BPR
valve on the flash economizer vessel and use one on each
compressor, as shown in Figure 12.
070.410-IOM (NOV 14)

Page 11
WARNING
Customer connections are made in the QuantumHD control
panel* mounted on the unit. The electrical enclosures
should be kept tightly closed whenever work is not being done inside. * Or starter panel (if provided).
VOLTAGE PROTECTION
NOTICE
Johnson Controls-Frick does not advise nor support the
use of UPS power systems in front of the QuantumHD
panel.
Figure 10 - Direct Expansion Economizer System
With a UPS power system providing shutdown protection

for the QuantumHD, 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
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 continuous 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 QuantumHD panel, and it will restart upon power
return. If the panel was in:
Auto Compressor motor will return to running as programmed.
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.
Figure 12 - Multiple Compressor Flash Economizer System
ELECTRICAL
NOTICE
Before beginning electrical installation, read the instructions in the section "Proper Installation of Electronic
Equipment" at the back of this manual.
RXF units are supplied with a QuantumHD control system.
Care must be taken that the controls are not exposed to
physical damage during handling, storage, and installation.
The single-box control door must be kept tightly closed to
prevent moisture and foreign matter from entry.
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
are the problem, then we recommend the use of a Sola
constant voltage (CV) transformer with a line suppression
feature. If a phase loss occurs, then you will typically get a
high motor amp shutdown. If problems continue to exist, then
an examination of the plants power factor may be in order.
Unless careful design failure analysis is considered in the
implementation of power systems, the alternative solutions
provide a safer and less expensive implementation. In either
case, only one Sola may be used per compressor. Each
compressor needs to be individually isolated from each other
through a dedicated control transformer. Sharing a common
control power source is an invitation for ground loops and
the subsequent unexplainable problems.
070.410-IOM (NOV 14)

Page 12

INSTALLATION
MOTOR STARTER PACKAGE
CAUTION
When starting at full voltage or across-the-line, a
shunting device must be installed or the Analog I/O
board in the QuantumHD panel may be severely damaged 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 supplied 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 horsepower and voltage for the starting method specified
(acrosstheline, autotransformer, wyedelta or solid-state).
NOTICE
If starting methods other than acrosstheline 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 combination starter with circuit breaker disconnect. However,
the motor overcurrent protection/disconnection device can
be applied by others, usually as a part of an electrical power
distribution board.
Figure 13 - Starter Wiring Diagram
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.
Figure 14 - Point-to-Point Wiring Diagram

5. The compressor motor Current Transformer (CT) can be
installed on any one phase of the compressor leads.
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.

INSTALLATION
CURRENT TRANSFORMER SIZE
Calculate (CT) size using the following formula where SF is
Service Factor and FLA is Full Load Amps of the Motor.
FLA x SF x 1.1 (round up to the next hundred)
Example: FLA = 379; Service Factor = 1.15
070.410-IOM (NOV 14)

Page 13
CONTROL POWER REGULATOR

Compressor units that will be used in areas that suffer brownouts and other significant power fluctuations can be supplied
with a control power regulator. See Figure 15, Recommended
Regulator Installation.
379 x 1.15 x 1.1 = 479

Use a 500:5 CT
DO NOT use undersized current transformers since the
panel will not be capable of reading potential current. If the
CT is higher than calculated, enter it's value for [CT Factor]
on the panel. The unit can operate with a CT one size larger
than calculated, however, replace with the proper size ASAP.
NOTICE
DO NOT operate unit with a CT more than one size
larger than recommended.
MINIMUM BURDEN RATINGS

The following table gives the minimum CT burden ratings.
This is a function of the distance between the motor starting
package and the compressor unit.
BURDEN
RATING
ANSI
VA
B-0.1
B-0.2
B-0.5
2.5
5
12.5
MAXIMUM DISTANCE FROM

FRICK PANEL
USING # USING # USING #
14 AWG
12 AWG
10 AWG
15 ft
25 ft
40 ft
35 ft
55 ft
88 ft
93 ft
148 ft
236 ft
NOTICE
Do not install a compressor HAND/OFF/AUTO switch in
the starter package as this would bypass the compressor safety devices.
Figure 15 - Recommended Regulator Installation
070.410-IOM (NOV 14)

Page 14

OPERATION
Operation
OPERATION and STARTUP INSTRUCTIONS
The Frick RXF Rotary Screw Compressor Unit is an integrated
system consisting of six major subsystems:
COMPRESSOR LUBRICATION SYSTEM

The RXF compressor is designed specifically for operation
without an oil pump for high stage service. Boosters and
some low-differential pressure applications will require the
demand pump option.
Control Panel See publications 090.040-O, M, & CS for

QUANTUMHD; Compressor; Compressor Lubrication System;
Compressor Oil Separation System; Compressor Hydraulic
System; Compressor Oil Cooling System.
The lubrication system on an RXF screw compressor unit

performs several functions:
The information in this section of the manual provides the

logical stepbystep instructions to properly start up and
operate the RXF Rotary Screw Compressor Unit.
2. Provides lubrication of the bearings and shaft seal.
NOTICE
For alarm descriptions and shutdown or cutout parameters, see publication 090.040-O.
WARNING
THE FOLLOWING SUBSECTIONS MUST BE READ AND
UNDERSTOOD BEFORE ATTEMPTING TO START OR
OPERATE THE UNIT.
RXF COMPRESSOR
The Frick RXF rotary screw compressor utilizes mating asymmetrical profile helical rotors to provide a continuous flow of
refrigerant vapor and is designed for high pressure applications. The compressor incorporates the following features:
1. High capacity roller bearings to carry radial loads at both
the inlet and outlet ends of the compressor.
2. Heavyduty angular contact ball bearings to carry axial
loads are mounted at the discharge end of compressor.
3. Moveable slide valve to provide infinite step capacity
control from 100% to 25% of full load capacity.
4. VOLUMIZER II adjusts to the most efficient of three volume
ratios (2.2, 3.5 or 5.0) depending upon system requirements.
5. Hydraulic cylinders to operate the slide valve.
6. Compressor housing suitable for 350 PSI pressure.
7. Most bearing and control oil is vented to closed threads in
the compressor instead of suction port to avoid performance
penalties from superheating suction gas.
8. The shaft seal is designed to maintain operating pressure
on the seal well below discharge pressure for increased
seal life.
9. Oil is injected into the rotors to maintain good volumetric
and adiabatic efficiency, even at very high compression ratios.
WARNING
It is mandatory that the coupling center be removed and
the direction of motor rotation be confirmed before running 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.

1. Lubricates the rotor contact area, allowing the male rotor

to drive the female rotor on a cushioning film of oil.
3. Serves to remove the heat of compression from the gas,
keeping discharge temperatures low and minimizing refriger
ant or oil breakdown.
4. Fills gas leakage paths between or around the rotors with
oil, thus greatly reducing gas leakage and maintaining good
compressor performance even at high compression ratios.
5. Provides oil pressure for development of balance load on
the balance pistons to reduce bearing loading and increase
bearing life.
NO PUMP OIL SYSTEM

The RXF screw compressor unit is designed to be selflubricating. Oil being supplied to the compressor from the oil
separator is at system head pressure. Within the compressor,
oil porting to all parts of the compressor is vented back to
a point in the compressors body that is at a pressure lower
than compressor discharge pressure. The compressors normal operation makes the compressor unit operate essentially
as its own oil pump. All oil entering the compressor is moved
by the compressor rotors out the compressor outlet and back
to the oil separator. For normal high-stage operation an oil
pump is not required.
COLD-START SYSTEM
The RXF package is equipped with a special "cold-start"
discharge check valve on the gas outlet connection of the
oil separator. This valve causes the oil separator to develop
oil pressure rapidly on initial start in order to lubricate the
compressor without requiring an oil pump, even in cold ambient temperatures with all pressures equalized. See Figure 16.
For high-stage packages, the cold-start valve is equipped
with a large spring that creates 30 psi of pressure in the oil
separator (above suction pressure), for lubrication of the
compressor.
CAUTION
DO NOT ATTEMPT TO SERVICE THE COLD-START
VALVE. PLEASE CONTACT THE FRICK SERVICE
DEPARTMENT.
Once the compressor is running it will begin to force gas
to the condenser at connection P2. See Figure 16. As the
condenser heats up it will begin to rise in pressure as the
compressor suction pulls down in pressure. As soon as differential pressure is developed between the condenser and
suction, these pressures act across a piston inside the coldstart valve to partially overcome the spring force. When the
differential pressure reaches and exceeds 30 psi, the piston
fully overcomes the spring force and powers the valve fully
open for very low operating pressure drop.

OPERATION
070.410-IOM (NOV 14)

Page 15
For booster applications, the valve is equipped with a lighter

spring which produces 1/2 bar (7 psig) oil pressure above suction pressure before it fully powers open. The heavier spring
is not required because booster compressors are equipped
with a demand oil pump.
The RXF package is also equipped with a suction check valve
bypass. The oil separator will slowly bleed down to system
suction pressure when the unit is stopped. This allows the
compressor drive motor to have an easier start, and the discharge check valve will seat more tightly. See the "SUCTION
CHECK VALVE BYPASS" section for operation.
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.
Figure 16 -"Cold-Start" Discharge Check Valve
DEMAND PUMP OIL SYSTEM

This system is designed to provide adequate compressor
lubrication for some high stage applications that operate
with low differential pressure across the compressor suction
and discharge and all booster applications.
On start-up, QuantumHD will calculate the pressure differential between the compressor discharge and the main oil
injection port. If this differential is less than 35 psi, then the
demand pump will turn on and will continue to run until 45 psi
differential is obtained. Then, the pump will shut down and
start only when the differential pressure falls below 35 psi.
NOTICE
For alarm descriptions and shutdown or cutout parameters, see publication 090.040-O.
COMPRESSOR OIL SEPARATION SYSTEM

The RXF is an oil-flooded screw compressor. Most of the oil
discharged by the compressor separates from the gas flow
in the oil charge reservoir. Some oil, however, is discharged
as a mist which does not separate readily from the gas flow
and is carried past the oil charge reservoir. The coalescer
filter element then coalesces the oil mist into droplets, the
droplets of oil fall to the bottom of the coalescer section of
the oil separator. The return of this oil to the compressor is
controlled by a hand expansion valve (HV1). See Figure 17.
NOTICE
Open HV1 only enough to keep the coalescer end of the
separator free of oil.
NOTICE
Normal operating level is between the top sight glass
and bottom sight glass located midway along the oil
separator shell.
COMPRESSOR HYDRAULIC SYSTEM

The hydraulic system of the RXF compressor utilizes oil
pressure from internally drilled passages in the compressor casing to selectively load and unload the compressor
by applying this pressure to the actuating hydraulic piston
of the movable slide valve (MSV). It also uses oil pressure
to actuate a hydraulic piston that moves the movable slide
stop, Volumizer II. This allows adjustment of the compressor
volume ratio, (Vi) while the compressor is running.
CAPACITY CONTROL
COMPRESSOR LOADING: The compressor loads when MSV
solenoid coil YY2 is energized and oil flows from the solenoid
valve through the needle valve (HV2) to compressor port 2,
where it enters the load side of the slide valve piston. This
equalizes the force on the slide valve piston and discharge
pressure on the slide valve area loads the compressor. See
Figure 18.
COMPRESSOR UNLOADING: The compressor unloads when
MSV solenoid YY1 is energized and oil is allowed to flow
from compressor port 2 thru the needle valve to the MSV
solenoid. This allows discharge pressure on the slide valve
piston to unload the slide valve as the piston moves outward.
ADJUSTMENT (Capacity Control): A needle valve (HV2)
is provided to adjust slide valve travel time, preventing
excessive slide valve hunting. HV2 should be adjusted to
restrict oil flow to the compressor port so that slide valve
travel time from full load to full unload, or vice versa, is a
minimum of 30 seconds.
070.410-IOM (NOV 14)

Page 16

OPERATION
NOTICE
A change in operating conditions, such as winter-tosummer operation, may require readjustment of slide
valve travel time.
wrong Vi, or to load or unload improperly. Operation at the

wrong compressor Vi can cause excessive power consumption, noise, vibration, or excessive oil foaming. See Figures
19 - 21 for correct installation of gaskets and location of
solenoids.
PRESSURE
YY3
COMMON
COMMON
PRESSURE
OUT
OUT
VENT
YY4
GASKET INSTALLATION
SIDE VIEW
Figure 19 - RXF 1219 Vi Control

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.
Vi
2.2
3.5
5.0
SOLENOID 3 / YY3
Energized
Deenergized
Deenergized
SOLENOID 4 / YY4
Energized
Energized
Deenergized
Proper operation of the Volumizer II control can be checked

as follows.
1. Set the compressor Vi to 2.2, then record the voltage that
is shown on the Slide Valve calibration screen for the current Slide Valve and 0% Slide Valve positions. The difference
between these voltages must be in the 1.35 - 1.65 Vdc range.
4. If the above voltage measurements are all in range, the
Volumizer II is working properly. If any of the voltages are
out of range, go to the troubleshooting section.
Proper installation of the Vi control valves and gaskets is

essential to the operation of this equipment. Incorrectly
installed parts may cause the compressor to operate at the
Slide valve calibration is performed on the QuantumHD

control panel in automatic mode. If further problems occur
or persist, contact Johnson Controls-Frick service.
SLIDE VALVE CALIBRATION

OPERATION
COMPRESSOR OIL COOLING SYSTEMS

The RXF unit can be equipped with one of several systems
for controlling the compressor oil temperature. They are
single or dual-port liquid injection, thermosyphon, or watercooled oil coolers. Each system is automatically controlled,
independentof compressor loading or unloading.
Oil cooling systems maintain oil temperature within the following ranges for R-717:
Liquid Injection Oil Cooling: 130 to 150F
External* Oil Cooling: 120 to 140F
* Thermosyphon Oil Cooling (TSOC) or Water-Cooled Oil
Cooling (WCOC).
SINGLE-PORT LIQUID INJECTION

The single-port liquid injection system is designed to permit
liquid refrigerant injection into one port on the compressor
at any given moment and operates as outlined.
The liquid injection solenoid valve is energized by the micro
processor when the temperature sensor, installed in the
compressor discharge, exceeds the setpoint. High-pressure
070.410-IOM (NOV 14)

Page 17
liquid refrigerant is then supplied to the motorized expansion

valve. Refer to P & I DIAGRAMS section for piping and
instrumentation drawings.
DUAL-PORT LIQUID INJECTION

The dual-port liquid injection system is designed to obtain
the most efficient compressor performance at high and low
compression ratios by permitting injection of liquid refrigerant
into one of two ports optimally located on the compressor.
This minimizes the performance penalty incurred with liquid
injection oil cooling.
The dual-port system contains all the components of the
single-port system with the addition of a 3-way motorized
valve and operates as outlined.
The liquid injection solenoid valve is energized by the micro
processor when the temperature sensor, installed in the
compressor discharge, exceeds the setpoint. Liquid refrigerant is then passed through the motorized expansion valve to
the 3-way motorized valve. Depending on the compressors
operating volume ratio (Vi), the microprocessor will select the
flow of the liquid refrigerant to the optimum compressor port.
QUANTUMHD EZ-COOL LIQUID INJECTION ADJUSTMENT PROCEDURE
Figure 22
DESCRIPTION: This screen allows the user to enter and

view the basic operating parameters related to EZ Cool
LIOC PI control.
EZ COOL PI CONTROL
The following are the EZ Cool LIOC Setup screen selections

available on this screen:
[Proportional Band] This setpoint determines the size of

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
[Setpoint] - Enter the value that you wish to control to.
070.410-IOM (NOV 14)

Page 18

OPERATION
corresponds to the difference between the Control Input

(Actual) and the Control Setpoint (Setpoint). Outside of this
region, the Proportional component is either 100% or 0%.
If the PIs Action is Forward, the Proportional Band extends
above the Control Setpoint. If the PIDs Action is Reverse,
the Proportional Band extends below the Control Setpoint.
Down arrow push button (Figures 23 and 24)

- Decreases parameter number by 1 at each activation.
Up arrow push button (Figures 23 and 24)
- Increases parameter number by 1 at each activation.
[Integration Time] - This setpoint controls the influence

that the Integral component exerts on the PI Output value.
The Integral component works to push the Control Input
toward the Control Setpoint by tracking the difference between the Control Input and the Control Setpoint over time.
High Limit - The highest value that the output can be.
Low Limit - The lowest value that the output can be.
I/O Board - One of the following will be shown:
None
Analog Board 1
Analog Board 2
I/O Channel - The output channel that will be used will be
shown.
Port Multiplier - The standard value is 1 (one).
Figure 23
DIGITAL CONTROL
An output is provided for an optional Liquid Injection solenoid valve. The function of this output is only available if the
compressor has Liquid Injection oil cooling and it has been
enabled. Liquid Injection controls the supply of liquid refrigerant to the compressor. Liquid Injection is off (the solenoid
is closed) if the compressor is off.
[On When Above] - When the Discharge Temperature is
above this setpoint, the Liquid Injection solenoid output will
energize, until the Discharge Temperature drops below this
setpoint.
[Off When Below] - When the Discharge Temperature is
below this setpoint, the Liquid Injection solenoid output will
de-energize, until the Discharge Temperature raises above
this setpoint.
STATUS
Discharge Temperature - The actual Discharge temperature is shown here.
Figure 24
Enter push button (Figures 23 and 24)
- Gives access to the Parameter list by keeping the push
button activated for 2 seconds. A Parameter list example
is shown below (parameter i08, Figure 25).
Control Output - The value of the Output signal as controlled by the PI. This is not a setpoint value.
Valve Position - The value shown here represents the position of the valve with relationship to the Control Output.
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
Control Valve) to the actual refrigeration application.
The setting of parameters is managed by means of the integrated ICAD (Figures 23 and 24) and consists of:
Figure 25
- Gives access to change a value once the Parameter list
has been accessed.
- Acknowledge and save change of value of a parameter.

OPERATION
- To exit from the Parameter list and return to the display
of Opening Degree (OD), keep the push button activated
for 2 seconds.
Display (Figure 26)
- Normally the Opening Degree (OD) 0 - 100% of the
ICM valve is displayed. No activation of push buttons
for 20 seconds means that the display will always show
0 (Figure 25).
070.410-IOM (NOV 14)

Page 19
1. Ensure that there is power to the valve (24 VDC) and all
wiring is complete prior to configuring the motorized valve.
The ICAD 600 requires 1.2 amps for operation and the ICAD
900 requires 2.0 amps.
2. Identify which actuator is being used (ICAD 600 or 900)
and which motorized valve is being used (ICM 20, 25, 32, 40,
50, or 65). Ensure that the correct actuator is being used
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.
Figure 26
Displays the parameter.
Displays the actual value of a parameter.
Displays the function status by means of text (Figure 23).
- Mod represents that ICAD is positioning the ICM valve
according to an analog input signal (Current).
- Low represents that ICAD is operating the ICM valve like
an ON/OFF solenoid valve with low speed according to
a digital input signal.
- Med represents that ICAD is operating the ICM valve like
an ON/OFF solenoid valve with medium speed according
to a digital Input signal.
- High represents that ICAD is operating the ICM valve like
an ON/OFF solenoid valve with high speed according to
a digital input signal (Figure 27).
4. Push the down arrow button and scroll until j10 is displayed
and push the enter button. Using the up arrow, scroll until
j11 is displayed and push the enter button. This step must be
completed within 20 seconds or the valve will reset.
5. Push the down arrow button again and scroll until j26 is
displayed and push the enter button. Identify the ICM valve
being used and push the up arrow until the correct number is
displayed for the ICM valve and then push the enter button.
The values are as follows:

1 for ICM20
2 for ICM25
3 for ICM32
4 for ICM40
5 for ICM50
6 for ICM65
6. The ICAD will store these parameters with the power

removed.
Alarms - ICAD can handle and display different alarms.
Description
No valve type
selected
Controller fault
All input error
ICM
Alarm Text
A1
A2
A3
Comments
At start-up A1 and CA will be
displayed
Internal fault inside electronics
When input amps are > 22 mA
Reset to factory setting:

Figure 27
Alarms
- If an alarm has been detected the ICAD display (Figure
23) will alternate between showing Actual alarm and
present Opening Degree.
- If more than one alarm is active at the same time, the
alarm with the highest priority will take preference. A1
has the highest priority, A3 the lowest.
- All alarms will automatically reset themselves when they
physically disappear.
- Old alarms (alarms that have been active, but have physically disappeared again) can be found in parameter i11.
Typically motorized valves are factory set. If adjustments are
needed, the following procedure can be used.
1. Remove the power supply.

2. Activate down arrow and up arrow push buttons at the
same time.
3. While continuing to push the down and up arrows, connect the power supply.
4. Release down arrow and up arrow push buttons.
5. When the display on ICAD (Figure 23) is alternating
between showing: CA and A1 the factory resetting is
complete.
070.410-IOM (NOV 14)

Page 20

OPERATION
Parameter list
Display
Name
Min.
Max.
Factory
Setting
100
Main Switch
j01
Mode
jo2
Analog Input signal
j03
Speed at ON/OFF
and Modulating Mode
j04
100
100
Automatic calibration
j05
Analog Output signal
j06
Fail-safe
j07
Digital Input function
j09
Password
j10
199
Old Alarms
j11
A1
A99
OD at powercut
j12
100
50
ICM configuration
j26
OD%
AI [mA]
AI [V]
AO [mA]
DI
DO Close
DO Open
DO Alarm
MAS mP SW ver.
SLA mP SW ver.
j50
0
0
0
0
0
0
0
0
0
0
100
20
10
20
1
1
1
1
100
100
Description
ICM OD
(Opening Degree)
j51
j52
j53
j54
j55
j56
j57
j58
j59
Unit Comments
%
mA
V
mA
-
ICM valve Opening Degree is displayed during normal operation.

Running display value (see j01, j05).
Internal main switch
1: Normal operation
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)
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
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
High also means ON/OFF operation.
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.
Always auto reset to 0.
CA will flash in the display during calibration.
Type of A0 signal for ICM valve position
0: No signal
1: 0 - 20mA
2: 4 - 20mA
Define condition at power cut when fail-safe is installed.
1: Close valve
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
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:
j26
Old alarms will be listed with the latest shown first. Alarm list can be
reset by means of activating down arrow and up arrow at the same
time for 2 seconds.
Only active if j07 = 4
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 valve Opening Degree
Analog Input signal
Analog Input signal
Analog Output signal
Digital Input signal
Digital Output Closed status. ON when OD < 3%
Digital Output Open status. ON when OD > 97%
Digital Output alarm status. ON when an alarm is detected
Software version for MASTER Microprocessor
Software version for SLAVE Microprocessor

OPERATION
THERMOSYPHON OIL COOLING

Thermosyphon oil cooling is an economical, effective method
for cooling oil on screw compressor units. Thermosyphon
cooling utilizes liquid refrigerant at condenser pressure and
temperature which is partially vaporized at the condenser
temperature in a shell and tube or plate-type vessel, cooling
the oil. The vapor, at condensing pressure, is vented to the
condenser inlet and reliquified. This method is the most cost
effective of all currently applied cooling systems since no
compressor capacity loss or compressor power penalties are
incurred. The vapor from the cooler need only be condensed,
not compressed. Refrigerant flow to the cooler is automa
tic, driven by the thermosyphon principle, and cooling flow
increases as the oil inlet temperature rises.
070.410-IOM (NOV 14)

Page 21
adequate oil flow. There is still an orifice installed in the

compressor to control maximum oil flow. At initial start-up
of the package the hand expansion valve must be fully open.
After initial start-up of the package the hand expansion valve
should be adjusted. There are two methods of determining
the correct adjustment of this valve.
The best method to determine target discharge temperature
is to run CoolWare with the operating conditions of the
compressor. The program will give you a theoretical discharge
temperature of the compressor. Once this temperature is
known, you may adjust the hand expansion valve. The ideal
discharge temperature is within 5F + or of the theoretical
discharge temperature. Adjust the valve to achieve the theoretical discharge temperature. If you do not have access to
CoolWare, 180F 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 180F
discharge temperature or the theoretical temperature from
CoolWare. Do not fully close the valve at any time while the
compressor is running.
Figure 28
SYSTEM OPERATION: Liquid refrigerant fills the cooler.
Warm or hot oil (above the liquid return temperature) flowing
through the cooler will cause some of the refrigerant to boil
and vaporize. The vapor rises in the return line.
The density of the refrigerant liquid/vapor mixture in the
return line is considerably less than the density of the liquid
in the supply line. This imbalance provides a differential
pressure which sustains a flow condition to the oil cooler.
This relationship involves:
1. Liquid height above the cooler.
2. Oil heat of rejection.
3. Cooler size and piping pressure drops.
Current thermosyphon systems are using single-pass oil
coolers and flow rates based on 3:1 overfeed.
The liquid/vapor returned from the cooler is separated in
the receiver. The vapor is vented to the condenser inlet and
need only be reliquified since it is still at condenser pressure
(see Figure 28).
INITIAL START-UP PROCEDURE

Having performed the checkpoints on the prestart check
list (see FORMS section), the compressor unit is ready for
startup. It is important that an adequate refrigerant load
be available to load test the unit at normal operating conditions. The following points should be kept in mind during
initial startup.
1. Models 58 - 101 ONLY! It is imperative that during the
initial start-up of the package that the hand expansion
valve on the main oil injection line is fully open to ensure
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
you will not be able adjust for the correct oil flow by using
the discharge temperature. 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
way. If it took 10 turns to open the valve completely, then
turn it in 5 turns. If it took 7 turns to open, then close the
valve 3 turns. Do not close the valve any further than
the number of turns required to fully open it.
WARNING
Failure to properly adjust this valve can lead to excessive noise and vibration of the compressor and package,
premature failure of the bearings, liquid loading of the
rotors, liquid starvation of the rotors and catastrophic
failure of the compressor.
2. All Models! For proper and safe operation, the compressor must be run at the proper speed and discharge pressure.
Exceeding design conditions creates a potential hazard.
3. Rotate and lubricate motor bearings according to manufacturers recommendations PRIOR to initial start-up as required.
4. After running the unit for approximately three hours, adjust liquid injection oil cooling if applicable. If unit has water
cooled oil cooling, adjust water control valve to cooler.
5. The compressor slide valve linear transmitter should be
calibrated.
6. Perform vibration analysis if equipment is available.
7. Pull and clean suction strainer after 24 hours operation. If
it is excessively dirty, repeat every 24 hours until system is
clean. Otherwise, follow the Maintenance Schedule. See the
RECOMMENDED MAINTENANCE PROGRAM section.
070.410-IOM (NOV 14)

Page 22

OPERATION
NORMAL START-UP PROCEDURE

1. Confirm system conditions permit starting the compressor.
2. Press the [RUN] key.
3. Allow the compressor to start up and stabilize. At startup, the slide stop (volumizer) and the slide valve (capacity
control) are in the AUTO mode.
4. Observe the compressor unit for mechanical tightness of
the external piping, bolts and valves. Ensure that the machine is clean from oil and refrigerant leaks. If any of these
occur, shut down the compressor and correct the problem
as necessary using good safety precautions.
5. RETIGHTEN OIL SEPARATOR COVER BOLTS at condenser design pressure (while system is running) to 90
ft-lb for models 12 - 50.
RETIGHTEN MANWAY BOLTS at condenser design pressure
(while system is running) to 150 ft-lb for models 58 - 101
(11" x 15" manway); 180 ft-lb on 12" x 16" manway for
oversized separator on 85/101 models.
RESTARTING COMPRESSOR UNIT AFTER CONTROL
POWER INTERRUPTION (PLANT POWER FAILURE)
1. Check ADJUSTABLE setpoints.
2. Follow normal start-up procedure.
VFD SKIP FREQUENCIES

Criteria for Identifying Elevated Energy on VFD
Packages and Establishing Skip Frequencies
With the RXF running loaded at full speed, the entire package
must be physically checked for elevated energy, including
any corresponding extremities such as valves, liquid injection piping, brackets, tubing, oil cooler and oil piping. The
VFD speed is to be decreased by 100 rpm increments and
the entire package physically checked for elevated energy at
each stage until the minimum speed range is reached. As the
high energy hot spots are identified, they are to be checked
with a vibration meter and any readings that meet or exceed
one inch per second must have that frequency range skipped
in the microprocessor for the VFD, eliminating the ability of
the package to operate within that frequency range. Each
identified range needs to have the skip set to as narrow a
frequency band as possible, only making it wider until full
range is accommodated. Please also reference 070.902-IB
for acceptable package vibration readings.
Skip frequencies should be reviewed and verified annually.

MAINTENANCE
Maintenance
This section provides instructions for normal maintenance,
a recommended maintenance program, troubleshooting and
correction guides, typical wiring diagrams and typical P and
I diagrams.
WARNING
This section must be read and understood before attempting to perform any maintenance or service to
the unit.
NORMAL MAINTENANCE OPERATIONS

When performing maintenance you must take several precautions to ensure your safety:
CAUTION
1. IF UNIT IS RUNNING, PUSH [STOP] KEY TO SHUT
DOWN THE UNIT.
2. DISCONNECT POWER FROM UNIT BEFORE PERFORMING ANY MAINTENANCE.
3. WEAR PROPER SAFETY EQUIPMENT WHEN COMPRESSOR UNIT IS OPENED TO ATMOSPHERE.
4. ENSURE ADEQUATE VENTILATION.
5. TAKE NECESSARY SAFETY PRECAUTIONS REQUIRED FOR THE REFRIGERANT BEING USED.
WARNING
070.410-IOM (NOV 14)

Page 23
Keep liquid injection valves properly adjusted and in good

condition to avoid flooding compressor with liquid. Liquid can
cause a reduction in compressor life and in extreme cases
can cause complete failure.
5. Protect the compressor during long periods of shut down.
If the compressor will be setting for long periods without running it is advisable to evacuate to low pressure and charge
with dry nitrogen or oil, particularly on systems known to
contain water vapor.
6. Preventive maintenance inspection is recommended any
time a compressor exhibits a noticeable change in vibration
level, noise or performance.
COMPRESSOR SHUTDOWN and START-UP

For seasonal or prolonged (six months) shutdown, use
the following procedure:
1. Push [STOP] key to shut down unit.
2. Open disconnect switch for compressor motor starter.
3. Turn off power.
4. Isolate the package by closing all package valves to the
system. Tag all closed valves.
CAUTION
Open any solenoid valves orother valves that may trap liquid
between the isolation valves and other package valves
to prevent injury or damage to components.
CLOSE ALL COMPRESSOR PACKAGE ISOLATION

VALVES PRIOR TO SERVICING THE UNIT. FAILURE TO
DO SO MAY RESULT IN SERIOUS INJURY.
5. With liquid injection, close the manual hand valve upstream of the solenoid and manually open the solenoid by
turning in the manual opening stem (clockwise viewed
from below valve).
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
areas critical to good compressor operation are:
1. Keep refrigerant and oil clean and dry, avoid moisture
contamination. After servicing any portion of the refrigera
tion system, evacuate to remove moisture before returning
to service. Water vapor condensing in the compressor while
running, or more likely while shut down, can cause rusting
of critical components and reduce life.
2. Keep suction strainer clean. Check periodically, particularly
on new systems where welding slag or pipe scale could
find its way to the compressor suction. Excessive dirt in the
suction strainer could cause it to collapse, dumping particles
into the compressor.
3. Keep oil filters clean. If filters show increasing pressure
drop, indicating dirt or water, stop the compressor and
change filters. Running a compressor for long periods with
high filter pressure drop can starve the compressor for oil
and lead to premature bearing failure.
4. Avoid slugging compressor with liquid refrigerant. While
screw compressors are probable the most tolerant to ingestion of some refrigerant liquid of any compressor type
available today, they are not liquid pumps. Make certain
to maintain adequate superheat and properly size suction
accumulators to avoid dumping liquid refrigerant into compressor suction.
7. Protect oil cooler from ambient temperatures below

freezing.
NOTICE
The unit should be inspected monthly during shutdown.
Check for leaks or abnormal pressure. Use the maintenance log to record readings to verify the pressure
stability of the unit. To prevent the seals and bearing
from drying out, run oil pump (if available) and manually
rotate the compressor shaft. Consult motor manufacturer for motor recommendations.
TO START UP AFTER SEASONAL OR PROLONGED SHUTDOWN, USE THE FOLLOWING PROCEDURE :
1. Perform routine maintenance. Change oil and replace
filters. Check strainers.
2. Any water necessary for the operation of the system that
may have been drained or shut off should be restored or
turned on.
3. Reset solenoid valves to automatic position, then open all
valves previously closed. Remove tags.
4. Compressor unit is ready for prestart checks. Refer to
PRESTART CHECKLIST.
070.410-IOM (NOV 14)

Page 24

MAINTENANCE
COMPRESSOR/MOTOR SERVICING
Before removing the motor from an RXF unit, it is critical that proper support be provided for the compressor to
prevent damage to the oil separator. Insert blocks or a jack
between the separator shell and compressor casting. Make
sure the weight is held safely by the separator shell. Loosen
the compressor discharge flange bolts to relax any flange
and pipe stress, then carefully remove the motor. Similarly,
before removing the compressor for servicing, the back end
of the motor must be supported to prevent damage. Again,
insert either blocks or a jack between the rear of the motor
and the separator shell.
GENERAL INSTRUCTIONS FOR REPLACING

COMPRESSOR UNIT COMPONENTS
When replacing or repairing components which are exposed
to refrigerant, proceed as follows:
1. Push [STOP] key to shut down the unit.
2. Open disconnect switches for compressor motor starter
and oil pump motor starter (if applicable).
CAUTION
Open any solenoid valves or other valves that may trap liquid
4. SLOWLY vent separator to low-side system pressure using
the suction check valve bypass.
NOTICE
Recover or transfer all refrigerant vapor, in accordance
with local ordinances, before opening to atmosphere.
The separator MUST be equalized to atmospheric
pressure.
CAUTION
Oil entrained refrigerant may vaporize, causing a separator pressure increase. Repeat transfer and recovery
procedure, if necessary.
5. Make replacement or repair.
6. Isolate the low pressure transducer, PE-4, to prevent damage during pressurization and leak test.
7. Pressurize unit and leak test.

CAUTION
SLOWLY vent separator to low-side system pressure using
the suction check valve bypass.
NOTICE
with local ordinances, before opening to atmosphere. The
separator MUST be equalized to atmospheric pressure.
CAUTION
3. Remove spin-on oil filter element and discard.
NOTICE
Use of oil filters other than Frick may cause warranty
claim to be denied.
4. Replace with new oil filter element. Make finger tight plus
an additional half turn.
6. Pressurize and leak test.
7. Evacuate unit to 29.88" Hg (1000 microns).
8. Open the suction and discharge service valves, and the
low pressure transducer. Close disconnect switches for the
compressor. Start the unit.
OIL FILTER (OF-1) Cartridge Style (58 101)

RXF compressor units are furnished with one main oil filter
(OF1). A second oil filter (OF2) is installed as optional
equipment to facilitate the changing of the filter element(s)
without unit shutdown.
NOTICE
Use of oil filters other than Frick may cause warranty
claim to be denied.
To change the filter cartridge proceed as follows:
9. Open all valves previously closed and reset solenoid valves

to automatic position. Remove tags.
1. If a single oil filter is installed, push [STOP] key to shut

down the unit. Open disconnect switches for the compressor
and (if applicable) oil pump motor starters.
10. Close disconnect switches for compressor motor starter

and oil pump motor starter, if applicable.
11. Unit is ready to put into operation.
OIL FILTER, SPIN-ON (RXF 12 50)

To change the filter proceed as follows:
1. Push [STOP] key to shut down the unit. Open disconnect
switches for the compressor.
If dual oil filters are installed, open the outlet, then inlet
service valves of the standby filter.
WARNING
Open inlet service valve slowly to prevent a sudden pressure drop which could cause an oil filter differential alarm.

MAINTENANCE
2. Close outlet then inlet service valves of filter being serviced.
3. Open bleed valve and purge pressure from the oil filter
cartridge.
4. Close discharge service valve. SLOWLY vent the separator
to lowside system pressure using the suction check valve
bypass. Close suction valve and suction check valve bypass.
NOTICE
CAUTION
Oil-entrained refrigerant may vaporize, causing a pressure increase. Repeat venting and recovery procedure,
if necessary.
5. Close oil filter isolation valves. Open drain valve on oil filter
head and drain the oil. Remove the canister cover. Discard
the cartridge and gasket.
6. Flush the filter body with clean Frick refrigeration oil; wipe
dry with a clean, lintfree cloth; and close drain valve.
7. Place a new cartridge in the filter canister. Replace the
gasket and spring and reinstall the canister cover. Torque
cover bolts in sequence to: a. Finger tight

b. 17 ft-lb

c. 35 ft-lb
8. Isolate the low pressure transducer, PE-4, to prevent
damage during pressurization and leak test.
9. Pressurize and leak test.
10. Evacuate the unit to 29.88" Hg (1000 microns).
11. Add 2 gallons of oil by attaching a suitable pressure-type
hose to the oil-charging valve located on top of the separator.
Use a pressure-type oil pump and recommended Frick oil.
12. Open the suction and discharge service valves, oil filter
isolation valves, and the low pressure transducer. Readjust
suction check valve bypass. Close disconnect switches for
the compressor and (if applicable) the oil pump motor starters. Start the unit.
COALESCER OIL RETURN STRAINER

1. Push [STOP] key to shut down the unit. Open disconnect
switches for the compressor.
CAUTION
Open any solenoid valves or other valves that may trap
liquid between the isolation valves and other package
valves to prevent injury or damage to components.
SLOWLY vent separator to low-side system pressure
using the suction check valve bypass.
NOTICE
070.410-IOM (NOV 14)

Page 25
CAUTION
Oil entrained refrigerant may vaporize, causing a separa
tor pressure increase. Repeat transfer and recovery
3. Close strainer isolation valves. Remove the large plug
from the bottom of the strainer and remove the element
from the strainer.
4. Wash the element in solvent and blow clean with air.
5. Replace the cleaned element and removed plug. Open
strainer isolation valves.
7. Pressurize and leak test. Evacuate unit to 29.88" Hg (1000
microns).
8. Open the suction and discharge service valves, and the
low pressure transducer. Close disconnect switches for the
compressor. Start the unit.
LIQUID INJECTION STRAINER

To clean the liquid injection strainer the unit must be shut
down. The procedure is as follows:
1. Push [STOP] key to shut down the unit, then open discon
nect switches for the compressor.
2. Close the liquid supply service valve located before the
liquid solenoid.
3. Immediately screw in the manual solenoid valve stem
to relieve liquid refrigerant pressure trapped between the
solenoid and the service valve.
4. Close the service valve located between the compressor
and the liquid injection thermal expansion valve.
5. Carefully loosen capscrews securing the strainer cover to
the strainer. Allow pressure to relieve slowly.
6. When all entrapped refrigerant has been relieved, carefully
remove loosened capscrews (as liquid refrigerant is sometimes
caught in the strainer), strainer cover, and strainer basket.
7. Wash the strainer basket and cover in solvent and blow
clean with air.
8. Reassemble the strainer.
9. Open the service valve between the compressor and the
liquid injection thermal expansion valve, purge entrained air,
and check for leakage.
10. Screw out the manual solenoid valve stem.
11. Carefully open the liquid supply service valve.
12. Leak test.
13. Close disconnect switches for compressor starter.
14. Start the unit.
OIL PUMP STRAINER (Optional)

To clean the full-lube oil pump strainer, the unit must be shut
down. The procedure is as follows:
1. Push [STOP] key to shut down the unit, then open the
disconnect switches for the compressor and (if applicable)
the oil pump motor starters.
070.410-IOM (NOV 14)

Page 26

MAINTENANCE
2. Close strainer service valves.

3. Open the drain valve located in the strainer cover and
drain the oil into a container.
4. Remove the capscrews securing the strainer cover, strainer
cover gasket, and element. Retain the gasket.
5. Wash the element in solvent and blow it clean with air.
6. Wipe the strainer body cavity clean with a lintfree clean cloth.
7. Replace the cleaned element and gasket, then reattach
the cover using the retained capscrews.
8. Reinstall the drain plug and open the strainer service valves.
9. Check for leakage.
10. Close the disconnect switches for the compressor and
(if applicable) the oil pump motor starters.
11. Start the unit.
SUCTION CHECK VALVE BYPASS

A 1/4" angle valve is installed between the compressor and
suction flange that can be used as a suction valve bypass.
This feature has several uses including reducing starting
torque, improving oil quality, and relieving the refrigerant
to low side for servicing.
6. Replace coalescer filter retainer and nut. Tighten the nut

to 21 ft-lb torque. DO NOT OVERTIGHTEN NUT. Excessive
torque can damage the element and result in oil carryover.
Install jam nut and tighten.
7. Install a new head gasket and replace the coalescer head.
8. Tighten the head bolts, first to finger tight, then 65 ft-lb,
then 130 ft-lb.
NOTICE
WHEN THE COMPRESSOR UNIT IS REPRESSURIZED,
RETIGHTEN SINCE HEAD BOLTS WILL LOOSEN.
9. Refer to CHANGING OIL, Steps 9 thru 14.
CHANGING OIL
WARNING
Shut down the unit when changing oil. At the same time all
oil filter cartridges must be changed and all oil strainer elements removed and cleaned. The procedure is as follows:
In most cases, the valve should be left open approximately 1 to

2 turns at all times. If the compressor back-spins or too much
oil foaming is experienced while venting, partially close valve
to slow speed of equalization. If system is on AUTO CYCLE and
short cycling occurs, the valve must be closed.
1. Push [STOP] key to shut down the unit.
To relieve refrigerant to low side, close separator discharge

service valve. Slowly open bypass valve (if closed) and wait
for pressure to equalize. Close bypass and suction service
valves before evacuating the unit.
4. Close discharge service valve. SLOWLY vent the separator

to low-side system pressure using the suction check valve
bypass. Close suction valve.
COALESCER FILTER ELEMENT
CAUTION
Use of coalescer filter elements other than Frick may
cause warranty claim to be denied.
When changing the coalescer filter element, it is recom
mended that the oil and oil filter be changed. Applicable
strainer elements should be removed and cleaned.
1. Refer to CHANGING OIL, Steps 1 thru 8.
2. Open disconnect switch for the compressor motor starter.

3. Close liquid injection service valves (if applicable).
NOTICE
CAUTION
Oil entrained refrigerant may vaporize, causing a separa
tor pressure increase. Repeat transfer and recovery
2. Remove coalescer head and gasket. Discard the gasket.
5. Open drain valve(s) located on the underside of the separator 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

Orings. Discard the filter element(s).
7. Remove and install new oil filter element.
5. Install new coalescer filter element(s).
NOTICE
Frick SuperCoalescer element (with drain feature), on
Models 24101, must be installed with the "DRAIN DOWN"
tag on the bottom at the 6 o'clock position.
CAUTION
Seat element in center of locating tabs on separator
bulkhead.
8. Remove, clean, and reinstall strainer elements in strainers.

10. Open suction service valve and pressurize the unit to
system suction pressure. Close the suction valve and leak test.
11. Add oil by attaching a suitable pressure-type hose to
the oil drain valve located on top of the separator. Using a
pressure-type oil pump and recommended Frick oil, open
the drain valve and fill the separator until oil level is midway
in the top sight glass.

MAINTENANCE
NOTICE
Evacuation of the oil separator will assist the flow of
oil into the unit. Also, fill slowly because oil will fill up
in the separator faster than it shows in the sight glass.
See Oil Charge section.
12. Open discharge and liquid injection service valves.
13. Close disconnect switch for compressor motor starter.
14. Start the unit.
SUCTION STRAINER CLEANING PROCEDURE

1. Open disconnect switch.
CAUTION
3. With liquid injection, close the manual hand valve upstream
of YY7 and manually open YY7 by turning in the manual
opening stem (clockwise viewed from below valve).
CAUTION
Failure to follow this procedure will damage valve YY7.
4. SLOWLY vent the separator to low-side system pressure
using the suction check valve bypass.
NOTICE
CAUTION
070.410-IOM (NOV 14)

Page 27
DEMAND PUMP DISASSEMBLY
DANGER
BEFORE OPENING ANY VIKING PUMP LIQUID CHAMBER (PUMPING CHAMBER, RESERVOIR, JACKET, ETC.)
ENSURE:
1. THAT ANY PRESSURE IN THE CHAMBER HAS BEEN
COMPLETELY VENTED THROUGH SUCTION OR DISCHARGE LINES OR OTHER APPROPRIATE OPENINGS
OR CONNECTIONS.
2. THAT THE DRIVING MEANS (MOTOR, TURBINE,
ENGINE, ETC.) HAS BEEN LOCKED OUT OR MADE
NONOPERATIONAL SO THAT IT CANNOT BE STARTED
WHILE WORK IS BEING DONE ON THE PUMP.
FAILURE TO FOLLOW ABOVE LISTED PRECAUTIONARY
MEASURES MAY RESULT IN SERIOUS INJURY OR DEATH.
1. Mark head and casing before disassembly to ensure proper
reassembly. The idler pin, which is offset in the pump head,
must be positioned up and equal distance between port connections to allow for proper flow of liquid through the pump.
2. Remove the head capscrews.
3. Tilt top of head back when removing to prevent idler from
falling off idler pin.
4. Remove idler and bushing assembly. If idler bushing needs
replacing, see INSTALLATION OF Carbon Graphite
Bushings.
5. Insert a brass bar or piece of hardwood in the port opening
and between the rotor teeth to keep the shaft from turning.
Turn the locknut counterclockwise and remove locknut. See
Figure 29 or 30.
6. Loosen the two setscrews in the face of bearing housing
and turn the thrust bearing assembly counterclockwise and
remove from casing. See Figure 29 or 30.
7. GG, HJ, HL: Remove the snap ring from the shaft. See
Figure 29. AS, AK, AL: Remove the bearing spacer from the
shaft. See Figure 30.
8. Remove the brass bar or piece of hardwood from the
port opening.
9. The rotor and shaft can now be removed by tapping on
the end of the shaft with a lead hammer or, if using a regular
5. Remove cover plate.

6. Remove strainer.
7. Clean strainer.
8. Reinstall the strainer in the proper direction (outboard
end is marked) and replace the gasket.
CAUTION
If the strainer is installed backwards, it will be damaged.
9. Pressurize and leak test. Evacuate unit to 29.88" Hg (1000
microns).
10. First, reset solenoid valves to automatic position then
open all valves previously closed. Remove tags. Close disconnect switches for compressor. Start unit.
Figure 29 - Thrust-Bearing assembly (GG, HJ, HL)
070.410-IOM (NOV 14)

Page 28

MAINTENANCE
Wash bearings in clean solvent. Blow out bearings with
compressed air. Do not allow bearings to spin; turn them
slowly by hand. Spinning bearings will damage the race
and balls. Make sure bearings are clean, then lubricate with
refrigeration oil and check for roughness. Roughness can
be determined by turning outer race by hand. Replace the
bearings if they have roughness.
Be sure shaft is free from nicks, burrs and foreign particles
that might damage mechanical seal. Scratches on shaft in
seal area will provide leakage paths under mechanical seal.
Use fine emery cloth to remove scratches or sharp edges.
DEMAND PUMP ASSEMBLY

Assembly Notes On Standard Mechanical Seal (Synthetic
Rubber Bellows Type)
NOTICE
Figure 30 - Thrust-Bearing assembly (AS, AK, AL)

hammer, use a piece of hardwood between the shaft and
hammer. The rotary member of the seal will come out with
the rotor and shaft.
10. AS, AK, AL: Remove the bearing retainer washer. The
washer may have stayed with rotor and shaft when removed
or is against ball bearing. See Figure 30.
11. Remove the mechanical seal rotary member and spring
from the rotor and shaft assembly.
12. GG, HJ, HL: Remove inner snap ring and single-row ball
bearing from the casing.
AS, AK, AL: Remove single-row ball bearing from casing.
13. Remove seal seat or stationary part of seal from casing.
14. Disassemble the thrust-bearing assembly.
GG, HJ, HL: Remove outer snap ring from the bearing housing
and remove the ball bearing. See Figure 29.
AS, AK, AL: Loosen the two set screws in flange outside
diameter. Rotate end cap and lip seal counterclockwise and
remove. Remove the ball bearing. See Figure 30.
The casing should be examined for wear, particularly in the
area between ports. All parts should be checked for wear
before the pump is put together.
When making major repairs, such as replacing a rotor and
shaft, it is advisable to also install a new mechanical seal,
head and idler pin, idler, and bushing. See INSTALLATION
OF Carbon Graphite Bushings.
Clean all parts thoroughly and examine for wear or damage.
Check lip seals, ball bearings, bushing, and idler pin and
replace if necessary. Check all other parts for nicks, burrs,
excessive wear and replace if necessary.
Figure 31
Read carefully before reassembling pump.

The seal used in this pump is simple to install and good
performance will result if care is taken during installation.
The principle of a mechanical seal is contact between the
rotary and stationary members. These parts are lapped to
a high finish and their sealing effectiveness depends on
complete contact.
Prior to installing the rotary portion of the mechanical seal,
prepare and organize the rotor shaft, head and idler assemblies, and appropriate gaskets for quick assembly
Once the rotary portion of the mechanical seal is installed on
the rotor shaft, it is necessary to assemble parts as quickly
as possible to ensure that the seal does not stick to the shaft
in the wrong axial position. The seal will stick to the shaft
after several minutes setting time.
Never touch sealing faces with anything except clean hands
or clean cloth. Minute particles can scratch the seal faces
and cause leakage.
1. Coat the idler pin with refrigeration oil and place idler
and bushing on idler pin in the head. If replacing a carbongraphite bushing, refer to "Installation 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
seat and inner diameter of seal housing bore with refrigeration oil.
3. Start seal seat in seal housing bore. If force is necessary,
protect seal face with a clean cardboard disc and gently tap it
in place with a piece of wood. Be sure seal seat is completely
seated in the bore.
Figure 32

MAINTENANCE
4. Place tapered installation sleeve on shaft. Refer to Figure
32. Sleeve is furnished with GG, AS, AK, and AL replacement
mechanical seals. Coat rotor shaft, tapered installation sleeve,
and inner diameter of mechanical seal rotary member with
a generous amount of refrigeration oil. Petrolatum may be
used but grease is not recommended.
5. Place seal spring on the shaft against the rotor hub. Refer
to Figure 32.
070.410-IOM (NOV 14)

Page 29
AS, AK, AL: Install the ball bearing into the bearing housing.
Install the lip seal in the bearing housing end cap. The lip
should face towards the end of the shaft. Put the bearing
spacer collar in the lip seal and install in the bearing housing
and tighten the set screws securely. See Figure 30.
16. Insert a brass bar or piece of hardwood through the
port opening between the rotor teeth to keep the shaft
from turning.
6. Slide rotary member, with lapped contact surface facing

away from the spring, over installation sleeve on shaft until
just contacting the spring. Do not compress the spring. Remove the installation sleeve.
17. Start the thrust bearing assembly into casing. Turn by hand
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
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.
9. Place Oring gasket on the head and install head and idler
assembly on pump. Pump head and casing were marked
before disassembly to ensure proper reassembly. If not, be
sure the idler pin, which is offset in pump head, is positioned
up and equal distance between port connections to allow for
proper flow of liquid through the pump.
10. Tighten the head capscrews evenly.
11. If the pump was equipped with a relief valve and was
removed during disassembly, install on the head with new
O-Rings or gaskets. The relief valve adjusting screw cap must
always point towards the suction port.
12. In 2005, the use of single seal bearings were phased out.
Pumps now use Sealed for Life bearings that have seals
on both sides. The new bearings can be installed either side
first and do not need to be packed with grease. For older
models with single seal bearings, pack the inner ball bearing
with multi-purpose grease, NLGI #2.
GG, HJ, HL: Drive the bearing into the bore. Tap the inner
race with a brass bar and lead hammer to position bearing.
Install the inner snap ring.
AS, AK, AL: Install the bearing retainer washer over the shaft
before installing the ball bearing. Install the ball bearing in
the casing with sealed side towards head end of the pump.
Drive the bearing into the bore. Tap the inner race with a
brass bar and lead hammer to position the bearing.
13. GG, HJ, HL: Install the shaft snap ring in groove in the
shaft. See Figure 29.
AS, AK, AL: Install the bearing spacer over the shaft and
against the single row ball bearing. See Figure 30.
14. Pack the lubrication chamber between the inner ball
bearing and double row ball bearing in the thrust bearing assembly approximately one-half full of multi-purpose grease,
NLGI #2. The thrust bearing assembly will take the remaining
space. See Figures 29 or 30.
15. Pack the double row ball bearing with multipurpose
grease, NLGI #2.
GG, HJ, HL: Install the ball bearing into the bearing housing
with shield side toward the coupling end of the shaft. See
Figure 29. Install the snap ring into bearing housing to retain
ball bearing. This snap ring has a tapered edge to fit tapered
groove in bearing housing. The tapered edge is located away
from the ball bearing.
18. Remove the brass bar or hardwood from port opening.
DANGER
BEFORE STARTING PUMP, ENSURE THAT ALL DRIVE
EQUIPMENT GUARDS ARE IN PLACE. FAILURE TO
PROPERLY MOUNT GUARDS MAY RESULT IN SERIOUS
INJURY OR DEATH.
THRUST BEARING ADJUSTMENT

Loosen two screws in face of thrust-bearing assembly. See
Figures 29 or 30.
If shaft cannot be rotated freely, turn thrust-bearing assembly
counterclockwise until shaft can be turned easily.
1. While turning rotor shaft, rotate thrust-bearing assembly
clockwise until noticeable drag occurs. This is zero end
clearance.
2. Mark position of bearing housing with respect to the casing.
3. Rotate thrust-bearing assembly counterclockwise the
distance listed below as measured on outside of bearing
housing.
4. Tighten two setscrews in face of bearing housing after
adjustment is made to secure thrust-bearing assembly
position.
For viscosities above 2500 SSU, add additional end clearance
(0.004" for GG, HJ and HL size pumps and 0.005" for AS,
AK and AL size pumps).
Pump
Size
Distance (in.) on O.D.

of Bearing Housing
End Clearance
(in.)
GG
HJ, HL
AS, AK, AL
7/16
9/16
1/2
.003
.003
.003
Installation Of Carbon Graphite Bushings

When installing carbon graphite bushings, extreme care must
be taken to prevent breaking. Carbon graphite is a brittle
material and easily cracked. If cracked, the bushing will
quickly disintegrate. Using a lubricant and adding a chamfer
on the bushing and the mating part will help in installation.
The additional precautions listed below must be followed
for proper installation:
1. A press must be used for installation.
2. Be certain bushing is started straight.
3. Do not stop pressing operation until bushing is in proper
position. Starting and stopping will result in a cracked bushing.
4. Check bushing for cracks after installation.
070.410-IOM (NOV 14)

Page 30

MAINTENANCE
TROUBLESHOOTING THE DEMAND PUMP
DANGER
BEFORE OPENING ANY VIKING PUMP LIQUID CHAMBER (PUMPING CHAMBER, RESERVOIR, JACKET, ETC.)
ENSURE:
1. THAT ANY PRESSURE IN THE CHAMBER HAS BEEN
COMPLETELY VENTED THROUGH SUCTION OR DISCHARGE LINES OR OTHER APPROPRIATE OPENINGS
OR CONNECTIONS.
2. THAT THE DRIVING MEANS (MOTOR, TURBINE,
ENGINE, ETC.) HAS BEEN LOCKED OUT OR MADE
NONOPERATIONAL SO THAT IT CANNOT BE STARTED
WHILE WORK IS BEING DONE ON THE PUMP.
FAILURE TO FOLLOW ABOVE LISTED PRECAUTIONARY
MEASURES MAY RESULT IN SERIOUS INJURY OR DEATH.
Mark valve and head before disassembly to ensure proper
reassembly.
If trouble does develop, one of the first steps toward finding the difficulty is to install a vacuum gauge in the suction
port and a pressure gauge in the discharge port. Readings
on these gauges often will give a clue as to where to start
looking for the trouble.
Vacuum GaugeSuction Port
1. High reading would indicate:
a. Suction line blocked - foot valve stuck, gate valve
closed, strainer plugged.
b. Liquid too viscous to flow through the piping.
c. Lift too high.
d. Line too small.
2. Low reading would indicate a. Air leak in suction line.
b. End of pipe not in liquid.
c. Pump is worn.
d. Pump is dry - should be primed.
3. Fluttering, jumping, or erratic reading:
a. Liquid vaporizing.
b. Liquid coming to pump in slugs - possibly an air leak
or insufficient liquid above the end of the suction pipe.
c. Vibrating from cavitation, misalignment, or damaged
parts.
Pressure Gauge - Discharge Port
1. High reading would indicate:
a. High viscosity and small and/or long discharge line.
b. Gate valve partially closed.
c. Filter plugged.
d. Vertical head did not consider a high specific gravity
liquid.
e. Line partially plugged from buildup on inside of pipe.
f. Liquid in pipe not up to temperature.
g. Liquid in pipe has undergone a chemical reaction and
has solidified.
h. Relief valve set too high.
2. Low reading would indicate:
a. Relief valve set too low
b. Relief valve poppet not seating properly.
c. Too much extra clearance.
d. Pump worn.
3. Fluttering, jumping, or erratic reading:
a. Cavitation.
b. Liquid coming to pump in slugs.
c. Air leak in suction line.
d. Vibrating from misalignment or mechanical problems.
Some of the following may also help pinpoint the problem:

1. Pump does not pump.
a. Lost its prime - air leak, low level in tank.
b. Rotating in wrong direction.
c. Motor does not come up to speed.
d. Suction and discharge valves not open.
e. Strainer clogged.
f. Relief valve set too low, relief valve poppet stuck open.
g. Pump worn out.
h. Any changes in the liquid system, or operation that
would help explain the trouble, e.g. new source of
supply, added more lines, inexperienced operators,
etc.
i. Tighten end clearance.
j. Head position incorrect.
2. Pump starts, then loses its prime.
a. Low level in tank.
b. Liquid vaporizing in the suction line.
c. Air leaks or air pockets in the suction line; leaking air
through packing or mechanical seal.
d. Worn out.
3. Pump is noisy
a. Pump is being starved (heavy liquid cannot get to pump
fast enough). Increase suction pipe size or reduce
length.
b. Pump is cavitating (liquid vaporizing in the suction
line). Increase suction pipe size or reduce length; if
pump is above the liquid, raise the liquid level closer
to the pump; if the liquid is above the pump, increase
the head of liquid.
c. Check alignment.
d. May have a bent shaft or rotor tooth. Straighten or
replace.
e. May be a foreign object trying to get into the pump
through the suction port.
4. Pump not up to capacity
a. Starving or cavitating - increase suction pipe size or
reduce length.
b. Strainer partially clogged - clean.
c. Air leak in suction piping or along pump shaft.
d. Running too slowly - is motor the correct speed and
is it wired up correctly
e. Relief valve set too low or stuck open.
f. Pump worn out.
g. Tighten end clearance.
h. Head position incorrect.
5. Pump takes too much power.
a. Running too fast - is correct motor speed, reducer
ratio, sheave size, etc. being used.
b. Liquid more viscous than unit sized to handle - heat
the liquid, increase the pipe size, slow the pump down,
or get a bigger motor.
c. Discharge pressure higher than calculated - check with
pressure gauge. Increase size or reduce length of pipe,
reduce speed (capacity), or get bigger motor.
d. Pump misaligned.
e. Extra clearance on pumping elements may not be
sufficient for operating conditions. Check parts for
evidence of drag or contact in pump and increase
clearance where necessary
6. Rapid Wear.
Examination of a pump that has gradually lost its ability to
deliver capacity or pressure would show a smooth wear pattern on all parts. Rapid wear shows up as heavy grooving,
galling, twisting, breaking, or similar severe signs of trouble.

MAINTENANCE
RECOMMENDED MAINTENANCE PROGRAM
070.410-IOM (NOV 14)

Page 31
the 6 month vibration analysis is not required. Frick PhD

provides continuous vibration monitoring that fulfills the
maintenance requirement. Should the Frick PhD have an
alarm or shut down event, a full spectrum vibration analysis
would then be required to specifically identify the cause of
the alarm or shut down.
In order to obtain maximum compressor unit performance

and ensure reliable operation, a regular maintenance program
should be followed (see Maintenance Schedule):
The compressor unit should be checked daily for leaks, abnormal vibration, noise, and proper operation. A log should
also be maintained. Initial oil analysis and vibration analysis
should be done at start-up and continued per the maintenance schedule.
In addition, a Frick compressor package without PhD monitoring already in operation can be retrofitted with the Frick
PhD on-board vibration monitoring system to fulfill the
vibration maintenance recommendation.However, it is also
necessary to establish a current baseline vibration with a
full spectrum analysis in order for the PhD retrofit to be
compliant.
Vibration analysis is recommended every 6 months to ensure

that the internal components of the screw compressor are
in compliance with expected vibration levels, based on the
initial, full spectrum baseline performed at start-up. If the
Frick PhD on-board vibration monitoring system is utilized,
MAINTENANCE SCHEDULE
Recommended schedule for Frick screw compressor package preventive maintenance operations.
Change Oil
Oil Analysis
Replace Oil Filters (g)
Clean Oil Strainers
Clean Liquid Strainers
Replace Coalescers
Check and Clean Suction Strainer
Check Coupling (a)
Suction & Disch Flange Bolts (b)
VFD Units Check Skip Freq. (c)
Check Electrical Connections (d)
Check Sensor Calibration (e)
Vibration Analysis (f)
Replace Shaft Seal
n
n
n
n
n
n
n
n
n
n
n
n
n
n
n
As Directed By Oil Analysis

Every 6 Months
As Directed By Oil Analysis
n
n
n
n
n
n
n
n
n
n
n
n
n
n
n
n
n
n
n
n
n
n
n
Annually Regardless of Operating Hours
n n n n n n n n n n n n n n
Check Annually
Every 6 Months, More Frequently If Levels Increase
When Leak Rate Exceeds 7 - 8 Drops Per Minute
n
n
95,000
90,000
85,000
80,000
75,000
70,000
65,000
60,000
55,000
50,000
45,000
40,000
35,000
30,000
25,000
20,000
15,000
10,000
8000
5000
1000
Maintenance
200
FREQUENCY OR Hours of Operation (Maximum)
n
n
n
n
n
n
n
n
n
n
n
n
n
n
a.
b.
c.
d.
e.
f.
Check bolts, shim packs, center inserts, keys, and all bolt torques.
Verify tightness of bolts on suction and discharge flanges. See table below for torque requirements.
Units with variable speed drives - check for excess vibration and skip frequencies any time unit operating conditions change.
Check and torque all terminals in the processor and starter panel per the specification posted in the enclosure.
Check calibration of Slide Valve, Slide Stop, pressures and temperatures. Calibration should be conducted with NIST certified devices.
Baseline vibration analysis is required during initial commissioning. Vibration measurement must be carried out continuously to obtain optimum
preventive control on bearings. If not continuously controlled, then every 6 months, more frequently if levels increase. See additional notes
in "Recommended Maintenance Program" section above.
g. The filter may need to be changed more frequently based on differential pressure or as directed by oil analysis.
RXF Model
12, 15, 19
24, 30, 39, 50
58, 68, 85, 101
Compressor
Model
XJF 95S,M,L
XJF 120S,M,L
XJF 151A,M,L,N
RXF Model
12, 15, 19
24, 30, 39, 50
58, 68, 85, 101
Compressor
Model
XJF 95S,M,L
XJF 120S,M,L
XJF 151A,M,L,N
Motor Flange to
Compressor Tunnel (1)
Bolt Size (in.)
Torque (ft-lb)
1/2 or 5/8
60
1/2 or 5/8
60
5/8 or 3/4
145
Compressor Suction Flange
Torque (2) (ft-lb)
180
250
300
Compressor Discharge Flange

to Separator Flange (2)
Bolt Size (mm)
Torque (ft-lb)
M20 X 2.5
80
M20 X 2.5
80
M22 X 2.5
80
Strainer Trap
Bolt Size (mm)
M20 X 2.5
M22 X 2.5
M24 X 3.0
1. Based on metal to metal contact.

2. Based on: Gaskets: Garlock Blue-Gard 3300; Bolts: class 8.8 or stronger hex head bolts, lightly oiled and clean
Torque (2) (ft-lb)

180
250
470
070.410-IOM (NOV 14)

Page 32

MAINTENANCE
Figure 33 - Lubrication Schedule And Instructions
VIBRATION ANALYSIS
Periodic vibration analysis can be useful in detecting bearing
wear and other mechanical failures. If vibration analysis is
used as a part of your preventive maintenance program, take
the following guidelines into consideration.
1. Always take vibration readings from exactly the same
places, at exactly the same percent of load.
2. Use vibration readings taken from the new unit at startup
as the base line reference.
3. Evaluate vibration readings carefully as the instrument
range and function used can vary. Findings can be easily
misinterpreted.
4. Vibration readings can be influenced by other equipment
operating in the vicinity or connected to the same piping as
the unit. For additional information, request Frick publication 070.902-IB.
1. Only use Frick oil filter elements or warranty claim

may be denied.
2. Participate in a regular, periodic oil analysis program to
maintain oil and system integrity. Oil Analysis Kit part number: 333Q0001853.
3. Oil samples for analysis should be taken after the oil filter. A
" purge valve is provided between the filter and compressor.
MOTOR BEARINGS
CAUTION
Lubricate motor bearings properly before start-up.
Maintain subsequent lubrication as recommended by
the motor manufacturer. See Figure 33.
OIL QUALITY and ANALYSIS

High quality refrigeration oil is necessary to ensure compres
sor longevity and reliability. Oil quality will rapidly deteriorate
in refrigeration systems containing moisture and air or other
contaminants. In order to ensure the quality of the refrigera
tion oil in the compressor unit.
WARNING
NOTICE
The Frick oil charge shipped with the unit is the best
suited lubricant for the conditions specified at the time
of purchase. If there is any doubt due to the refrigerant,
operating pressures, or temperatures, refer to Frick Oil
publication 160.802-SPC for guidance.
OPERATING LOG
The use of an operating log, as shown in this manual (see
Table of Contents...FORMS), permits thorough analysis of
the operation of a refrigeration system by those responsible
for its maintenance and servicing. Continual recording of
gauge pressures, temperatures, and other pertinent information enables the observer and serviceman to be constantly
familiar with the operation of the system and to recognize
immediately any deviations from normal operating conditions. It is recommended that readings be taken at least
every four hours.
TROUBLESHOOTING GUIDE
Successful problem solving requires an organized approach to
define the problem, identify the cause, and make the proper
correction. Sometimes it is possible that two relatively obvious problems combine to provide a set of symptoms that
can mislead the troubleshooter. Be aware of this possibility
and avoid solving the wrong problem.

MAINTENANCE
ABNORMAL OPERATION
ANALYSIS and CORRECTION
Four logical steps are required to analyze an operational
problem effectively and make the necessary corrections:
1. Define the problem and its limits.
PRESSURE TRANSDUCERS TESTING

Test Procedure:
1. Shut compressor down and allow pressures to equalize.
2. Isolate suction transducer (PE-4) from unit and depressurize.
2. Identify all possible causes.
NOTICE
3. Test each cause until the source of the problem is found.

4. Make the necessary corrections.
The first step in effective problem solving is to define the
limits of the problem. If, for example, the compressor periodically experiences high oil temperatures, do not rely on
this observation alone to help identify the problem. On the
basis of this information, the apparent corrective measure
would appear to be a readjustment of the liquid injection
system. Lowering the equalizing pressure on the thermal
expansion valve would increase the refrigerant feed and the
oil temperature should drop.
If the high oil temperature was the result of high suction
superheat, however, and not just a matter of improper liquid
injection adjustment, increasing the liquid feed could lead to
other problems. Under low load conditions the liquid injection
system may have a tendency to overfeed. The high suction
superheat condition, moreover, may only be temporary.
When system conditions return to normal, the unit's liquid
injection will overfeed and oil temperature will drop. In solving the wrong problem a new problem was created.
The following list of abnormal system conditions can cause
abnormal operation of the RXF compressor unit:
1. Insufficient or excessive refrigeration load.
2. Excessively high suction pressure.
3. Excessively high suction superheat.
4. Excessively high discharge pressure.
5. Inadequate refrigerant charge or low receiver level.
6. Excessively high or low temperature coolant to the oil
cooler.
7. Liquid return from system (carryover).
8. Refrigerant underfeed or overfeed to evaporators.
9. Blocked tubes or plates in water-cooled oil cooler from
high mineral content of water.
10. Insufficient evaporator or condenser sizing.
11. Incorrect refrigerant line sizing.
12. Improper system piping.
13. Problems in electrical service to compressor unit.
14. Air and moisture present in the system.
Make a list of all deviations from normal plant operation and
normal compressor unit operation. Delete any items which
do not relate to the symptom and separately list those items
that might relate to the symptom. Use the list as a guide to
further investigate the problem.
The second step in problem solving is to decide which items
on the list are possible causes and which items are additional
symptoms. High discharge temperature and high oil temperature readings may both be symptoms of a problem and not
casually related. High suction superheat or a low receiver
level, however, could cause both symptoms.
The third step is to identify the most likely cause and take
action to correct the problem. If the symptoms are not
relieved, move to the next item on the list and repeat the
procedure until you have identified the cause of the problem.
Once the cause has been identified and confirmed, make the
necessary corrections.
070.410-IOM (NOV 14)

Page 33

3. Measure the DC voltage of (PE-4) on connector (P6A) (terminals 2 and 3) on the analog board with a digital voltmeter.
4. The voltage reading should be between 1.48 VDC and
1.72 VDC at standard atmospheric pressure (14.7 PSIA or
0 PSIG). When checking transducers at higher elevations,
an allowance in the readings must be made by subtracting
approximately 0.02 VDC per 1000 feet of elevation above
sea level. Barometric pressure can generally be ignored but
in extreme cases may be compensated for by adding/subtracting 0.002 VDC for each 0.1 inch of barometric pressure
(adjusted to sea level) above/below 0 PSIG. Therefore, if
(PE-4) is measured at 5000 feet elevation under relatively
normal weather conditions, the output voltage should differ
by 0.10 VDC to read between 1.38 VDC and 1.62 VDC.
5. Subtract 1 from the voltage.
6. Multiply by 25.
7. This result is the absolute suction pressure (PSIA). Subtract
14.7 to obtain PSIG which the Operating display will indicate.
8. Isolate the oil pressure transducers (PE1 & PE-2) from
the package and depressurize.
NOTICE
9. Measure the voltage of (PE1 & PE-2) on connector (P5A)
(terminals 5 and 6) on the analog board.
10. The voltage reading should be between 1.1 VDC and 1.29
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
span of 200 PSI. Therefore, atmospheric pressure changes
have a lesser effect which is 0.0067 VDC per 1000 feet of
elevation and 0.00067 VDC per 0.1 inch Hg barometric deviation.
11. Subtract 1.2 from the voltage.
12. Multiply by 75, the result will be PSIG.
13. Since the discharge pressure (PE-3) cannot be closed
off from its sensing point (code requirements), remove all
transducers from atmosphere and open them to their sensing
points so all transducers can equalize to separator pressure.
14. Measure the voltage of (PE-3) on connector (P5B) (terminals 5 and 6) on the analog board.
15. Test complete.
PRESSURE TRANSDUCERS REPLACEMENT

1. Shut off control power.
2. Close the applicable transducer isolation valve.
070.410-IOM (NOV 14)

Page 34
Sensor
Voltage
1.0
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2.0
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3.0
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
4.0
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
5.0
At 0 psig

MAINTENANCE
100 psi
Range - PSIG*
low
high
29.92"
19.74"
29.92"
14.65"
29.92"
9.57"
24.83"
4.48"
19.74"
0.30
14.65"
2.80
9.57"
5.30
4.48"
7.80
0.30
10.30
2.80
12.80
5.30
15.30
7.80
17.80
10.30
20.30
12.80
22.80
15.30
25.30
17.80
27.80
20.30
30.30
22.80
32.80
25.30
35.30
27.80
37.80
30.30
40.30
32.80
42.80
35.30
45.30
37.80
47.80
40.30
50.30
42.80
52.80
45.30
55.30
47.80
57.80
50.30
60.30
52.80
62.80
55.30
65.30
57.80
67.80
60.30
70.30
62.80
72.80
65.30
75.30
67.80
77.80
70.30
80.30
72.80
82.80
75.30
85.30
77.80
87.80
80.30
90.30
1.388 V
1.788 V
PRESSURE TRANSDUCER CONVERSION DATA

200 psi
Range - PSIG*
low
high
29.92"
9.57"
29.92"
0.30
29.92"
5.30
19.74"
10.30
9.57"
15.30
0.30
20.30
5.30
25.30
10.30
30.30
15.30
35.30
20.30
40.30
25.30
45.30
30.30
50.30
35.30
55.30
40.30
60.30
45.30
65.30
50.30
70.30
55.30
75.30
60.30
80.30
65.30
85.30
70.30
90.30
75.30
95.30
80.30
100.30
85.30
105.30
90.30
110.30
95.30
115.30
100.30
120.30
105.30
125.30
110.30
130.30
115.30
135.30
120.30
140.30
125.30
145.30
130.30
150.30
135.30
155.30
140.30
160.30
145.30
165.30
150.30
170.30
155.30
175.30
160.30
180.30
165.30
185.30
170.30
190.30
175.30
195.30
1.094 V
1.494 V
300 psi
Range - PSIG*
low
high
29.92"
7.0"
29.92"
4.10
22.3"
11.60
7.0"
19.10
4.10
26.60
11.60
34.10
19.10
41.60
26.60
49.10
34.10
56.60
41.60
64.10
49.10
71.60
56.60
79.10
64.10
86.60
71.60
94.10
79.10
101.60
86.60
109.10
94.10
116.60
101.60
124.10
109.10
131.60
116.60
139.10
124.10
146.60
131.60
154.10
139.10
161.60
146.60
169.10
154.10
176.60
161.60
184.10
169.10
191.60
176.60
199.10
184.10
206.60
191.60
214.10
199.10
221.60
206.60
229.10
214.10
236.60
221.60
244.10
229.10
251.60
236.60
259.10
244.10
266.60
251.60
274.10
259.10
281.60
266.60
289.10
274.10
296.60
1.046 V
1.346 V
500 psi
Range - PSIG*
low
high
29.92"
4.10
29.92"
16.60
17.1"
29.10
4.10
41.60
16.60
54.10
29.10
66.60
41.60
79.10
54.10
91.60
66.60
104.10
79.10
116.60
91.60
129.10
104.10
141.60
116.60
154.10
129.10
166.60
141.60
179.10
154.10
191.60
166.60
204.10
179.10
216.60
191.60
229.10
204.10
241.60
216.60
254.10
229.10
266.60
241.60
279.10
254.10
291.60
266.60
304.10
279.10
316.60
291.60
329.10
304.10
341.60
316.60
354.10
329.10
366.60
341.60
379.10
354.10
391.60
366.60
404.10
379.10
416.60
391.60
429.10
404.10
441.60
416.60
454.10
429.10
466.60
441.60
479.10
454.10
491.60
466.60
504.10
0.968 V
1.268 V
* Below 0 PSIG measured in inches of mercury.
NOTICE
To change the discharge pressure transducer (PE-3), it
will be necessary to depressurize the entire compressor
package. Follow "General Instructions For Replacing Compressor Unit Components" section before going to step 3.
1
3
2
CABLE COLOR CODE

PIN 1
+ SUPPLY
PIN 2
DC COMMON
PIN 3
SIGNAL
CASE GND
Figure 34 - Pressure Transducer Color Key

3. Refer to Figure 34 to identify wiring harness connectors.
4. Remove DIN connector screw, then remove DIN connector
from the transducer.
TRANSDUCER
Suction Pressure
Discharge Pressure
Oil Pressure
CONNECTION
PE4
PE3
PE1 & PE-2
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.
6. Install new transducer, reconnect DIN connector, and
retighten DIN connector screw.
7. Recalibrate.
NOTICE
If replacing older hard-wired transducer, cut cable at
back of old transducer and rewire to the Danfoss unit.
8. Reopen the transducer isolation valve or compressor
package isolation valves.
9. Turn on control power.

MAINTENANCE
SLIDE VALVE TRANSMITTER

REPLACEMENT - SLIDE STOP
The Slide Valve Transmitter (Figure 35) is located on the
right side of the compressor (facing shaft) at the inlet end.
The linear transmitter with hermetic enclosure is based on
the inductive measuring principle. It features removable
electronics (from the sensor well) eliminating the need to
evacuate the compressor for replacement. This type of
transmitter is dedicated to volume ratio control and has no
user adjustments.
2. Remove DIN connector plug from transmitter.
3. Loosen set screws.
4. Remove transmitter unit.
5. Install new transmitter unit.
6. Tighten set screws.
7. Apply DIN connector plug to transmitter.
070.410-IOM (NOV 14)

Page 35
4. Apply thermal compound to new sensor assembly, insert

into thermal well, and tighten knurled ring.
NOTICE
For calibration instructions, refer to QuantumHD Operator's Manual 090.040-O.
OIL LEVEL TRANSMITTER

REPLACEMENT
The Oil Level Transmitter is located on the front of the separator near the bottom/center. See Figure 37.
NOTICE
For calibration of the Slide Valve unit, refer to the Analog Calibration instructions in publication 090.040-O.
Figure 37 - Oil Level Transmitter
Figure 35 - Slide Valve Transmitter
The linear transmitter with hermetic enclosure is based on

the capacitive measuring principle. It features removable
electronics (from the sensor well) eliminating the need to
evacuate the compressor for replacement. This transmitter
is dedicated to oil level control and has no user adjustments.
CAUTION
TEMPERATURE SENSOR REPLACEMENT
If it is necessary to replace the well, the separator must

be purged and the oil drained. Refer to the section
"CHANGING OIL."
2. Remove DIN connector plug from transmitter.
3. Loosen set screws.
4. Remove transmitter unit.
5. Install new transmitter unit.
6. Tighten set screws.
Figure 36 - Temperature Transmitter
CAUTION
This device is static sensitive. Please follow proper ESD
procedures when handling.
2. Remove DIN connector plug from transmitter. See Figure 36.
3. Unscrew knurled ring and remove transmitter unit.
TEMPERATURE and/or PRESSURE

ADJUSTMENT
All temperature and pressure sensors are factory set. If calibration is required, refer to Analog Calibration for temperature or pressure in QUANTUMHD publication 090.040-O.
BARE COMPRESSOR MOUNTING

Refer to publication 070.660-SM.
070.410-IOM (NOV 14)

Page 36

MAINTENANCE
TROUBLESHOOTING THE COMPRESSOR

SYMPTOM
PROBABLE CAUSES and CORRECTIONS
EXCESSIVE NOISE and

VIBRATION
Loose bolts on compressor mounting. Tighten bolts.

No oil getting to compressor. Check oil level, oil filter and oil pressure.
Bearing damage or excessive wear.
Coupling loose on shaft. Tighten coupling. Replace if damaged.
Volumizer not adjusted correctly. Readjust.
Refrigerant flood-back. Correct system problem.
TROUBLESHOOTING THE OIL SEPARATOR

SYMPTOM
GRADUAL OIL LOSS WITH AN

OIL LEVEL IN THE COALESCER
SECTION SIGHT GLASS
Maintaining too high an oil level. Lower level.

Refrigerant carryover or liquid injection overfeeding. Correct operation.
Contaminated oil or damaged coalescer filter elements. Replace oil charge and coalescers.
Coalescers may be loose. Tighten.
Oil return valve closed. Open return valve.
Return oil strainer blocked. Clean strainer.
RAPID LOSS WITH NO OIL

LEVEL IN THE COALESCER
SECTION SIGHT GLASS
Compressor unit suction check valve did not close on shutdown. Repair valve.
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.
TROUBLESHOOTING THE LIQUID INJECTION OIL COOLING SYSTEM

SYMPTOM
HIGH OIL TEMPERATURE
Insufficient liquid supply. Check receiver level. Check strainer.

Suction superheat too high. Correct system problem.
Liquid strainer blocked. Clean strainer.
Operating conditions significantly different from design.
Malfunctioning Vi Control Solenoids. See function check of the compressor
"Volumizer II Vi Control" for further detail.
Check motor valve operation and calibration.
Check calibration of analog output.
LOW OIL TEMPERATURE
Equalizing pressure too low. Raise pressure.

Suction superheat too low or refrigerant flood back on compressor. Correct system problem.
Operating conditions significantly different from design.
Check motor valve operation and calibration.
Check calibration of analog output.
OIL TEMPERATURE
FLUCTUATES
System conditions rapidly fluctuate causing liquid injection system to overrespond. Stabilize
system operation.
Check calibration and operation of motor valve - Adjust P & ID setpoints for analog output.

MAINTENANCE
070.410-IOM (NOV 14)

Page 37
TROUBLESHOOTING THE HYDRAULIC SYSTEM

SYMPTOM
SLIDE VALVE WILL NOT LOAD

OR UNLOAD
Solenoid coil burned out. Replace coil.

HV2 needle valve closed. Open valve.
Solenoid spool may be stuck or centering spring broken. Free spool or replace spring.
Solenoid may be mechanically actuated by inserting a piece of 3/16" rod against armature pin and pushing
spool to opposite end. Push A side to confirm unload capability. If valve works, problem is electrical.
Solenoid valve piston hung in bore or bolt loose. Check piston or tighten bolt.
SLIDE VALVE WILL LOAD BUT

WILL NOT UNLOAD
YY1 solenoid coil burned out. Replace coil.

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

BUT WILL NOT LOAD
YY2 solenoid coil burned out. Replace coil.

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 FUNCTION IN EITHER DIRECTION
Solenoid coil burned out. Replace coils.
SLIDE VALVE and/or SLIDE

STOP WILL NOT MOVE
Slipper seals worn out or damaged.
Solenoid valve sticking. Replace valve.
Unloader spindle or slide valve jammed.

Slide stop indicator rod jammed.
070.410-IOM (NOV 14)

Page 38

MAINTENANCE
COMPRESSOR PORT LOCATIONS - RXF 12 - 19
PORT
1
3
4
5
7
8
10
11
12
16
18
20
21
22
CONNECTION SIZE
3/4 - 14 NPTF
3/8 - 18 NPTF
3/8 - 18 NPTF
3/4 - 14 NPTF
1/4 - 18 NPTF
3/8 - 18 NPTF
1/4 - 18 NPTF
1/4 - 18 NPTF
1/4 - 18 NPTF
3/4 - 14 NPTF
1/2 - 14 NPTF
1/4 - 18 NPTF
3/4 - 14 NPTF
1/4 - 18 NPTF

MAINTENANCE
070.410-IOM (NOV 14)

Page 39
PORT
1
2
3
4
5
6
7
8
10
11
12
15
16
18
19
20
21
22
CONNECTION SIZE
1 - 11 NPTF
1/4 - 18 NPTF
3/8 - 18 NPTF
3/8 - 18 NPTF
1 - 11 NPTF
1/2 - 14 NPTF
1/4 - 18 NPTF
1/4 - 18 NPTF
1/4 - 18 NPTF
1/4 - 18 NPTF
1/4 - 18 NPTF
3/8 - 18 NPTF
3/4 - 14 NPTF
1/8 - 27 NPTF
1/4 - 18 NPTF
1/8 - 27 NPTF
3/8 - 18 NPTF
1/4 - 18 NPTF
070.410-IOM (NOV 14)

Page 40

MAINTENANCE
SAE STRAIGHT THREAD O-RING FITTINGS - ASSEMBLY PROCEDURE FOR RXF 58 - 101
When performing maintenance or replacing the compressor, the hydraulic tubing may need to be removed and
re-installed. The following procedure outlines the proper
installation of SAE straight thread fittings to SAE straight
thread ports.
The male and female ends of SAE straight thread O-ring
ports have UN/UNF straight threads. An elastomeric O-ring
is fitted to the male end. On assembly, the O-ring is firmly
sandwiched between the angular sealing surface of the female port and the shoulder of the male end. Sealing is thus
affected and maintained by the O-ring compression which
results from the clamping force generated by the tightening
action. The straight threads do not offer sealing action; they
provide the resistance (holding power) for service pressure.
1. Inspect components to ensure that male and female port

threads and sealing surfaces are free of burrs, nicks and
scratches or any foreign material.
2. If the O-ring is not pre-installed to the fitting on the male
end, install the proper size O-ring.
3. Lubricate the O-ring with a light coating of system oil or
petroleum jelly.
4. Screw the fitting into the female port until the hex flat
contacts the port face. Light wrenching may be necessary.
5. Tighten to the appropriate torque value shown in the
Assembly Torque Table.
ASSEMBLY TORQUE TABLE
Fitting Size
2
3
4
5
6
8
10
12
16
20
24
Straight and Adjustable Fittings or Plugs (steel)

Assembly Torque
SAE Port Thread Size
Inch lb
5/16 24
65 5
3/8 24
130 10
7/16 20
170 10
1/2 - 20
260 15
9/16 18
320 20
3/4 - 16
500 25
7/8 14
720 30
960 50
1Z\zn 12
1380 75
1B\zn 12
2700 150
1B\, 12
3000 160
1M\, - 12
NOTE: Compressor port locations for RXF 58 -101 are located on the following page.
Foot lb
5.5 0.5
11 1.0
14 1.0
22 1.0
27 2.0
42 2.0
60 2.5
80 5.0
115 6.0
225 12.0
250 12.0

MAINTENANCE
070.410-IOM (NOV 14)

Page 41

17 - Dedicated Closed Thread
16 - Oil Pressure
11 - Thermowell (Suction Temp)
4 - High Vi
Liquid Injection
DRIVE SHAFT
1 - Main Oil Supply

16 - Oil Pressure
18 - Dedicated Capacity Valve

Vent to Suction Pressure
10 - Coalescer
Bleed Line
3 - Low Vi Liquid Injection
6 - Suction Pressure
9 - Liquid Injection
Bleed Line
13 - Suction
Pressure
5 - Economizer
COMPRESSOR
DRIVE SHAFT
7 - Closed Thread
12 - Main Oil Injection
8 - Pressure
Discharge
14 - Seal Weepage
15 - Electrical Connection
2 - Slide Valve Piston

PORT
1
2
3
4
5
6
7
8
9
CONN SIZE
1Z\zn - 12UN-2B
7/16 - 20UNF-2B
1Z\zn - 12UN-2B
1Z\zn - 12UN-2B
1M\, - 12UN-2B
9/16 - 18UNF-2B
1Z\zn - 12UN-2B
7/16 - 20UNF-2B
9/16 - 18UNF-2B
PORT
10
11
12
13
14
15
16
17
18
CONN SIZE
9/16 - 18UNF-2B
3/4 - 14 NPTF
1Z\zn - 12UN-2B
1/4 - 18 NPTF
1/8 - 27 NPTF
1/2 - 14 NPTF
9/16 - 18UNF-2B
1Z\zn - 12UN-2B
9/16 - 18UNF-2B
P & I DIAGRAM, LIQUID INJECTION SINGLE PORT

COMPRESSOR LOW VI,
ECONOMIZER, OR
CLOSED THREAD
SOLENOID
VALVE
STRAINER
LIQUID REFRIGERANT
FROM RECEIVER
LIQUID LINE
SIGHT
GLASS
S
COMPRESSOR
HIGH VI,
BOOSTER ONLY
TUBING LINE
MOTORIZED
EXPANSION
VALVE
070.410-IOM (NOV 14)

Page 42

MAINTENANCE
P & I DIAGRAM, LIQUID INJECTION DUAL PORT (NEW DESIGN)

3-WAY
MOTORIZED
VALVE
COMPRESSOR
HIGH VI
COMPRESSOR
LOW VI
M
TUBING LINE
SOLENOID
VALVE
MOTORIZED
EXPANSION
VALVE
STRAINER
S
LIQUID REFRIGERANT
FROM RECEIVER
LIQUID
LINE
SIGHT
GLASS
P & I DIAGRAM, LIQUID INJECTION DUAL PORT (OLD DESIGN)
YY
9
COMPRESSOR
SUCTION PRESS.
COMPRESSOR
LOW VI
COMPRESSOR
HIGH VI
TUBING LINE
TO SEPARATOR
SOLENOID
VALVE
STRAINER
S
LIQUID REFRIGERANT
FROM RECEIVER
LIQUID
LINE
MOTORIZED
EXPANSION
VALVE
SIGHT GLASS
RXF COOLING OPTIONS (See P & I Diagrams) PLATE OIL COOLER

MAINTENANCE
070.410-IOM (NOV 14)

Page 43
RXF MODELS 12 through 19 without OIL PUMP (See OIL COOLING ADDITIONS)
LEGEND*

C
CV
F
HTR
LG
LSL
LSLL
M
NV
P
PAH
PAHH
PAL
PALL
COMPRESSOR
CHECK VALVE
FILTER OR FILTER DRIER
HEATER
SIGHT OR LEVEL GLASS
OIL LEVEL SWITCH LOW
LOW OIL LEVEL SHUTDOWN
MOTOR
NEEDLE VALVE
PUMP
HIGH PRESSURE ALARM
HIGH PRESSURE SHUTDOWN
LOW PRESSURE ALARM
LOW PRESSURE SHUTDOWN
PE
PI
PIC/TIC
PM
PSV
PV
STR
TAH
TAHH
TAL
TALL
TCV
TE
YY
PRESSURE ELEMENT
PRESSURE INDICATOR
PRESS./TEMP. INDICATING CONTROLLER
PUMP MOTOR
PRESSURE SAFETY VALVE
PRESSURE VESSEL
STRAINER
HIGH TEMPERATURE ALARM
HIGH TEMP. SHUTDOWN
LOW TEMPERATURE ALARM
LOW TEMPERATURE SHUTDOWN
TEMPERATURE CONTROL VALVE
TEMPERATURE ELEMENT
SOLENOID VALVE/EVENT VALVE
XE
XAH
XAHH
ZT
ZI
VIBRATION ELEMENT
VIBRATION HIGH ALARM
VIBRATION HIGH SHUTDOWN
POSITION TRANSMITTER
POSITION INDICATOR
* Continued following page
070.410-IOM (NOV 14)

Page 44

MAINTENANCE
RXF MODELS 12 through 19 with OIL PUMP (See OIL COOLING ADDITIONS)
LEGEND (Cont.)
CONNECTIONS **
NOTES:
1. PRESSURE TRANSDUCERS INDICATE:

PE-1 OIL PRESSURE
PE-3 DISCHARGE PRESSURE
PE-4 SUCTION PRESSURE
2. TEMPRERATURE PROBES INDICATE:
TE-1 SUCTION GAS TEMPERATURE
TE-2 DISCHARGE GAS TEMPERATURE
TE-3 LUBE OIL TEMPERATURE
TE-4 SEPARATOR OIL TEMPERATURE
3. TERMINATIONS "A" THROUGH "C" REFER TO
CONNECTION POINTS FOR VARIOUS OPTIONS.
1
2
7
10
11
12
16
18
22
MAIN OIL SUPPLY

SLIDE VALVE PISTON
SUCTION PRESSURE
DISCHARGE PRESSURE
LIQ. INJ. BLEED LINE
COALESCER BLEED LINE
THERMOWELL
MAIN OIL INJECTION
CAPACITY VALVE VENT TO SUCTION
** N
ot all ports are shown. See COMPRESSOR
PORT LOCATIONS for all ports.

MAINTENANCE
070.410-IOM (NOV 14)

Page 45
RXF MODELS 24 throughy 50 without OIL PUMP (See OIL COOLING ADDITIONS)
LEGEND*

C
CV
F
HTR
LG
LSL
LSLL
M
NV
P
PAH
PAHH
PAL
PALL
COMPRESSOR
CHECK VALVE
FILTER OR FILTER DRIER
HEATER
OIL LEVEL SWITCH LOW
LOW OIL LEVEL SHUTDOWN
MOTOR
NEEDLE VALVE
PUMP
HIGH PRESSURE ALARM
LOW PRESSURE ALARM
PE
PI
PIC/TIC
PM
PSV
PV
STR
TAH
TAHH
TAL
TALL
TCV
TE
YY
PRESSURE ELEMENT
PRESSURE INDICATOR
PUMP MOTOR
PRESSURE VESSEL
STRAINER
HIGH TEMP. SHUTDOWN
TEMPERATURE ELEMENT
ZT
POSITION TRANSMITTER
ZI
POSITION INDICATOR

* Continued following page
070.410-IOM (NOV 14)

Page 46

MAINTENANCE
RXF MODELS 24 through 50 with OIL PUMP (See OIL COOLING ADDITIONS)
LEGEND (Cont.)
CONNECTIONS **
NOTES:

PE-1 OIL PRESSURE
3. TERMINATIONS "A" THROUGH "C" REFER TO
CONNECTION POINTS FOR VARIOUS OPTIONS.
1
2
7
10
11
12
16
19
22
MAIN OIL SUPPLY

SLIDE VALVE PISTON
SUCTION PRESSURE
DISCHARGE PRESSURE
THERMOWELL
SUCTION PRESSURE
CAPACITY VALVE VENT TO SUCTION
** N

MAINTENANCE
070.410-IOM (NOV 14)

Page 47
RXF MODELS 58, 68, 85, & 101 without OIL PUMP (See OIL COOLING ADDITIONS)
LEGEND *

C
CV
HTR
LG
M
OF
P
PAH
PAHH
PAL
PALL
COMPRESSOR
CHECK VALVE
HEATER
MOTOR
OIL FILTER
PUMP
HIGH PRESSURE ALARM
LOW PRESSURE ALARM
PE
PI
PIC/TIC
PM
PSV
STR
TAH
TAHH
TAL
TALL
TCV
PRESSURE ELEMENT
PRESSURE INDICATOR
PUMP MOTOR
STRAINER
HIGH TEMP. SHUTDOWN
TE
TI
YY
TEMPERATURE ELEMENT
TEMPERATURE INDICATOR
* See additional Legend items on opposite

page.
070.410-IOM (NOV 14)

Page 48

MAINTENANCE
RXF Models 58, 68, 85, & 101 with OIL PUMP and DUAL OIL FILTERS (See OIL COOLING ADDITIONS)
LEGEND (Cont.)
NOTES:
CONNECTIONS

1
2
6
8
9
10
11
12
13
MAIN OIL SUPPLY

SLIDE VALVE PISTON
SUCTION PRESSURE
DISCHARGE PRESSURE
THERMOWELL (SUCT. TEMP.)
MAIN OIL INJECTION
SUCTION PRESSURE
16
18
OIL PRESSURE
CAPACITY VENT VALVE TO SUCTION
** N

PE-1 OIL PRESSURE
3. TERMINATIONS "A" THROUGH "C" REFER TO CONNECTION POINTS FOR VARIOUS OPTIONS.

MAINTENANCE
WIRING HARNESS - External for Analog Devices
070.410-IOM (NOV 14)

Page 49
070.410-IOM (NOV 14)

Page 50

MAINTENANCE
WIRING HARNESS - AC to Heaters and Valves (External)
WIRING HARNESS - AC Conduit - Quantum to DBS Panel

PROPER INSTALLATION OF ELECTRICAL EQUIPMENT
Installation Of Electronic Equipment
070.410-IOM (NOV 14)

Page 51
PROPER INSTALLATION OF ELECTRONIC EQUIPMENT IN AN INDUSTRIAL ENVIRONMENT
In todays refrigeration plants, electronic controls have

found their way into almost every aspect of refrigeration
control. Electronic controls have brought to the industry
more precise control, improved energy savings, and operator
conveniences. Electronic control devices have revolutionized
the way refrigeration plants operate today.
The earlier relay systems were virtually immune to radio
frequency interference (RFI), electromagnetic interference
(EMI), and ground loop currents. Therefore installation and
wiring were of little consequence and the wiring job consisted of hooking up the point-to-point wiring and sizing
the wire properly. In an electronic system, improper installation will cause problems that may outweigh the benefits
of electronic control. Electronic equipment is susceptible to
RFI, EMI, and ground loop currents which can cause equipment shutdowns, processor memory and program loss, as
well as erratic behavior and false readings. Manufacturers of
industrial electronic equipment take into consideration the
effects of RFI, EMI, and ground loop currents and incorporate protection of the electronics in their designs. However,
these design considerations do not make the equipment
immune, so manufacturers require that certain installation
precautions be taken to protect the electronics from these
effects. All electronic equipment must be viewed as sensitive
instrumentation and therefore requires careful attention to
installation procedures. These procedures are well known to
instrumentation, networking, and other professions but may
not be followed by general electricians.
There are a few basic practices that if followed, will minimize
the potential for problems resulting from RFI, EMI and/or
ground loop currents. The National Electric Code (NEC) is a
guideline for safe wiring practices, but it does not necessarily
deal with procedures used for electronic control installation.
Use the following procedures for electronic equipment installation. These procedures do not override any rules by the
NEC, but are to be used in conjunction with the NEC code
and any other applicable codes.
cessor, a computer, or a PLC, to malfunction momentarily or

cause a complete reset of the control system. If the wire is
loaded to its maximum capacity, the voltage dips are much
larger, and the potential of a malfunction is very high. If the
wire is sized one size larger than required, the voltage dips
are smaller than in a fully loaded supply wire and the potential
for malfunction is much lower. The NEC code book calls for
specific wire sizes to be used based on current draw. An
example of this would be to use #14 gauge wire for circuits
up to 15 amps or #12 gauge wire for circuits of up to 20 amps.
Therefore, when connecting the power feed circuit to an
electronic control panel, use #12 gauge wire for a maximum
current draw of 15 amp and #10 wire for a maximum current
draw of 20 amp. Use this rule of thumb to minimize voltage
dips at the electronic control panel.
VOLTAGE SOURCE
Selecting the voltage source is extremely important for
proper operation of electronic equipment in an industrial
environment. Standard procedure for electronic instrumentation is to provide a clean, isolated, separate-source voltage
in order to prevent EMI (from other equipment in the plant)
from interfering with the operation of the electronic equipment. Connecting electronic equipment to a breaker panel
(also known as lighting panels or utility panels) subjects the
electronic equipment to noise generated by other devices
connected to the breaker panel. This noise is known as electromagnetic interference (EMI). EMI flows on the wires that
are common to a circuit. EMI cannot travel easily through
transformers and therefore can be isolated from selected
circuits. Use a control power transformer of the proper VA
rating, usually provided in the compressor drive motor starter,
to isolate the electronic control panel from other equipment
in the plant that generate EMI. See Figure 38.
With exclusion of the three phase wire sizing, Frick drawing

649D4743 should be used as a reference for properly sizing
control wires and other wiring specifications.
Throughout this document the term Electronic Control Panel
is used to refer to the microprocessor mounted on the compressor package or a Central Control System panel.
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 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.
WIRE SIZING
Control power supply wires should be sized one size
larger than required for amperage draw to reduce instantaneous 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 (NOV 14)

Page 52

GROUNDING
Grounding is the most important factor for successful operation and is typically the most overlooked. The NEC states that
control equipment may be grounded by using the rigid conduit
as a conductor. This worked for the earlier relay systems, but
it is in no way acceptable for electronic control equipment.
Conduit is made of steel and is a poor conductor relative
to an insulated stranded copper wire. Electronic equipment
reacts to very small currents and must have a proper ground
in order to operate properly; therefore, stranded copper
grounds are required for proper operation.
For proper operation, the control power ground circuit must
be a single continuous circuit of the proper sized insulated
stranded conductor, from the electronic control panel to the
plant supply transformer (Figure 39). Driving a ground stake
at the electronic control may also cause additional problems
since other equipment in the plant on the same circuits may
ground themselves to the ground stake causing large ground
flow at the electronic control panel. Also, running multiple
ground conductors into the electronic control panel from
various locations can create multiple potentials resulting in
ground loop currents. A single ground wire (10 AWG or 8
AWG) from the electronic control panel, that is bonded to the
control power neutral at the secondary side of the control
power transformer in the starter and then to the 3-phase
ground point, will yield the best results.
NEC size ratings are for safety purposes and not necessarily
for adequate relaying of noise (EMI) to earth ground to avoid
possible interference with sensitive equipment. Therefore
sizing this conductor 1 2 sizes larger than required by code
will provide better transfer of this noise.
Frick requirements for the ground conductor are:
Stranded Copper
Insulated
One size larger than NEC requirements for conventional
starters
Two sizes larger than NEC requirements for VFD starters
Conduit must be grounded at each end
This circuit must be complete from the motor to the
starter continuing in a seamless manner back to the plant
supply transformer (power source).
For Direct Coupled, Package Mounted Starters, the ground
between the motor and the starter may need to be made
externally (Figure 40). The connection on the starter end
must be on the starter side of the vibration isolators. Be
certain the connection is metal to metal. Paint may need
to be removed to ensure a proper conductive circuit. The
use of counter-sunk star washers at the point of connection at each end will maximize metal to metal contact.
Figure 40
Figure 39
VFD APPLICATIONS
NOTICE
Structural grounding can also result in multiple ground
potentials and is also a relatively poor conductor.
Therefore, this is not an acceptable method for proper
operation of electronic equipment.
The primary ground conductor that accompanies the threephase supply must be stranded copper, insulated and two
sizes larger than the minimum required by the NEC or any
other applicable codes. This is necessary due to the increased
generation of EMI which is a characteristic of a VFD output
to the motor when compared to a conventional starter.
There must be a ground for the three-phase power wiring.

This must be sized in accordance to the NEC and any local
codes relative to the highest rated circuit overload protection provided in the circuit. The manufacturer may require a
larger ground conductor than what is required by the NEC for
proper steering of EMI from sensitive circuits. This conductor must also be insulated to avoid inadvertent contact at
multiple points to ground, which could create Ground Loops.
In many installations that are having electronic control problems, this essential wire is usually missing, is not insulated,
or improperly sized.
For VFD applications, isolation of the control power, analog

devices, and communications ground from the 3-phase
ground within the starter and the electronic control panel may
be necessary. This is due to the higher noise (RFI/EMI) levels
generated between the VFD output and the motor, relative
to a conventional starter. If these grounds are left coupled
by a common back-plate in the starter/drive, this noise can
be direct coupled to the control power, analog device, and
communications grounding and may cause unexplained
behavior and possible damage to components.

To install correctly, run a separate, properly sized (10 or 8
AWG typically) insulated ground along with and taken to
ground with, the 3-phase ground at the 3-phase supply
transformer (plant). This will require that the 3-phase ground
and the control power ground be electrically isolated except
for the connection at the plant supply transformer.
This style of grounding should steer the noise (EMI/RFI)
to earth ground, reducing the potential for it to affect the
sensitive equipment, which could occur if the grounds were
left coupled.
070.410-IOM (NOV 14)

Page 53
electrical ducts carrying 3-phase power to starters/vfd or

motors.
Control power, communications, analog, or signal wiring
should be run overhead (preferred) or in a separate trench.
If these lines are not in threaded metallic or threaded PVCcoated metallic, abiding by the separation requirements
noted above is necessary.
Though not recommended, if cable trays are used, metallic
dividers must be used for separation of conductors of
unlike voltages and types (AC or DC).
NOTICE
NOTICE
If all other recommendations for grounding are followed,

this process should not be necessary.
When in doubt contact the factory or use threaded

metallic or threaded PVC coated metallic conduit.
CONDUIT
WIRING PRACTICES
All national and local codes must be followed for conduit

with regard to materials, spacing and grounding. In addition,
Johnson Controls-Frick requirements must be followed
where they exceed or match national or local codes. Conversely, there is no allowance for any practices that are
substandard to what is required by national or local codes.
Do not mix wires of different voltages in the same conduit.

An example of this would be the installation of a screw
compressor package where the motor voltage is 480 volts
and the electronic control panel power is 120 volts. The 480
volt circuit must be run from the motor starter to the motor
in its own conduit. The 120 volt circuit must be run from the
motor starter control transformer to the electronic control
panel in its own separate conduit. If the two circuits are run
in the same conduit, transients on the 480 volt circuit will be
induced onto the 120 volt circuit causing functional problems
with the electronic control panel. Metallic dividers must be
used in wire way systems (conduit trays) to separate unlike
voltages. The same rule applies for 120 volt wires and 220
volt wires. Also, never run low voltage wires for DC analog
devices or serial communications in the same conduit with
any AC wiring including 120 volt wires. See Figure 41.
Johnson Controls-Frick conduit requirements:

For variable frequency drives (VFDs) of any type, threaded
metallic or threaded PVC-coated metallic is required
for both the power feed (line side) from the source and
between the VFD output and the motor (load side).
PVC conduit is acceptable only when VFD rated cable of
the proper conductor size and ground is used. This applies
to both the line side and load side of the drive. When VFD
rated cable is not used, threaded metallic or threaded
PVC-coated metallic must be used.
When threaded metallic or threaded PVC-coated metallic
is used, it must be grounded at both ends.
When not required to be in metal or other material by
national or local codes, conduits for the power feed
(3-phase) of constant speed starters may be PVC.
When not required to be in metal or other material by
national or local codes, conduits between a constant speed
starter and the motor (3-phase) may be PVC.
Any unshielded control voltage, signal, analog, or
communication wiring that does not maintain 12 inches
of separation from any 3-phase conductors for every 33
feet (10 meters) of parallel run must be in metal conduit
which will be grounded.
Separation: (0-33 feet, 0-10 meters 12 inches, .3 meters),
(33-66 feet, 10-20 meters 24 inches, .6 meters)
Since PVC conduit does absolutely nothing to protect lower
voltage lines from the magnetic field effects of higher
voltage conductors, running either the lower or the higher
voltage lines in PVC, does not reduce these requirements
on separation. Only running in metal conduit can relieve
these requirements.
Due to the level of EMI that can be induced onto lower
voltage lines when running multiple feeders in a trench,
control power, communications, analog, or signal wiring
cannot be run in trenches that house multiple conduits/
Figure 41
Never run any wires through an electronic control panel
that do not relate to the function of the panel. Electronic
control panels should never be used as a junction box. These
wires may be carrying large transients that will interfere with
the operation of the control panel. An extreme example of
this would be to run 480 volts from the starter through
the electronic control panel to an oil pump motor.
When running conduit to the electronic control panel, use
the access holes (knockouts) provided by the manufacturer.
These holes are strategically placed so that the field wiring
does not interfere with the electronics in the panel. Never
allow field wiring to come in close proximity with the controller boards since this will almost always cause problems.
070.410-IOM (NOV 14)

Page 54

Do not drill into an electronic control panel to locate conduit

connections. You are probably not entering the panel where
the manufacturer would like you to since most manufacturers recommend or provide prepunched conduit connections.
You may also be negating the NEMA rating of the enclosure.
Drilling can cause metal filings to land on the electronics and
create a short circuit when powered is applied. If you must
drill the panel, take the following precautions:
First, call the panel manufacturer before drilling into the
panel to be sure you are entering the panel at the right
place.
Take measures to avoid ESD (electrostatic discharge) to the
electronics as you prep the inside of the Electronic control
panel. This can be done by employing an antistatic wrist
band and mat connected to ground.
If the electronic control panel has a starter built into the

same panel, be sure to run the higher voltage wires where
indicated by the manufacturer. EMI from the wires can
interfere with the electronics if run too close to the circuitry.
Never daisy-chain or parallel-connect power or ground
wires to electronic control panels. Each electronic control
panel must have its own control power supply and ground
wires back to the power source (Plant Transformer). Multiple
electronic control panels on the same power wires create
current surges in the supply wires, which may cause controller malfunctions. Daisy-chaining ground wires, taking them
to ground at each device, allows ground loop currents to
flow between electronic control panels which also causes
malfunctions. See Figure 42.
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.
Never add relays, starters, timers, transformers, etc. inside 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.
Never run refrigerant tubing inside an electronic control
panel. If the refrigerant is ammonia, a leak will totally destroy
the electronics.
Figure 42

070.410-IOM (NOV 14)

Page 55
COMMUNICATIONS
UPS POWER AND QUANTUM HD PANELS
The use of communications such as serial and ethernet

in industrial environments are commonplace. The proper
installation of these networks is as important to the proper
operation of the communications as all of the preceding
practices are to the equipment.
Johnson Controls, Inc. does not advise nor support the use
of uninterrupted power supply systems for use with the
QuantumHD panel. With a UPS system providing shutdown
protection for a Frick Quantum panel, the panel may not
see the loss of the 3-phase voltage on the motor because
the UPS may prevent the motor starter contactor from
dropping out. With the starter contactor still energized, the
compressor auxiliary will continue to feed an okay signal
to the QuantumHD panel. This may allow the motor to be
subjected to the fault condition on the 3-phase bus.
Serial communications cable needs to be of the proper gauge

based on the total cable distance of the run. Daisy-chaining
is the only acceptable style of running the communications
cable. While Star Networks may use less cable, they more
often than not cause problems and interruptions in communications, due to varying impedances over the varying lengths
of cable. Ground or drain wires of the communications cable
are to be tied together at each daisy-chain connection and
only taken to ground in the central control system panel.
It is important to carefully consider the type of cable to be
used. Just because a cable has the proper number of conductors and is shielded does not mean it is an acceptable cable.
Johnson Controls-Frick recommends the use of Belden #9829
for RS-422 communications and Belden # 9841 for RS-485 up
to 2000 feet (600 Meters) total cable length. Refer to Frick
drawing 649D4743 for more detail
Comm Port Protection: Surge suppression for the comm
ports may not be the best method, since suppression is required to divert excess voltage/current to ground. Therefore,
the success of these devices is dependent on a good ground
(covered earlier in this section). This excess energy can be
quite high and without a proper ground, it will access the
port and damage it.
Isolation or Optical Isolation is the preferred comm port
protection method. With optical isolation, there is no continuity between the communications cable and the comm
port. There is no dependence on the quality of the ground.
Be sure to know what the voltage isolation value of the
optical isolator is before selecting it. These may range from
500 to 4000 Volts.
Frick Optical Isolation Kits are offered under part number
639C0133G01. One kit is required per comm port.
A couple of fault scenarios are: 1. The 3-phase bus has

power on and off in a continuous cycle manner which
may cause the motor to overheat due to repeated excessive in-rush current experiences. 2. The motor cycling may
damage the coupling or cause other mechanical damage
due to the repeated high torque from rapid sequential motor
bumps. 3. Prolonged low voltage may cause the motor to
stall and possibly overheat before the motor contactor is
manually turned off.
Under normal conditions, the loss of 3-phase power will
shut down the QuantumHD panel and it will reboot upon
proper power return. If the panel was in Auto, it will come
back and return to running as programmed. If the unit was
in Remote, the external controller will re-initialize the
panel and proceed to run as required. If the panel was in
Manual mode, the compressor will have to be restarted
manually after the 3-phase bus fault/interruption has been
cleared / restored.
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
are the problem, then a constant voltage (CV) transformer
with a noise suppression feature is recommended. Johnson
Controls, Inc. can provide these types of transformers for
this purpose. Contact Johnson Controls for proper sizing (VA
Rating) based on the requirement of the job. If a phase loss
occurs, then you will typically get a high motor amp shutdown. If the problem continues, an analysis of the facilitys
power supply quality may be necessary.
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 (NOV 14)

Page 56
Forms

FORMS
OPERATING LOG SHEET

FORMS
070.410-IOM (NOV 14)

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.
Mechanical Checks
__ Package installed according to Frick publication

070.210-IB, Screw Compressor Foundations.
__ Confirm that motor disconnect is open
__ Isolate suction pressure transducer
__ Pressure test and leak check unit
__ Evacuate unit
__ Remove compressor drive coupling guard
__ Remove coupling center and do not reinstall

(motor rotation must be checked without center)
__ Check for correct position of all hand, stop, and check
valves prior to charging unit with oil or refrigerant
__ Charge unit with correct type and quantity of oil
__ Lubricate electric drive motor bearings PRIOR to
checking motor rotation
__ Check oil pump alignment (if applicable)
__ Check for correct economizer piping (if applicable)
__ Check separate source of liquid refrigerant supply (if
applicable, liquid injection oil cooling)
__ Check water supply for water-cooled oil cooler (if applicable, water cooled oil cooling)
__ Check thermosyphon receiver refrigerant level (if applicable, thermosyphon oil cooling)
__ Check for proper pipe supports and correct foundation
__ Check to ensure ALL piping INCLUDING RELIEF VALVES
is completed
Electrical Checks
__ Package installed according to Frick publication

090.400-SB, Proper Installation of Electrical
Equipment In An Industrial Environment.
__ Confirm that main disconnect to motor starter and micro
is open
__ Confirm that electrical contractor has seen this sheet,
all pertinent wiring information, and drawings
__ Confirm proper power supply to the starter package
__ Confirm proper motor protection (breaker sizing)
__ Confirm that all wiring used is stranded copper and is
14 AWG or larger (sized properly)
__ Confirm all 120 volt control wiring is run in a separate
conduit from all high voltage wiring
__ Confirm all 120 volt control wiring is run in a separate
conduit from oil pump and compressor motor wiring
__ Confirm no high voltage wiring enters the micro panel
at any point
__ Check current transformer for correct sizing and installation
__ Check all point-to-point wiring between the micro and
motor starter
__ Confirm all interconnections between micro, motor
starter, and the system are made and are correct
__ Ensure all electrical panels are free from installation
debris, METAL PARTICLES, and moisture
After the above items have been checked and verified:

__
__
__
__
__
Close the main disconnect from the main power supply to the motor starter
Close the motor starter disconnect to energize the micro
Manually energize oil pump and check oil pump motor rotation
Leave micro energized to ensure oil heaters are on and oil temperature is correct for start-up
DO NOT energize compressor drive motor ! This should only be done by authorized Factory Field Service Technicians.
Summary: The Frick Field Service Supervisor should arrive to find the above items completed. He should find an uncoupled
compressor drive unit (to verify motor rotation and alignment) and energized oil heaters with the oil at the proper standby
temperatures. Full compliance with the above items will contribute to a quick, efficient and smooth start-up.
The Start-up Supervisor will:

1. Verify position of all valves
2. Verify all wiring connections
3. Verify compressor motor rotation
4. Verify oil pump motor rotation
5. Verify the % of FLA on the micro display
6. Verify and finalize alignment (if applicable)

7. Calibrate slide valve and slide stop
8. Calibrate temperature and pressure readings
9. Correct any problem in the package
10. Instruct operation personnel
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.
Frick Sales Order Number:_______________________
Compressor Model Number:______________________
Unit Serial Number:_____________________________
End User Name:_ _______________________________
Address of Facility:______________________________
City, State, Zip: _________________________________
Print Name:____________________________________
Company:______________________________________
Job Site Contact:________________________________
Contact Phone Number:_________________________
Signed: _ ______________________________________
070.410-IOM (NOV 14)

Page 58

FORMS
Start-up Report
Frick Order No:_________________________
Sold To:_ _______________________________________ Contact Name:__________________________ Date:__________________

End User:_______________________________________ Contact Name:__________________________ Phone:__________________
End User Address:_ ______________________________________________________________________ Fax No:__________________
City, State, Zip:__________________________________ Start-up Representative_ _________________
Unit General Information

Unit Model #____________________________________________ Customer Package Identification #_ _________________________
Compressor Serial #______________________________________ Separator National Board #_________________________________
Unit Serial #_____________________________________________ Oil Cooler National Board #_ _______________________________
Evaporator National Board #________ Serial #________________ Condenser National Board #_________ Serial #________________
Oil Pot National Board #__________________________________ H.P. Receiver National Board #_______
Economizer National Board #______________________________ Suction Accumulator National Board #_______________________
Refrigerant_______________ Oil Filters_________________ Lube Oil Type__________
Design Operating Conditions
Oil Cooling _ _____________________________________
___________ 0 Suct. /__________ 0 Disch.
Micro Information
Micro Type_________________________ Program Software Ver #________ and Date___________ UL Serial # __________________
Digital I/O Board #1 Serial #__________________________________ Software Ver #___________ and Date ____________________
Digital I/O Board #2 Serial #__________________________________ Software Ver #___________ and Date ____________________
Analog Board #1 Serial #_____________________________________ Software Ver #___________ and Date ____________________
Analog Board #2 Serial #_____________________________________ Software Ver #___________ and Date ____________________
Compressor Motor Starter / Drive Information

Manufacturer ___________________________ Part #____________________ Model # ______________________
Starter Type_____________________________ Serial #__________________________
Input Voltage_______________ Voltage Range____________ Phase______________ Hz_ _____________ Current_____________
Output Voltage_________ Phase_________ Hz ________ Max FLA _________Max LRA ______ Min Load FLA_ ____ Job FLA_ _____
Logic Board Serial #___________________ U33 Prog. Ver._________ Date_ ___________P/N ________________________

U34 Prog. Ver._________ Date_ ___________P/N ________________________

U45 Prog. Ver._________ Date ____________P/N ________________________
Harmonic Filter Serial #____________________ Prog. Ver._________ Date ____________P/N ________________________
Frick Interface Serial #_____________________ Prog. Ver._________ Date ____________P/N ________________________
CT Location Checked CT Phase_______ CT Ratio_______ Transition Time__________ DBS Ver.#_ _____________
Oil Pump Information

Pump Mfg.____________ Model #__________ Serial #_________________ Motor Mfg.______________ H.P._________________
Motor RPM___________ Service Factor_______ Volt________ HZ_______ FLA_ _____ Design _____ Code______ Starter Size_______
Cooling Fan Information

Motor HP_______ RPM__________ Service Factor____________ Volt________ Hz_ _________ FLA_ _______ Cooling Fans________
Special Options
_______________________
____________________________
__________________________
_________________________
Prestart Checks
Installation, Foundation
Compressor PHD Setup
Coolant Installed
Position of all valves
Motor PHD Setup
4-20 Coolant Loop Pump Setup
Proper oil charge
Motor Winding RTDs Setup
Coolant Loop Temp Setup
All wiring connections
Motor Bearing RTDs Setup
Cooling Fan Motor I/O Setup
Starter Cleanliness
Motor Temperature Thermistor Setup
Cooling Fan Rotation Checked
All micro settings
4-20 Motor Drive Signal Calibrated
Oil pump motor rotation
4-20 CT Channel 16 Setup
Cold alignment
Motor rotation
4-20 Output Calibration Liquid Makeup Valve, Coolant Temp Valve, Economizer Makeup Valve
Configuration
Capacity
Channel
Mode 1______________
___________
Mode 2______________
___________
Mode 3______________
___________
Mode 4______________
___________
VFD Hi & Low PI Control
___________
Miscellaneous
Sequencing
________________
Condenser
________________
Screen Saver ________________
Direction
____________
____________
____________
____________
____________
Package
Compressor _______________
Pump _______________
Dual Pump _______________
Drive ____________________________
Refrigerant ___________ K-Factor__________
Filter______________________________
PowerPac_____________

FORMS
Page 2
070.410-IOM (NOV 14)

Page 59
Unit Serial #______________________________ Frick Order No:_____________________________
Capacity Control Setpoints

Setpoint
Regulation Safeties

High
Low
Load Inhibit_ ________
Prop. Band
_________ ________ Force Unload_________
Dead Band
_________ ________
Warning___________
Cycle Time
_____ Sec _____ Sec Warning Delay____ Sec
VFD Prop Band _________ ________
Shutdown__________
VFD Integ. Time _____ Sec _____ Sec Shutdown Delay____ Sec

Channel
_ ________________________

Auto Cycle
Low Suction
Start
_ ________
Load Inhibit ___________
Start Delay _ ____ Min Force Unload ___________
Stop
_ ________
Warning ___________
Stop Delay _ ____ Min Warning Delay _______ Sec

Shutdown ___________

Shutdown Delay _______ Sec
Setpoint
Regulation Safeties
High
Low
Load Inhibit_ _________
Prop. Band
________ _________ Force Unload__________
Dead Band
________ _________
Warning____________
Cycle Time
_____Sec _____ Sec Warning Delay_____ Sec
VFD Prop Band ________ _________
Shutdown___________
VFD Integ. Time _____Sec _____ Sec Shutdown Delay_____ Sec
Channel
__________________________
Auto Cycle
Low Suction
Start
__________
Load Inhibit ___________
Start Delay ______ Min Force Unload ___________
Stop
__________
Warning ___________
Stop Delay ______ Min Warning Delay _______ Sec
Shutdown ___________
Shutdown Delay _______ Sec
Compressor Safeties

High Discharge Temperature
High Suction Pressure

Load Inhibit ________

Load Inhibit ________ PSIG

Force Unload ________

Force Unload ________ PSIG

Warning ________
Start Differential
Warning ________ PSIG
Warning Delay ________ Sec
Pressure Below
Warning Delay ________ Sec

Shutdown ________
50 PSI
Shutdown ________ PSIG
Shutdown Delay ________ Sec
Shutdown Delay ________ Sec
High Discharge Pressure
Dual Mode ________________
Economizer ________________
Regulation Modes 1 & 3 Modes 2 & 4
On When Above _______%
Load Inhibit
_____ PSIG
_____ PSIG
Off When Below _______%
Force Unload
_____ PSIG
_____ PSIG
Override Discharge Pressure ________
Warning
_____ PSIG
_____ PSIG
Port Value ________
Warning Delay
_____ Sec
_____ Sec
Pressure Input __________________
Shutdown
_____ PSIG _____ PSIG
Fixed Pressure Setpoint __________________
Shutdown Delay _____ Sec
_____ Sec

Maximum Discharge Pressure _ ______________ PSIG

Highest Cap. To Permit Start _ ______________ %
Balance Piston
Start Period Before Cap. Increase _ ______________
On _ ____ %
Stopping Period For Cap. Unload _ ______________
Off _ ____ %
Compressor Auto Mode Min. Cap. _ ______________ %
Ignore Delay _ ____ Min

Capacity Unload Assist. _ ______________ Rate_ __________%
Fail Delay _ ____ Min

Separator Velocity Ref. _ ______________
Oil Log_ _______________ Delay _______ Sec.

Compression Ratio _ ______________

Liquid Slug Warning _ ______________
Main Oil Injection On When Discharge Temperature

Liquid Slug Shutdown _ ______________
Is Above___________ F for_ _____ Sec
Package Safeties
Low Compressor Oil Temperature
Warning _ __________ Delay ______ Sec
Shutdown _ __________ Delay_______ Sec
High Compressor Oil Temperature
Warning _ ______ Delay________ Sec
Shutdown _ ______ Delay________ Sec
Low Compressor Oil Pressure
Warning _ ________ PSI Delay_________ Sec
Shutdown _ ________ PSI Delay_________ Sec
High Filter Pressure
Warning _ ________ PSI Delay_________ Min
Shutdown _ ________ PSI Delay_________ Min
Main Oil Injection________________________
Shutdown _ ________ PSI Delay_________ Sec

Oil Heater Off Above_ ________

High Level Shutdown Delay_ ________ Sec

Low Oil Level Delay_ ________ Sec
Oil Pump Lube Time Before Starting_ ________ Sec

Dual Pump Transition Time_ ________ Sec
Pull Down _______________________

Capacity Position _________ %
Amount of Time __________ Sec
Pump Down _____________________
On When Suction Above _____ PSIG Delay______ Min
DX Circuit
#1 Action________________________
Off When Below _ _______ %
On When Above _ _______ %
#2 Action _______________________
Off When Below__________ %
On When Above__________ %
Liquid Injection __________________
On When Above _ __________ Delay________ Sec
Dual Port Transition _________
Hot Gas Bypass __________ %
Power Assist __________ Sec
070.410-IOM (NOV 14)

Page 60
Page 3

FORMS
Unit Serial #______________________________ Frick Order No:_____________________________
Compressor Motor Setpoints and Information

Motor Name Plate
VFD

Motor Amps ____________
Maximum Drive Output____ %

Volts ____________
Minimum Drive Output ____ %
Service Factor ____________
Remote Control

Horsepower ____________
Rate Of Increase_________ % Delay_____ Sec

CT Factor ____________
Rate Of Decrease________ % Delay_____ Sec
Recycle Delay___________ Min
Capacity Control
High Motor Amps
When Slide Valve Reaches_ ________ %

Load Inhibit______________
Drive Speed Reaches _________ %
Force Unload__________
Variable Speed Min. Slide Valve Position _ _______ %

Warning________ Delay____ Sec
Skip Frequency Bands

Shutdown________ Delay____ Sec
Bottom
Top

_ _______
______
Low Motor Amps
_ _______
______
Shut Down_________ Delay_______ Sec
_ _______
______
Confirmed Running Motor Amps________
_ _______
______
Starting Motor Amps Ignore Period _________ Sec
_ _______
______
Manufacturer_________________
Frame Size_______________
H.P._____________________
RPM ____________________
Serial #__________________
Service Factor____________
Voltage__________________
Hz_ _____________________
Design __________________
Code____________________
Bearing Type_________________
Motor Coupling _ _____________
Vyper Coolant Setpoints

Vyper Standby Time_______

Vyper Coolant Low Temp. Alarm______ Delay_______ Shutdown_______ Delay_________

High Temp. Alarm______ Delay_______ Shutdown_______ Delay_________
PHD Monitoring Setpoints
Condenser Control
Compressor Bearing _____________
Condenser Control Setpoint ______________
Suction End
Delay
High Warning_______ gF______ Sec
High Shutdown_____ gF______ Sec

Motor Bearing _______________
Discharge End
Delay
High Warning_ _____ gF______ Sec
High Shutdown_____ gF______ Sec
Shaft Side
Delay
High Warning________ F______ Sec
High Shutdown______ F______ Sec

Motor Stator_ _________________

Stator 1
Delay
High Warning_______F_ ______ Sec
High Shutdown_____F_ ______ Sec

Stator 3
Delay
High Warning_______F_ ______ Sec
Opposite Shaft Side Delay

High Warning_ ______ F______ Sec
High Shutdown______ F______ Sec
Digital Controls
Module A
Module B
Module C
Module D
Step Order
________
________
________
________
Step Up Dead Band

_________ PSI
Step Up Delay
________ Sec
Step Down Dead Band _________ PSI
Step Down Delay
________ Sec
High Pressure Override _________ PSI
High Pressure Override Delay_ _____ Sec
Stator 2
Delay
High Warning_ _____F_ ______ Sec
Analog Controls Analog Output A ____________
Analog Output B ____________
Proportional Band _________ PSI
Integration Time ________ Sec
High Limit _________ PSI
Low Limit ________ Sec
Miscellaneous
Remote Capacity Deadband________ %
High Compressor Oil Pressure _________________
Shutdown______PSI Delay _____ Sec
Max Slide Valve Timer________ 1/10 Sec

Max Discharge Pressure ____________ PSI
Max Discharge and Oil Temp_ ________F

FORMS
Page 4
070.410-IOM (NOV 14)

Page 61
Unit Serial #_________________ Frick Order No: __________________________________________
P&ID Setpoints
Name
Control
Action
Control Point
Device Source
Device Channel
Setpoint
Dead Band
Prop. Band
Integral Gain
_________________ __________
____________
____________
____________
____________
__________________
______________
__________
______
____________
____________
____________
____________
____________
____________
____________
____________
_________________
____________
____________
__________________
______________
______
____________
____________
____________
____________
__________
____________
____________
__________
____________
____________
____________
____________
Communications
Compressor ID_______
Comm 1
Baud Rate__________
Data Bits __________
Stop Bits __________
Parity _____________
RS 485 Connection________
Protocol ___________
Comm 2
Baud Rate ___________
Data Bits_____________
Stop Bits ____________
Parity _______________
Protocol __________
Comm 3
Baud Rate____________
Data Bits_____________
Stop Bits_____________
Parity_______________
Protocol ___________
Use Map File_________
Ethernet
IP Data
Address Type
__________
IP Address
__________
Gateway Address __________
Subnet Mask
__________
Web Server Port __________
Naming Data
Host Name___________
Work Group__________
Comments___________
Protocols
ModBus TCP_ ________
Ethernet I/P__________
Profinet______________
070.410-IOM (NOV 14)

Page 62

FORMS
VIBRATION DATA SHEET

___________________________________________
Date:
End User:
Sales Order Number:_________________________________
________________________________________
Address: ___________________________________________
Equipment ID (As in Microlog):
Installing Contractor:_________________________________

Service Technician:___________________________________
_____________________
Compressor Model Number:___________________________

Compressor Serial Number:_ __________________________
Compressor Serial Number:_ __________________________
Unit Serial Number:_ _________________________________
National Board Number:_ _____________________________
Running Hours:______________________________________
Manufacturer and Size of Coupling:_____________________
Motor Manufacturer: RAM_____________________________
Motor Serial Number:_________________________________
RPM:_________ Frame Size:____________ H.P.___________
Refrigerant:
Ambient Room Temperature: _____________F
Operating Conditions:
SUCTION
DISCHARGE
OIL
SEPARATOR
Press
Press
Press
Temp
Temp
Temp
Compressor Outboard
(Noncoupled End)
Axial Direction
____.____ IPS Overall
Compressor
Outboard
Vertical Direction
____.____ IPS (Male)
____.____ IPS (Female)
Compressor Inboard
(Coupling End Center)
Vertical Direction
Compressor Inboard
(Jackshaft)
Horizontal Direction
Temp
Slide Valve Position

F
V.I. Ratio
F.L.A.
Motor Inboard (Coupled End)

Horizontal _______ . ______ IPS Overall
Vertical _______ . ______ IPS Overall

Axial _______ . ______ IPS Overall
Motor Outboard (Noncoupled

Horizontal _______ . ______
Vertical _______ . ______

Axial _______ . ______
End)
IPS Overall
IPS Overall
IPS Overall

Notes
070.410-IOM (AUG 14)

Page 63
070.410-IOM (AUG 14)

Page 64

Notes

INDEX
070.410-IOM (NOV 14)

Page 65
Index
Symbols
3-phase ground, 53
3-phase supply, 53
B
Back Flushing, 9
Bleed Valve, 25
Booster Applications, 15
Brownouts, 13
C
Cable Trays, 53
Carbon Graphite Bushings, 27, 28, 29
Chemical Cleaning Process, 9
CH Coupling Data Table, 6
Clamping Bolts, 7
Closed-Loop Fluids, 9
Closed-Loop System, 9
Coalescer, 15
Coalescer Filter Element, 8
Codes, 53
Cold-Start Valve, 14
Comm Port, 55
Comm Port Protection, 55
Communications, 55
Compressor
Discharge, 15
Motor, 11
Compressor Motor Starter, 12
Compressor Port Locations

RXF 12 - 19, 38

RXF 24 - 50, 39

RXF 58 - 101, 41
Compressor Prestart Checklist, 57
Compressor Shaft, 6, 14
Compressor Unloading, 15
Compressor Volume Ratio, 15, 16
Conduit, 53
Cone/Button, 8
Constant Speed Starters, 53
Constant Voltage (Cv) Transformer, 55
Control Power Regulator, 13
Cooling Tower Water, 9
Cooling Water, 9
CoolWare, 21
coupling, 11
Current Transformer, 12
Cutout Parameters, 15
D
Daisy-Chaining, 55
Demand Pump
Bearing Retainer Washer, 28
Bearings, 28
Bearing Spacer, 27
Carbon Graphite Bushings, 29
Casing, 27, 29
End Clearance, 29
Head, 27
Idler, 27
Idler Pin, 27
Locknut, 27
ORing Gasket, 29
Pump, 28
Pump Head, 27, 29
Refrigeration Oil, 28
Rotor, 28, 29
Rotor Hub, 28
Rotor Shaft, 29
Rotor Teeth, 29
Seal, 28
Seal Housing Bore, 28
Seal Seat, 28
Seal Spring, 29
Snap Ring, 27
Spring, 28, 29
Tapered Installation Sleeve, 29
Thrust-Bearing Assembly, 28
Troubleshooting, 30
Air Leak, 30
Alignment, 30
Cavitation, 30
Discharge Port, 30
Discharge Pressure, 30
End Clearance, 30
Filter, 30
Foot Valve, 30
Gate Valve, 30
Head, 30
Misalignment, 30
Motor, 30
Motor Speed, 30
Pressure Gauge, 30
Pump, 30
Relief Valve, 30
Sheave Size, 30
Strainer, 30
Suction Line, 30
Suction Pipe, 30
Suction Port, 30
Vacuum Gauge, 30
Valve, 30
Vaporizing, 30
Vibrating, 30
Differential Pressure, 14
Direct Expansion Economizer System,
11
Direct Motor Drive, 6
Discharge Temperature, 21
Drive Hubs, 6
Dry Nitrogen, 7
DX Economizer, 10
E
Economizer
Back-Pressure Regulator Valve, 10
Balancing Load, 10
Check Valve, 10
DX Economizer, 10
Economizer Port, 10
Flashing Liquid, 10
Flash Vessel, 10
Isolation Valve, 10
Microprocessor, 10
Outlet Pressure Regulator, 10
Strainer, 10
Subcooling Liquid, 10
Elastomeric Gear, 6
EMI, 53
External Controller, 11
External Oil Cooling, 21
F
Filter Elements, 8
Flexible Drive Coupling, 6
Forklift, 6
Foundation, 3, 5, 14, 51, 56
Anchor Bolts, 5
Grout, 5
Housekeeping Pads, 5
I-Beams, 5
Pipe Supports, 5
Reinforced Concrete, 5
Vibration Expert, 5
H
Hand Expansion Valve, 21
Handling And Moving, 5
Crane, 5
Forklift, 5
Lifting Ring, 6
Rigging, 5
Hard Water Conditions, 9
Heat Exchanger, 9
Heat-Sink Paste, 9
High-Stage Operation, 14
Hydraulic System, 15
I
Initial Start-Up, 21
Inlet Service Valve, 24
J
Jack, 6
L
Liquid Carryover, 7
Liquid Injection, 9, 17
Analog Input Signal, 19
Danfossliquid Injection Valve, 18
Digital Input Signal, 19
Dual Dip Tube Method, 10
Enter Push Button, 18
High-Stage Units, 10
ICAD (Industrial Control Actuator
with Display), 18
ICM Valve, 19
Low Condensing Pressures, 10
Mod, 19
Motorized Industrial Control Valve,
18
070.410-IOM (NOV 14)

Page 66
Opening Degree, 19
Parameters, 18
Parameter List, 20
Analog Output Signal, 20
Automatic Calibration, 20
Digital Input Function, 20
Fail-Safe, 20
ICM Configuration, 20
Main Switch, 20
Mode, 20
Modulating Mode, 20
Old Alarms, 20
Password, 20
Solenoid Valve, 19
Liquid Injection Oil Cooling, 21
Liquid Injection Thermal Expansion
Valve, 21
Liquid Loading, 21
Liquid Refrigerant, 17
Liquid Starvation, 21
Low Voltage, 11
Lubrication System, 14
M
Magnetic Field, 53
Main Oil Injection Port, 15
Maintenance, 23
Abnormal Vibration, 31
Bare Compressor Mounting, 35
Bearing Failure, 23
Coalescer Filter Element, 26
DIN Connector Plug, 35
Discharge Service Valve, 26
Disconnect Power, 23
Disconnect Switches, 24
Drain Valve, 26
Dry Nitrogen, 23
Filter Elements, 32
Isolation Valves, 23
Leaks, 31
Linear Transmitter, 35
Liquid Injection Strainer, 25
Liquid Injection Valves, 23
Low Pressure Transducer, 24
Moisture, 32
Motor Bearings, 32
Lubrication, 32
Noise, 31
Nuisance Oil Level Cutouts, 26, 32
Oil-Charging Valve, 26
Oil Cooler, 26
Oil Filter Element, 26
Oil Filters, 24
Oil Foaming, 26
Oil Level Control, 35
Oil Level Transmitter, 35
Oil Pressure Loss, 26, 32
Oil Pump Strainer, 25
Oil Quality, 32
Operating Log, 32

INDEX
P & I Diagram, 41
Pressure Sensors, 35
Pressure Transducers, 33
Conversion Data, 34
Replacement, 33
Testing, 33
Refrigerant Vapor, 24, 25
Refrigeration Oil, 32
Safety Equipment, 23
Sensor Well, 35
Service Valves, 24
Spin-On Oil Filter Element, 24
Starting Torque, 26
Strainer Elements, 26
Strainer Service Valves, 26
Suction Check Valve Bypass, 24, 26
Suction Service Valve, 26
Suction Strainer, 23
Suction Valve Bypass, 26
Superheat, 23
Temperature Sensor, 35
Temperature Transmitter, 34, 35
Troubleshooting. See Index,TROUBLESHOOTING
Ventilation, 23
Vibration Analysis, 32
Vibration Data Sheet, 62
Vibration Level, 23
Volume Ratio Control, 35
Water Vapor, 23
Wiring Harness, 50
Maintenance Schedule, 31
Maximum Oil Flow, 21
Mechanical, 57
Metal Conduit, 53
Microprocessor, 10, 17
Moments, 9
Motor, 11
Bearings, 21
Contactor, 11
Cycling, 11
Rotation, 6, 14
Motor Starter Contactor, 11
Mounting Bolts, 6
Movable Slide Valve, 15
Multiple Compressor Economizer
System, 11
N
Neoprene Drive Spacer, 6
Noise Suppression, 55
O
Dual Oil Filters, 24
Main Oil Filter, 24
Oil Charge Reservoir, 15
Oil Cooling
Liquid Injection, See "Liquid Injection" On Page 65
Thermosyphon, See "Thermosyphon Oil Cooling" On Page 67
Oil Distillers, 7
Oil Filter, 8
Oil Heaters, 7
Operating Volume Ratio, 17
Optical Isolation, 55
O-Ring Compression, 40
P
pH, 9
Power Feed, 53
Power Fluctuations, 13
Pressure Differential, 15
Proper Installation of Electronic Equipment, 51
PVC-Coated Metallic, 53
PVC conduit, 53
Q
QuantumHD, 11, 15, 55
R
Reboot, 55
Recovery Procedure, 27
RXF Rotary Screw Compressor, 14
Moveable Slide Valve, 14
Shaft Seal, 14
S
Scaling, 9
SelfLubricating, 14
Separator, 6
Severe Water Conditions, 9
Shell And Coil Economizer System, 10
Shipping Gauges, 7
Shutdown, 23
Liquid Injection, 23
Package Valves, 23
Solenoid Valves, 23
Strainers, 23
Sight Glass, 7, 15, 27
Signal Wiring, 53
Single-Port Liquid Injection, 17
Skip Frequencies, 22
Slide Stop, 22
Slide Valve, 22
Slide Valve Piston, 15
Sola Constant Voltage (Cv) Transformer, 11
Solenoid Valve, 17
Star Networks, 55
Start-Up
Start-Up
Coolware, 21
Discharge Temperature, 21
Hand Expansion Valve, 21
Initial StartUp, 21
Prestart Checklist, 21
Theoretical Discharge Temperature,
21
Water Control Valve, 21

INDEX
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
Surge Suppression, 55
T
Temperature Sensor, 17
Thermosyphon Oil Cooling, 8, 17, 21
Condensing Pressure, 21
Drain Valve, 8
Refrigerant-Side Safety Valve, 8
Thermostatically Controlled Mixing
Valve, 8
Vapor Mixture, 21
Welding, 9
Threaded Metallic, 53
Threaded Pvc-Coated Metallic, 53
TROUBLESHOOTING, 3637
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
W
Water Control Valve, 21
Water-Cooled Oil Cooling, 17
Water Treatment, 9
Welding, 9
070.410-IOM (NOV 14)

Page 67
November 2014 Form Revisions

p.17 Replaced double acting solenoid valve with 3-way motorized valve text
p.31 Added PhD vibration analysis requirement text
p.65 Revised multiple index entries
Form 070.410-IOM 2014-11

Supersedes: 070.410-IOM 2014-08
Subject to change without notice
Published in USA PDF
2014 Johnson Controls Inc. - ALL RIGHTS RESERVED
Johnson Controls
100 CV Avenue
Waynesboro, PA 17268-1206 USA
Phone: 717-762-2121 FAX: 717-762-8624
www.jci.com/frick

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Form 070.

410-IOM (NOV 2014)

SERVICE MANUAL - Section 70

ROTARY SCREW COMPRESSOR UNITS

THIS MANUAL CONTAINS RIGGING, ASSEMBLY, START-UP,

Please check www.jci.com/frick for the latest version of this publication.

070.410-IOM (NOV 14)

RXF ROTARY SCREW COMPRESSOR UNITS

OIL FILTER, SPIN-ON (RXF 12 50)..................................24

RXF ROTARY SCREW COMPRESSOR UNITS

070.410-IOM (NOV 14)

Immediately upon arrival examine all crates, boxes, and

This manual has been prepared to acquaint the owner and

TRANSIT DAMAGE CLAIMS

It is recommended that the entering vapor temperature to

UNIT DATA PLATE

SAFETY PRECAUTION DEFINITIONS

070.410-IOM (NOV 14)

RXF ROTARY SCREW COMPRESSOR UNITS

COMPRESSOR DATA PLATE

Month: A = JAN, B = FEB, C = MAR, D = APR, E = MAY, F =

GEOMETRICAL SWEPT VOLUME TABLE

RXF ROTARY SCREW COMPRESSOR UNITS

070.410-IOM (NOV 14)

disconnected from the compressor. See table for Allowable

ALLOWABLE FLANGE LOADS

Proper foundations and proper installation methods are vital;

HANDLING and MOVING

070.410-IOM (NOV 14)

RXF ROTARY SCREW COMPRESSOR UNITS

The unit can be moved with a forklift by forking through

unit mounting supports to the skid before lowering the unit

Spreader bars may be required on both the length and

1. Inspect the shaft of the motor and compressor to ensure

CH Coupling Data Table

Between Shaft Spacing

RXF ROTARY SCREW COMPRESSOR UNITS

HOLDING CHARGE and STORAGE

070.410-IOM (NOV 14)

Add oil by attaching the end of a suitable pressure type

All units must be kept in a clean, dry location to prevent

Figure 3 - Oil Drain Valve

070.410-IOM (NOV 14)

RXF ROTARY SCREW COMPRESSOR UNITS

SUCTION ISOLATION VALVE MOUNTING

The liquid level in the refrigerant source must be 6 to 8 feet

Figure 5 - Thermosyphon Oil-Cooled System

THERMOSYPHON OIL COOLING

6. An angle valve should be installed in the piping before the

RXF ROTARY SCREW COMPRESSOR UNITS

WATER-COOLED OIL COOLING

070.410-IOM (NOV 14)

Johnson Controls-Frick recommends a closed-loop system

Figure 6 - Application of heat-sink paste before welding

Figure 7 - Maximum static forces and moments

LIQUID INJECTION OIL COOLING

LIQ. LINE SIZE*

No oil heat of rejection

CONDITIONS: High Stage at 0F Evap, and 95F Cond, 10F