070.610-Iom Rwfii 2021-07

Form 070.
610-IOM (JUL 2021)

Installation–Operation–Maintenance
File: Service Manual – Section 070
Replaces: 070.610-IOM (MAR 2020)
Distribution: 3, 3a, 3b, 3c
RWF II
Rotary Screw Compressor
All Refrigerants
Models 100 to 1080
This manual contains installation, operation, 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 incorrect operation.
Check www.FrickCold.com for the latest version of this publication.

070.610-IOM (JUL 21) RWF II Rotary Screw Compressor Units
Page 2 Installation - Operation - Maintenance
Table of Contents
General information Suction check valve power assist kit................................ 31
Preface............................................................................... 3 Balance piston pressure regulator.................................... 31
Design limitations............................................................... 3 Initial start-up.................................................................. 31
Job inspection.................................................................... 3 Initial start-up procedure................................................. 31
Transit damage claims........................................................ 3 VFD skip frequencies........................................................ 32
Unit identification............................................................... 3 Normal start-up procedure.............................................. 32
Compressor identification.................................................. 4 Maintenance
Installation General information......................................................... 33
Foundation......................................................................... 5 Normal maintenance operations...................................... 33
Rigging and handling.......................................................... 5 General maintenance....................................................... 33
Skid removal...................................................................... 6 Compressor shutdown and start-up................................. 33
Compressor/motor coupling installation............................. 6 General instructions for replacing compressor unit
Oil pump coupling.............................................................. 7 components.............................................................. 33
Holding charge and storage............................................... 7 Oil filter (OF‑1) cartridge style......................................... 34
Piping connections............................................................. 8 Strainer – demand oil pump............................................. 35
Strainer – liquid injection................................................. 35
Compressor unit oil............................................................ 8
Coalescer filter element................................................... 35
Oil charge........................................................................... 8
Changing oil..................................................................... 36
Oil heaters......................................................................... 8
Demand pump disassembly.............................................. 36
Oil filters............................................................................ 9
Demand pump assembly.................................................. 37
Suction valve mounting...................................................... 9
Thrust bearing adjustment............................................... 38
Thermosyphon oil cooling.................................................. 9
Installing carbon graphite bushings.................................. 39
Liquid injection oil cooling - optional............................... 10
Troubleshooting the demand pump.................................. 39
Water or glycol oil cooling - optional............................. 11
Maintenance schedule...................................................... 40
High-stage economizer - optional................................... 11
Preventive maintenance................................................... 40
Economizer load balancing............................................... 13
Maintenance program...................................................... 41
Economizer Vi control...................................................... 13
Vibration analysis............................................................. 41
Economizing with VSDs.................................................... 13
Oil quality and analysis..................................................... 42
Electrical.......................................................................... 13
Oil sampling procedure.................................................... 42
Motor starter package...................................................... 14
Operating log................................................................... 42
Current transformer (CT) ratios........................................ 15
Motor bearings................................................................. 42
Installation of electronic equipment in
Relubrication interval and instructions –
an industrial environment......................................... 16
WEG electric motor.................................................. 43
Minimum burden ratings.................................................. 16
Relubrication interval and instructions – Marathon ......... 43
Control power regulator................................................... 16
Grease compatibility......................................................... 44
Wire sizing....................................................................... 17
Troubleshooting guide...................................................... 44
Voltage source................................................................. 17
Abnormal operation analysis and correction.................... 44
Grounding........................................................................ 17
Servicing the cold-start valve.......................................... 45
VFD applications.............................................................. 18
EZ-CAL High pressure cut-out check valve test block...... 46
Conduit............................................................................ 19
Pressure transducers – testing......................................... 46
Wiring practices............................................................... 19
Pressure transducers – replacement................................ 47
Communications.............................................................. 21
Capacity linear transmitter – slide valve.......................... 47
UPS power and Quantum HD panels................................ 21
Volume ratio control transmitter – slide stop................... 47
Operation Temperature sensor......................................................... 48
Oil level transmitter......................................................... 48
Operation and startup instructions................................... 23
Troubleshooting the RWF II compressor........................... 50
SGC compressor............................................................... 23
Troubleshooting the demand pump system...................... 50
Compressor lubrication system........................................ 23
Troubleshooting the oil separation system....................... 51
No pump oil system......................................................... 23
Troubleshooting the hydraulic system.............................. 51
Demand pump oil system................................................. 24
Motor and bare compressor replacement........................ 52
Compressor oil separation system................................... 24
Shutdown due to improper oil pressure (high stage and
Cold-start system............................................................ 24
booster).................................................................... 52
Compressor hydraulic system.......................................... 25
SAE straight thread o-ring fittings assembly procedure... 52
Volume ratio control........................................................ 25
Compressor port locations............................................... 53
Compressor oil cooling systems....................................... 26
Piping and instrumentation diagrams............................... 61
Single-port liquid injection............................................... 26
Dual-port liquid injection................................................. 26 Forms
Quantum HD EZ-COOL Liquid injection adjustment
Operating log sheet......................................................... 66
procedure................................................................. 27
RWF II compressor prestart checklist............................... 67
Operation of Danfoss liquid injection valve...................... 28
Vibration data sheet......................................................... 72
Suction check valve bypass.............................................. 29
Low ambient operation.................................................... 29
RWF II Rotary Screw Compressor Units 070.610-IOM (JUL 21)
General Information Page 3
General information Job inspection

Immediately upon delivery examine all crates, boxes and
Preface exposed compressor and component surfaces for damage.
Unpack all items and check against shipping lists for any
This manual describes the installation, operation, and
discrepancy. Examine all items for damage in transit.
maintenance procedures of the Frick® RWF II Rotary
Screw Compressor Units.
For information about the functions of the Quantum™HD
Transit damage claims
control panels, communications, specifications, and wiring All claims must be made by consignee. This is an ICC
diagrams, see publication series 090.040-O, 090.040-M, requirement. Request immediate inspection by the agent
090.040-CS, and 090.040-SPC. of the carrier and be sure the correct claim forms are
executed.
It is most important that these units be properly applied
to an adequately controlled refrigeration system. Your Report damage or shortage claims immediately to Johnson
authorized Frick representative should be consulted for Controls Inc., Frick Sales Administration Department, in
their expert guidance in this determination. Waynesboro, PA.
Proper performance and continued satisfaction with these

units is dependent upon: Unit identification
Each compressor unit has 2 identification data plates. The
• Correct installation compressor data plate containing compressor model and
• Correct operation serial number is mounted on the compressor body. The
• Regular, systematic maintenance unit data plate containing unit model, serial number and
To ensure correct installation and application, select and Frick sales order number is mounted on the side of the
connect the equipment to a correctly designed and installed Quantum™ HD control panel.
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.
NOTICE
When inquiring about the compressor or unit, or order-
A refrigeration compressor is a vapor pump. To ensure
ing repair parts, provide the model, serial, and Frick
that it is not being subjected to liquid refrigerant carry-
sales order numbers from these data plates.
over it is necessary that refrigerant controls are carefully
selected and in good operating condition; the piping is Figure 1: Unit data plate
properly sized and traps, if necessary, are correctly ar-
ranged; 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; and that high side condensers are sized
within system and compressor design limits.
It is recommended that the entering vapor temperature
to the compressor be superheated to 10°F above the
refrigerant saturation temperature. This ensures 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 070.610-SED.
NOTICE
Trained personnel are required for handling and in-
stallation.
Safety precaution definitions

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious
DANGER injury.
Indicates a potentially hazardous situation or practice which, if not avoided, will result in death or
WARNING serious injury.
Indicates a potentially hazardous situation or practice which, if not avoided, will result in damage
CAUTION to equipment and/or minor injury.
NOTICE Indicates an operating procedure, practice, etc., or portion thereof which is essential to highlight.
Page 4 General Information
Compressor identification Rotary screw compressor serial numbers are defined by

the following information:
Each compressor has an identification data plate (see
below), containing compressor model and serial number Example: 10240A90000015Z
mounted on the compressor body. Plant Decade Month Year Global Additional
seq. no. remarks
Figure 2: Compressor data plate 1024 0 A 9 0000015 Z
Plant: 1024 = Waynesboro, 1153 = Monterrey
Month:
REFERENCE TABLE ON
SHEET 2 AND
A=NOTE
JAN,3 B = FEB, C = MAR, D = APR, E = MAY, F = JUN,
100 CUMBERLAND VALLEY AVENUE
WAYNESBORO, PA 17268 G = JUL, H = AUG, K = SEP, L = OCT, M = NOV, N = DEC.
Additional Remarks:
R = Remanufactured; REFERENCE M
ROTARY SCREW COMPRESSOR SHEET 1 OF P
MODEL NO. R1 = Rebuild;
SGXB2 4021 R2 = Rebuild Plus; SGXB2 4021
PART NO.
Z = Deviation from standard configuration.
REFERENCE
US2430129999900010 GENERATED BY SAP US2430125370500010 SHEET 2 AND
SERIAL NO.
10241A89999999R 10241A89999999R
MAX DRIVER SPEED MAX ALLOWABLE PRESSURE
RPM 3600 PSIG 600 BARG 41 3600 600 41
ASSEMBLED IN USA USA

REFERENCE TABLE
FROM FOREIGN AND DOMESTIC MATERIALS ASSEMBLY PL
ON SHEET 2
534C2933H01 534C2934H01
Table 1: Geometrical swept volume and displacement
COMPRESSOR OPERATES ON AND IS
COMPATIBLE WITH THE FOLLOWING
RWF II Compressor Rotor
REFRIGERANTS
Rotor Max Geo. swept volume Displacement
model model diameter speed drive shaft end 4150 rpm 3550 rpm 2950 rpm
R50, R134a, R170, R290, R404A, R410A, R507,
mmR717, R728,L/d
R513A, R600, R600A, R729, R744, rpm 534B2719
ft³/ rev (m³/rev) cfm (m³/h) cfm (m³/h) cfm (m³/h)
R1150, NATURAL GAS
100 - 591 (1,004) 491 (835)
SGC 1913 1.35 0.16653 (0.00472)
119 SS 691 (1,174) - -
193 4,500
134 - 788 (1,339) 655 (1,113)
SGC 1918 1.8 0.22204 (0.00629)
159 SS 921 (1,566) - -
177 COMPRESSOR OPERATES ON AND IS - 1,040 (1,767) 864 (1,469)
SGC 2313 1.35
COMPATIBLE WITH THE FOLLOWING 0.29301 (0.00830)
209 SS REFRIGERANTS 1,216 (2,066) - -
222 233
R290, R1270, NATURAL GAS 4,500 - 1,310 (2,225) 1,088 (1,849)
SGC 2317 1.7 0.36897 (0.01045)
534B2720
264 SS 1,531 (2,602) - -
270 SGC 2321 2.1 0.45580 (0.01291) - 1,618 (2,749) 1,345 (2,285)
316 - 1,864 (3,167) 1,549 (2,631)
SGC 2813 1.35 0.52501 (0.01487)
375 SS 2,179 (3,702) - -
399 - 2,347 (3,988) 1,950 (3,314)
SGC 2817
COMPRESSOR283 1.7AND IS
OPERATES ON 4,200 0.66113 (0.01872)
472 SS COMPATIBLE WITH THE FOLLOWING 2,744 (4,662) - -
480 SGC 2821
REFRIGERANTS 2.1 0.79546 (0.02253) - 2,824 (4,798) 2,347 (3,987)
546 SGC 2824
R22 2.4 0.90402 (0.02560) - 3,209 (5,453) 2,667 (4,531)
496 SGCH/B 3511 1.1 534B2721
0.82248 (0.02329) - 2,920 (4,961) 2,426 (4,122)
676 SGCH/B 3515 1.5 1.12154 (0.03176) - 3,981 (6,765) 3,309 (5,621)
SGCH/B 3519 355 3,600
856
SGXH/B 3519
1.9 1.42748 (0.04042) - 5,068 (8,610) 4,211 (7,155)
1080 SGXH 3524 COMPRESSOR SHAFT 2.4 1.80328 (0.05106) - 6,402 (10,876) 5,320 (9,038)
852 SGXH 4013 1.3
Note: SS indicates a super speed model.
1.41180 (0.03998) - 5,012 (8,515) 4,165 (7,076)
1179 SGXH 4018 408 1.8 3,600 1.95481 (0.05535) - 6,940 (11,790) 5,767 (9,798)
1395 SGXH 4021 2.1 2.31320 (0.06550)
534B2722 - 8,212 (13,952) 6,824 (11,594)
CLOCKWISE ROTATION
Installation Page 5
Installation a combination of both, to prevent the transmission of

compressor vibration directly to the structure. However,
this may increase package vibration levels because the
Foundation compressor is not in contact with any damping mass. The
If the RWF II Rotary Screw Compressor unit is shipped mounting and support of suction and discharge lines is
mounted on a wood skid, it must be removed before also very important. Rubber or spring pipe supports may
installing the unit. be required to avoid exciting the building structure at any
pipe supports close to the compressor package. It is best
WARNING to employ a vibration expert in the design of a proper
mounting arrangement.
Allow space for servicing the unit per factory draw-
ings. In any screw compressor installation, suction and dis-
charge lines should be supported in pipe hangers (prefer-
The first requirement of the compressor foundation is that ably within two feet of vertical pipe run) so that the lines
it must be able to support the weight of the compres- won’t move if disconnected from the compressor. See
sor package including coolers, oil, and refrigerant charge. Table 2.
Screw compressors are capable of converting large quan-
tities of shaft power into gas compression in a relatively Table 2: Allowable flange loads
small space and a mass is required to effectively dampen Nozzle Moments (ft-lbf) Load (lbf)
these relatively high-frequency vibrations. size Axial Vert. Lat. Axial Vert. Lat.
Firmly anchoring the compressor package to a suitable NPS MR MC ML P VC VL
foundation by proper application of grout and elimina- 1 25 25 25 50 50 50
tion of piping stress imposed on the compressor is the 1.25 25 25 25 50 50 50
best insurance for a trouble-free installation. Use only 1.5 50 40 40 100 75 75
2 100 70 70 150 125 125
the certified general arrangement drawings from Frick
3 250 175 175 225 250 250
to determine the mounting foot locations and to allow
4 400 200 200 300 400 400
for recommended clearances around the unit for ease of 5 425 400 400 400 450 450
operation and servicing. Foundations must be in compli- 6 1,000 750 750 650 650 650
ance with local building codes and materials should be of 8 1,500 1,000 1,000 1,500 900 900
industrial quality. 10 1,500 1,200 1,200 1,500 1,200 1,200
The floor must be a minimum of 6 inches of reinforced 14 2,000 1,800 1,800 1,700 2,000 2,000
concrete and housekeeping pads are recommended. Consult a licensed architect to determine the proper foun-
Anchor bolts are required to firmly tie the unit to the dation requirements for any large engine or turbine drive.
floor. After the unit is rigged into place (see Rigging and
handling), the feet must then be shimmed in order to level When applying screw compressors at high pressures, the
the unit. The shims should be placed to position the feet customer must be prepared for package vibration and
roughly one inch above the housekeeping pad to allow noise higher than the values predicted for normal refrig-
room for grouting. An expansion-type epoxy grout must eration duty. Proper foundations and proper installation
be worked under all areas of the base with no voids and methods are vital; and even then, sound attenuation or
be allowed to settle with a slight outward slope so oil and noise curtains may be required to reduce noise to desired
water can run off of the base. levels.
When installing on a steel base, the following guidelines For more detailed information on screw compressor foun-
should be implemented to properly design the system dations, refer to 070.210-IB.
base:
1. Use I-beams in the skid where the screw compres-
Rigging and handling
sor will be attached to the system base. They should run
parallel to the package feet and support the feet for their WARNING
full length. This screw compressor package may be
2. The compressor unit feet should be continuously welded top-heavy. Use caution in rigging and
to the system base at all points of contact. handling. Improper handling could result in
3. The compressor unit should not be mounted on vibra- serious injury or death.
tion isolators in order to hold down package vibration
levels.
4. The customer’s foundation for the system base should
WARNING
fully support the system base under all areas, but most Package may contain oil. The center of gravity may
certainly under the I-beams that support the compressor shift during rigging and handling. Mishandling or im-
package. proper installation can cause serious injury or death.
When installing on the upper floors of buildings, extra Oil is flammable. Avoid sources of ignition including
precautions should be taken to prevent normal package welding, sparks, stray currents, and static.
vibration from being transferred to the building structure.
It may be necessary to use rubber or spring isolators, or
Page 6 Installation
The unit can be moved with rigging, using a crane and Compressor/motor coupling
spreader bar, by hooking into the four lifting eyes on the
oil separator. If a motor is mounted, appropriate adjust-
installation
ment in the lifting point should be made to compensate The RWF II unit has compressor to motor alignment
for motor weight. Adjustment of the lifting point must also through the use of a machined cast iron tunnel. This tun-
be made for any additions to the standard package such as nel is factory set through machining tolerances ensuring
an external oil cooler, etc., because the center of balance motor compressor alignment. No alignment is required in
will be affected. Refer to supplied engineering drawings to the field. See Figure 4.
determine the package center of gravity. Figure 4: BP coupling diagram
The unit can be moved with a forklift by forking under the
skid, 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.
Skid removal
If the unit is rigged into place, the skid can be removed
by taking off the nuts and bolts that are fastening the 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 BP coupling installation procedure
the skid. Using a 10-ton jack under the separator raise the 1. Install the motor and compressor coupling hubs and
unit at the compressor end until it clears the two mounting keys on their respective shafts. Ensure that they can slide
bolts. Spread the skid to clear the unit mounting support, horizontally so Figure 5: BP coupling
then lower the unit to the surface. Repeat procedure on that once the
opposite end. Check the motor/compressor rotation. disc packs are
installed, no axial
WARNING stress is trans-
ferred to the disc
Make sure coupling hubs are tightened to the shaft
packs by a stuck
before rotating the motor to prevent them from flying
coupling hub.
off and possibly causing serious injury or death.
Use no lubri-
cants.
WARNING 2. Rotate both
Injury may occur if loose clothing, etc, becomes en- hubs so that the
tangled on the spinning motor shaft. keys are 180° op-
posed. With the hubs mounted and the axial spacing set,
proceed to place the spacer between the two hub flanges.
Compressor rotation is Figure 3: Direction of rotation Care should be taken when handling the spacer. Be sure
clockwise when facing the spacer is fully supported at this time. Damage to the
the end of the compressor unitized flex discs may result after they have been installed
shaft. Under no conditions if the spacer is not fully supported.
should the motor rota-
tion be checked with the Install the unitized flex disc. Start a bolt through a bolt
coupling center installed as hole in the spacer. Put the unitized flex disc between
damage to the compressor the hub and spacer until a bushing hole in the unitized
may result. Bump the motor flex disc lines up with the bolt. Slide the bolt through the
to check for correct compressor rotation. After verifica- bushing hole in the unitized flex disc. To avoid thread
tion, install disc drive spacer (metal center section or damage, ensure that every other bolt is installed in the
elastomeric gear) as applicable. opposite direction as shown in the photo.
Table 3: BP series coupling data table

BP Disc pack locknut Hub clamping bolts Keyway setscrew
series Torque (lube*) Size UNF Torque Size UNF Torque Size NC
size ft-lb N.m ft-lb N.m ft-lb N.m
BP 38 17 23.1 5/16-24 41 55.6 3/8-24 22 29.8 3/8-16
BP 43 40 54.2 7/16-20 41 55.6 3/8-24 22 29.8 3/8-16
BP 48 40 54.2 7/16-20 41 55.6 3/8-24 53 71.9 1/2-13
BP 53 60 81.4 1/2-20 66 89.5 7/16-20 53 71.9 1/2-13
BP 58 120 162.7 5/8-18 101 137.0 1/2-20 53 71.9 1/2-13
BP 63 120 162.7 5/8-18 101 137.0 1/2-20 186 252.2 3/4-10
Installation Page 7
Install the locknut until it is snug. Make sure that all bolt 1. Inspect the shaft of the motor and compressor to en-
threads are clean and lightly oiled. Do not torque any lock- sure that no nicks, grease, or foreign matter is present.
nuts at this time. Now pivot the unitized flex disc until the
other bushing holes in the flex disc are in line with the bolt 2. Inspect the bores in the coupling hubs to make sure
holes in the spacer. Install the rest of the spacer bolts at that they are free of burrs, dirt, and grit.
this time. The remaining bolts for this end of the coupling 3. Check that the keys fit the hubs and shafts properly.
can be installed through the hub bolt holes and flex disc
bushing holes. 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
Install the unitized flex disc in the other end of the cou- to open the bore before the hubs will slide on the shafts.
pling. The unitized flex disc, as installed, should look flat
and parallel with the mating hub and spacer flanges. 5. Rotate both hubs so that the keys are 180° opposed.
Torque the disc pack locknuts as suggested in Table 3. 6. Hold the elastomeric gear between the hubs and slide
The bolts should be held in place while the locknuts are both hubs onto the gear to fully engage the mating teeth.
torqued. Center the gear and hub assembly so there is equal en-
gagement on both shafts. Note that the hubs may over-
3. Center the coupling between the shafts. Ensure that hang the ends of shafts. Adjust the face spacing between
the keys are fully engaged in their keyways. hubs as specified in the Table 4. Ensure that the keys are
4. Tighten the motor and compressor shaft clamping bolts fully engaged in their keyways.
evenly. Torque to the recommended specification in 7. Torque the clamping bolts in both hubs to the torque
Table 3. value given in the Table 4.
5. Torque the keyway setscrews as recommended in
Table 3. NOTICE
DO NOT USE ANY LUBRICANT ON THESE BOLTS.
NOTICE
Only after the shaft clamping bolts are tightened to 8. Torque the keyway setscrew in both hubs to the torque
their final torque can the keyway set screws be tight- value given in the Table 4.
ened. If the keyway set screws are tightened before
the shaft clamping bolts are tightened, then the hubs NOTICE
can be cocked on the shaft. Only after the shaft clamping bolts are tightened to
their final torque can the keyway set screws be tight-
CH Series coupling ened. If the keyway set screws are tightened before
the shaft clamping bolts are tightened, then the hubs
WARNING can be cocked on the shaft.
CH couplings are not to be used over 3600 rpm.

Oil pump coupling
Compressor units with direct motor/pump coupled pumps
Table 4: CH Series coupling data need no pump/motor coupling alignment since this is
CH Face Clamp bolt Keyway setscrew maintained by the close-coupled arrangement.
series spacing Torque (dry) Size Torque Size
Size
9
in.
17⁄16
mm
36.5
ft-lb N.m UNF
55 74.6 3⁄8-24
ft-lb N.m UNC
13 17.6 5
⁄16 -18
Holding charge and storage
10 111⁄16 42.9 130 176.3 ½ -20 13 17.6 5
⁄16 -18 Each RWF II compressor unit is pressure and leak tested
11 17⁄8 47.6 130 176.3 ½ -20 13 17.6 5
⁄16 -18 at the factory and then thoroughly evacuated and charged
with dry nitrogen to ensure the integrity of the unit during
shipping and short-term storage before installation.
CH coupling installation procedure
The CH Coupling is used in most applications. This cou- CAUTION
pling consists of two drive hubs and a gear-type Hytrel or Care must be taken when entering the unit to ensure
EDPM and neoprene drive spacer. The split hub is clamped that the nitrogen charge is safely released.
to the shaft by tightening
Figure 6: CH coupling
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/compres-
sor adapter housing on the
RWF II, no field alignment is
necessary.
Page 8 Installation
WARNING RWF II models

Table 5: Model charge
Basic charge* (gal)
Holding-charge shipping gauges on separator and 100, 119 SS, 134, 159 SS 45 or 50†
external oil cooler are rated for 30 PSIG and are for 177, 209 SS, 222, 264 SS 90
checking the shipping charge only. They must be re- 270, 316, 375 SS, 399, 472 SS 120
moved before pressure testing the system and before 480, 546 130
charging the system with refrigerant. Failure to re- 496 190
move these gauges may result in catastrophic failure 676, 856, 1080 220
of the gauge and uncontrolled release of refrigerant *Includes total in horizontal oil separator and piping. Add 5 gal. for oil cooler
up to Model 270, 10 gal. for 316 - 1080.
resulting in serious injury or death. †
For overall vessel length of 128 5⁄16 = 45 gal
For overall vessel length of 136 5⁄16 = 50 gal
All units must be kept in a clean, dry location to prevent
The normal charging level is midway in the top sight
corrosion damage. Reasonable consideration must be glass located midway along the oil separator shell. Nor-
given to proper care for the solid-state components of the mal operating level is midway between the top sight glass
microprocessor. Contact Frick service for long term stor- and bottom sight glass. The table gives the approximate
age requirements. oil charge quantity.
Piping connections Add oil by attaching the end of a suitable pressure type
hose to the oil drain valve located under the oil separator.
See the Foundation section for additional information. See Figure 7. Using a pressure-type pump and the recom-
mended Frick oil, open the drain valve and pump oil into
WARNING the separator.
Use caution and appropriate safety methods when
welding to a package that contains oil. NOTICE
Evacuation of the oil separator will assist the flow of
oil into the unit. Also, fill slowly because oil will fill
NOTICE up in the separator faster than it shows in the sight
glass.
Check and remove temporary end plates, sealing
discs, threaded plugs, and blind flanges on customer
connections before connecting piping. Figure 7: Oil drain valve
Compressor unit 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 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 re- Oil distillers and similar equipment which act to trap oil
frigerant, operating pressures, or temperatures, refer must be filled prior to unit operation to normal design
outlet levels. The same pump used to charge the unit can
to Frick Oil publication 160.802-SPC. be used for filling these auxiliary oil reservoirs.
Oil charge NOTICE

NOTICE The sight glass located in the coalescing end of the
separator near the discharge connection should remain
Oil may migrate from the wet sump area to the dry empty.
coalescer area during transportation and handling.
Prior to commissioning the compressor, check for any
oil migration. Oil transfer may be needed. Oil heaters
Standard units are equipped with one to three 1000 W
oil heaters, providing sufficient heat to maintain the oil
temperature for most indoor applications during shutdown
cycles to permit safe start-up. Should additional heating
capacity be required because of low ambient temperature,
contact Johnson Controls-Frick. The heaters are energized
only when the unit is not in operation.
Installation Page 9
Figure 8: Valve installation

WARNING
INCORRECT!
Do not energize the heaters when there is no oil in the
unit, the heaters will burn out. The oil heaters will be
energized whenever 120 V control power is applied to
the unit and the compressor is not running, unless the
16 amp circuit breaker in the micro enclosure is turned
off.
Oil filters
NOTICE
Use of filter elements other than Frick may cause
warranty claim to be denied.
The oil filter(s) and coalescer element(s) shipped with the

unit are best suited to ensure proper filtration and operation
of the system.
Suction valve mounting

The suction isolation valve is shipped loose from the fac- CORRECT!
tory, 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 Thermosyphon oil cooling
cone/button. See Figure 8. When the isolation valve is
Thermosyphon oil cooling is an economical, effective
installed in this position, uneven flow is generated across
method for cooling oil on screw compressor units. Ther
the suction check valve which is mounted at the inlet to
mosyphon cooling uses liquid refrigerant at condenser
the compressor. This uneven flow causes the disks in the
pressure and temperature that is partially vaporized at the
check valve to strike against the stop pin, and eventually
condenser temperature in a plate and shell vessel, cool-
damage the internals of the check valve. If the isolation
ing the oil to within 35°F of that temperature. The vapor,
valve is mounted at the compressor suction, do install
at condensing pressure, is vented to the condenser inlet
with flow across the cone/button. See Figure 8.
and reliquified. This method is the most cost effective of
A length of pipe (up to 12 in. long) must be installed all currently applied cooling systems since no compressor
between the weld neck flange and the stop valve. This capacity is lost or compressor power penalties incurred.
is necessary in order to provide sufficient room for bolt The vapor from the cooler need only be condensed, not
installation and removal during service. Please design your compressed. Refrigerant flow to the cooler is automatic,
system piping accordingly. driven by the thermosyphon principle and cooling flow
increases as the oil inlet temperature rises.
CAUTION Equipment - The basic equipment required for a ther
mosyphon system consists of:
After removing the suction sealing disc, confirm that
the check valve hinge pin is in the vertical position! If 1. A source of liquid refrigerant at condensing pressure
the hinge pin is not in a vertical position, then failure and temperature, located in close proximity to the unit
of the check valve may occur. to minimize piping pressure drop. The liquid level in the
refrigerant source must be 6 ft to 8 ft minimum above the
center of the oil cooler.
2. A plate and shell oil cooler with:
Plate Side: Oil 400 psi design
Shell Side: Refrigerant 400 psi design
Due to the many variations in refrigeration system design
and physical layout, several systems for assuring the above
criteria are possible.
Page 10 Installation
Figure 9: Thermosyphon receiver system

NOTICE
The component and piping arrangement shown in Fig-
ure 10 is intended only to illustrate the operating prin-
ciples of thermosyphon oil cooling. Other component
layouts may be better suited to a specific installation.
Refer to publication 070.900-E for additional informa-
tion on Thermosyphon Oil Cooling.
Figure 10: TSOC Piping Arrangement
System operation - Liquid refrigerant fills the cooler shell

side up to the Thermosyphon receiver liquid level.
Hot oil (above the liquid 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 pres-
sure that sustains a flow condition to the oil cooler. This 1. The thermosyphon oil cooler is supplied with oil side
relationship involves: piped to the compressor unit and stub ends supplied on
1. Liquid height above the cooler. the refrigerant side.
2. Oil heat of rejection. 2. A refrigerant-side safety valve is required in this loca-
3. Cooler size and piping pressure drops. tion only when refrigerant isolation valves are installed be-
Current thermosyphon systems are using two-pass oil tween the cooler and thermosyphon receiver. If no valves
coolers and flow rates based on 3:1 overfeed. are used between the cooler and TSOC receiver, the
safety valve on the TSOC receiver must be sized to handle
The liquid/vapor returned from the cooler is separated in the the volume of both vessels. Then, the safety valve on the
receiver. The vapor is vented to the condenser inlet and need cooler vent (liquid refrigerant side) can be eliminated.
only be reliquified because it is still at condenser pressure.
3. The system receiver must be below the thermosyphon
See Figure 9.
receiver in this arrangement.
Oil temperature control - Oil temperature will generally
run about 15 - 35°F above condensing temperature. In Liquid injection oil cooling -
many cases, an oil temperature control is not required if optional
condensing temperature is above 65°F as oil temperature
The liquid injection system provided on the unit is self-
can be allowed to float with condenser temperature.
contained but requires the connection of the liquid line,
Condensing Temperature: 65°F to 105°F sized as shown in Table 6.
Oil Temperature: 80°F to 140°F
It is imperative that an uninterrupted supply of high pres-
Installation - The plate-and-shell type thermosyphon oil sure liquid refrigerant be provided to the injection system
cooler with oil-side piping and a thermostatically con- at all times. Two items of extreme importance are the
trolled mixing valve are factory mounted and piped. The design of the receiver/liquid injection supply and the size
customer must supply and install all piping and equipment of the liquid line.
located outside of the shaded area on the piping diagram
It is recommended that the receiver be oversized
with consideration given to the following:
sufficiently to retain a 5-min supply of refrigerant for oil
1. The refrigerant source, thermosyphon or system cooling. The evaporator supply must be secondary to
receiver, should be in close proximity to the unit to mini- this consideration. Two methods of accomplishing this are
mize piping pressure drop. shown.
2. The liquid level in the refrigerant source must be 6 ft to
The dual dip tube method (see Figure 11) uses two dip
8 ft minimum above the center of the oil cooler.
tubes in the receiver. The liquid injection tube is below the
3. A safety valve should be installed if refrigerant isolation evaporator tube to ensure continued oil cooling when the
valves are used for the oil cooler. receiver level is low.
Installation Page 11
Figure 11: Dual dip tube Water or glycol oil cooling -

optional
The plate-and-shell type water or glycol oil cooler is
mounted on the unit complete with all oil piping. The
customer must supply adequate water connections. De-
termine the size of the oil cooler supplied with the unit,
as outlined on the Frick P&I diagram and general arrange-
ment drawings. The water or glycol supply must be
sufficient to meet the required flow.
The glycol or water entering temperature should be no
The level-control method (see Figure 12) uses a float level lower than 60°F.
control on the receiver to close a solenoid valve feeding
A closed-loop system is recommended for the water or
the evaporator when the liquid falls below that amount
glycol side of the oil cooler. Careful attention to water
necessary for 5 min of liquid injection oil cooling.
treatment is essential to ensure adequate life of the cooler
Figure 12: Level control if cooling tower water is used. It is imperative that the
condition of cooling water or glycol 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 sev-
eral times in the first 24 hours of operation.
In some applications, the plate and shell 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 perfor-
mance of the heat exchanger. A chemical cleaning process
Table 6: Liquid line size and receiver volume will extend the life of the plate-and-shell heat exchanger.
Refrigerant RWF II Min. Max. 5 min supply Heat load It is important to establish regular cleaning schedules.
model line Lbm/ lb ft3 kBtu/hr TR
size* min Cleaning: A 3% solution of phosphoric or oxalic acid is
100-134 0.75 16.0 80 2.2 506 42 suggested. You can obtain other cleaning solutions from
R-717
177-270 1 32.0 160 4.4 1016 85 your local distributor, but they must be suitable for stain-
316-399 1.25 46.6 233 6.3 1478 123 less steel. It is possible to clean the oil cooler in place by
high
480-546 1.25 63.8 319 8.7 2022 169
stage
676 1.25 82.4 412 11.2 2613 218
back flushing with suggested solution for approximately
856 1.5 105.2 526 14.3 3335 278 30 min. After back flushing, rinse the heat exchanger with
100-134 0.5 2.6 13 0.4 85 7 fresh water to remove any remaining cleaning solution.
177-270 0.5 4.9 25 0.7 162 14
R-717
316-399
480-546
0.5
0.75
7.2
9.9
36
50
1.0
1.3
237
326
20
27
High-stage economizer - optional
Booster
676 0.75 12.6 63 1.7 414 35 The economizer option provides an increase in system
856 0.75 16.2 81 2.2 531 44 capacity and efficiency by subcooling liquid from the
1080 1 21.0 105 2.9 688 57
condenser through a heat exchanger or flash tank before
100-134 1.25 51.3 257 4.1 221 18
177-270 1.5 102.6 513 8.3 441 37 it goes to the evaporator. The subcooling is provided by
R-507† flashing liquid in the economizer cooler to an intermediate
316-399 1.5 149.0 745 12.0 641 53
high
stage
480-546 2 203.8 1019 16.4 877 73 pressure level. The intermediate pressure is provided by a
676 2 266.9 1335 21.5 1149 96
port located part way down the compression process on
856 2 269.4 1347 21.7 1159 97
100-134 0.5 8.7 44 0.7 41 3 the screw compressor.
177-270 0.75 14.7 74 1.2 68 6
R-507† 316-399 0.75 21.4 107 1.7 99 8
As the screw compressor unloads, the economizer port
Booster 480-546 1 29.3 147 2.4 136 11 will drop in pressure level, eventually being fully open to
676 1 42.1 211 3.4 196 16 suction. Because of this, an output from the microproces
856 0.75 9.6 48 0.8 45 4 sor is generally used to turn off the supply of flashing
Conditions: HI Stage: 0°F Evap, and 95°F Cond, 10°F suc- liquid on a shell and coil or DX economizer when the
tion (line) superheat; Booster: -40°F Evap, 95°F Cond and capacity falls below approximately 60% to 70% capacity
20°F Intermediate, 10°F suction (line) superheat (85% to 90% slide valve position). This is done because
* Based on 100 foot liquid line. For longer runs, increase line the compressor will be more efficient operating at a higher
size accordingly. slide valve position with the economizer turned off, than
† Unloaded slide valve. it will at a low slide valve position with the economizer
turned on. Please note however that shell and coil and DX
economizers can be used at low compressor capacities in
cases where efficiency is not as important as assuring that
the liquid supply is subcooled. In such cases, the economi
zer liquid solenoid can be left open whenever the com
pressor is running.
Due to the tendency of the port pressure to fall with de For refrigeration plants employing multiple compressors on
creasing compressor capacity, a back-pressure regulator a common economizing vessel, regardless of economizer
valve (BPR) is generally required on a flash economizer sys- type, each compressor must have a back-pressure regulat
tem (see Figure 15) in order to maintain some preset pres- ing valve in order to balance the economizer load, or gas
sure difference between the subcooled liquid in the flash flow, between compressors. The problem of balancing load
vessel and the evaporators. If the back-pressure regula- becomes most important when one or more compressors
tor valve is not used on a flash economizer, it is possible run at partial load, exposing the economizer port to suction
that no pressure difference will exist to drive liquid from pressure. In the case of a flash vessel, there is no need for
the flash vessel to the evaporators, since the flash vessel the redundancy of a back-pressure regulating valve on the
pressure will approach suction pressure at a decreased vessel and each of the multiple compressors. Omit the BPR
slide valve position. In cases where wide swings in pres- valve on the flash economizer vessel and use one on each
sure are anticipated in the flash economizer vessel, it may compressor, as shown in Figure 16. It is also recommended
be necessary to add an outlet pressure regulator to the that the back-pressure regulating valves, used on econo-
flash vessel outlet to avoid overpressurizing the economizer lines, should be specified with electric shutoff option.
mizer port, which could result in motor overload. Example: The electric shutoff feature is necessary to prevent flow
A system feeding liquid to the flash vessel in batches. from the common economizer vessel to the suction side
of a stopped compressor, through the suction check valve
The recommended economizer systems are shown in Fig-
bypass line, if the other compressors and the common
ure 13 to Figure 16. Notice that in all systems there should
economizer vessel are still operating and the HV2 valve on
be a strainer (STR) and a check valve (VCK) between the
the suction bypass is open.
economizer vessel and the economizer port on the com-
pressor. The strainer prevents dirt from passing into the For refrigeration plants using a Packaged Refrigerant
compressor and the check valve prevents oil from flowing Recirculation Unit and a direct expansion (DX) economizer
from the compressor unit to the economizer vessel during system it is necessary to operate the liquid feed solenoid
shutdown. on the unit and the liquid feed solenoid on the DX vessel
off of a common signal to avoid liquid overfeed on the DX
CAUTION economizer system.
Other than the isolation valve needed for strainer If multiple compressors are operated with a common
cleaning, it is essential that the strainer be the last economizer vessel, it is necessary to install a back-pres-
device in the economizer line before the compressor. sure regulator valve with an electric shutoff option in the
The strainer must be strong enough to handle the gas vapor line piped to the compressor's economizer port.
pulsations from the compressor. Johnson Controls-
Frick recommends an R/S or Hansen strainer. Also, Figure 13: Shell and coil economizer system
piston-type check valves are recommended for instal-
lation in the economizer line, as opposed to disc-type SUCTION
check valves. The latter are more prone to gas-pul- INTERMEDIATE PRESSURE
sation-induced failure. The isolation and check valves HV-2 GAS TO COMPRESSOR
and strainer should be located as closely as possible ECONOMIZER

to the compressor, preferably within a few feet. STR VCK COOLER
HIGH
PRESSURE
SUBCOOLED LIQUID
HIGH PRESSURE
WARNING LIQUID TO
EVAPORATOR
Heat generated from compression could result in a

fire, serious injury or property damage. ECON1
Recompression of gas between the compressor side/ Figure 14: Direct expansion economizer system
economizer port and a check valve may occur during
low or no flow situations. This is common when an SUCTION
INTERMEDIATE PRESSURE
isolation or solenoid valve is closed upstream of the GAS TO COMPRESSOR HIGH
compressor port. Excessive heat will occur in this HV-2
PRESSURE
LIQUID
piping section.
STR VCK
Minimize the length of affected piping by installing a
check valve as close to the side/economizer port as
SUBCOOLED WIRING
possible. If this section of piping requires insulation, HIGH PRESSURE
then only high temperature insulation shall be used. LIQUID TO
EVAPORATOR
Trained technicians are required for servicing. ECONOMIZER

ECON2 COOLER
Figure 15: Flash economizer system Economizer Vi control

Based on suction and discharge pressures, the control
SUCTION
INTERMEDIATE PRESSURE panel calculates the proper volume ratio (Vi) for the com-
GAS TO COMPRESSOR
pressor. However, additional refrigerant vapor entering
HV-2
through the economizer port affects this calculation. If the
ECONOMIZER
VESSEL addition of economizer gas is not taken into account the
STR VCK BPR compressor will over-compress. This uses more energy
HIGH
PRESSURE
LIQUID
than necessary.
CONTROLLED
PRESSURE Quantum control panels are capable of adjusting the Vi to
SATURATED LIQUID
TO EVAPORATOR compensate for economized compressors. If the econo-
mizer pressure is fixed, a regulating valve may be used. In
ECON3
this case, the economizer operating pressure can simply
be entered into the control panel.
Figure 16: Multiple compressor economizer system
If the economizer pressure fluctuates, then the econo-
SUCTION mizer pressure can be relayed to the control panel via a
INTERMEDIATE PRESSURE
GAS TO COMPRESSOR
ECONOMIZER
pressure transducer to an analog input. This is the purpose
HV-2 VESSEL of the powermizer option. If the powermizer option is
selected, Frick provides a factory mounted and wired
STR VCK BPR pressure transducer on the economizer inlet.
Economizing with VSDs

Economizing on a variable speed machine can present
CONTROLLED PRESSURE
challenges. At low load conditions, the mass flow through
SATURATED LIQUID TO EVAPORATOR
ECON4 the economizer line is reduced. This tends to cause the
economizer check valve to chatter. Chattering will lead to
Economizer load balancing premature failure of the check valve.
The most energy efficient manner to operate an econo- This can be avoided through the use of a smaller check
mizer system, when using multiple compressors on a com- valve or by limiting the minimum speed of the compres-
mon economizer vessel, is to take as much of the flash gas sor. The disadvantage of using a smaller check valve is
as possible to the compressors that are fully loaded. This increased pressure drop during full load conditions. If ex-
can be done in at least two ways. tended periods of low compressor loading are anticipated,
1. Use the economizer output from the microprocessor it is recommended to use an automated (non-modulating)
to turn off a solenoid, or to actuate the electric shutoff full port ball valve in lieu of a check valve. This valve shall
option on a back-pressure regulator, based on percent of be equivalent in size to the economizer line size. The ball
slide valve travel. This will direct all the flash vapor to the valve shall be opened when the compressor starts, and
other loaded compressors. closed when the compressor stops. The ball valve must
close automatically upon power failure.
2. A dual-setpoint, back-pressure regulator valve can
be used in each of the individual economizer vapor lines. Electrical
When a compressor is running near full load, the BPR
valve will operate on the desired setpoint, or basically
wide open, to minimize pressure drop in the line. When
NOTICE
one compressor unloads below the slide valve position Before proceeding with electrical installation, read
where the economizer output on the microprocessor turns the instructions in the section “Proper Installation of
on, the dual-setpoint feature of the regulator can be actu- Electronic Equipment in an Industrial Environment”.
ated by this output to control the pressure, on the vessel
side of the regulator, to be a few psi higher. Consequently, RWF II units are supplied with a Quantum™ HD control
the flash gas will be sent to the loaded compressors first, system. Care must be taken that the controls are not
until they can’t handle all the vapor and the pressure in exposed to physical damage during handling, storage, and
the vessel starts to rise. Then, some of the vapor will go installation. The single-box control door must be kept
to the unloaded compressor to help maintain the vessel tightly closed to prevent moisture and foreign matter from
at the desired pressure. An example of a back-pressure entry.
regulator with electric shutoff and the dual-setpoint fea-
ture is an R/S A4ADS. NOTICE
All customer connections are made in the single-
box control mounted on the oil separator. This is
the ONLY electrical enclosure and it should be kept
tightly closed whenever work is not being done in it.
Voltage protection Motor starter package

NOTICE CAUTION
Johnson Controls-Frick does not advise nor support The motor is supplied with copper ring-type lugs
the use of UPS power systems in front of the crimped on the motor leads. These lugs are intended
Quantum™ HD panel. to be bolted together and wrapped with sufficient in-
sulating tape, in accordance with established national
With a UPS power system providing shutdown protection
and local electrical codes and practices.
for the Quantum™ HD, the panel may not see the loss of
the three-phase voltage on the motor because the UPS The removal of these lugs for the use of alternate
could prevent the motor starter contactor from drop- connection methods may cause electrical failure, fire,
ping out. With the starter contactor still energized, the or electrical shock hazards. Therefore, IF THE FAC-
compressor auxiliary will continue to feed an Okay signal TORY-SUPPLIED LUGS ARE REMOVED OR ALTERED
to the panel. This will allow the motor to be subjected IN ANY MANNER, THE MOTOR WARRANTY WILL BE
to a fault condition on the three-phase bus. Some fault VOIDED.
scenarios are:
Motor starter and interlock wiring requirements are shown
1. The three-phase bus has power On and Off in a in Figure 17. All of the equipment shown is supplied by the
continuous cyclic manner which may cause the motor to installer unless a starter package is purchased separately
overheat due to repeated excessive in-rush currents. from Johnson Controls-Frick. Starter packages should
consist of:
2. Motor cycling may damage the coupling or cause other
mechanical damage due to the repeated high torque mo- 1. The compressor motor starter of the specified HP and
tor bumps. voltage for the starting method specified (across-the-line,
wye-delta, or solid-state).
3. Prolonged low voltage may cause the motor to stall
and overheat before the motor contactor is manually
turned off. NOTICE
Under normal conditions, the loss of three-phase power If starting methods other than across-the-line are
will shut down the Quantum™ HD panel and it will restart desired, a motor/compressor torque analysis must
upon power return. If the panel was in: be done to ensure that sufficient starting torque is
available, particularly in booster applications. Contact
• Auto – Compressor motor will return to running as Johnson Controls-Frick if assistance is required.
programmed.
• Remote – The external controller would reinitialize the 2. If specified, the starter package can be supplied as
panel and proceed to run as required. a combination starter with circuit breaker disconnect.
• Manual – The compressor will have to be restarted However, the motor overcurrent protection/disconnection
manually after the three-phase bus fault has been device can be applied by others, usually as a part of an
cleared. electrical power distribution board.
If the local power distribution system is unstable or prone 3. The oil pump starter with fuses, or in the case where
to problems, there are other recommendations to satisfy the compressor motor is a different voltage from the oil
these problems. If power spikes or low or high line volt- pump motor, with a circuit breaker disconnect suitable for
ages are the problem, then we recommend the use of a separate power feed.
Sola® constant voltage (CV) transformer with a line sup-
4. A 3.0 KVA control power transformer (CPT) to sup-
pression feature. If a phase loss occurs, then you typically
ply 120 V control power to the microprocessor control
get a high motor amp shutdown. If problems continue to
system and separator oil heaters is included. If environ
exist, then an examination of the plant’s power factor may
mental conditions require more than the usual two 500
be in order.
W oil heaters, an appropriately oversized control trans-
Unless careful design failure analysis is considered in the former will be required. If frequent power fluctuations are
implementation of power systems, the alternative solu- anticipated or extremely noisy power lines are encoun
tions provide a safer and less expensive implementation. tered, a regulating control transformer should be consid-
In either case, only one Sola® may be used per compres- ered. Contact Johnson Controls-Frick for assistance.
sor. Each compressor needs to be individually isolated
5. For customer-supplied across-the-line starters, a
from each other through a dedicated control transformer.
shunting device must be installed across the Current
Sharing a common control power source is an invita-
Transformer (terminals 3 and 4).
tion for ground loops and the subsequent unexplainable
problems.
WARNING
If the shunting device is not installed, the Analog I/O
board on the Quantum™HD panel may be severely
damaged at start-up. See Figure 12.
Figure 17: Starter wiring diagram Figure 18: Point-to-point wiring diagram
NOTE: REFERENCE 090.040-M QUANTUM HD

NOTE: CUSTOMER GROUND REQUIRED MAINTENANCE MANUAL.
SEE WIRING DIAGRAM IN
090.040-M PUBLICATION.
OPTIONAL CIRCUIT BREAKER FRICK SUPPLIED COMBINATION

DISCONNECT CONSULT STARTER AND MOTOR WIRING DIAGRAMS STARTER PACKAGE
FOR EXACT WIRING CONFIGURATION RWF II • QUANTUM HD
USED WITH ACROSS-THE-LINE ONLY
HI-LEVEL CUTOUT
AND/OR OTHER
FRICK QUANTUM HD FIELD SAFETY
ENCLOSURE CUTOUTS
NOTE: WHEN COMPRESSOR MOTOR VOLTAGE IS AS REQUIRED.
DIFFERENT FROM OIL PUMP MOTOR VOLTAGE,
SUPPLY CIRCUIT BREAKER DISCONNECT FEED
IN LIEU OF FUSES.
CHECK MOTOR STARTER
MANUFACTURER’S INSTRUCTIONS
AND 090.040-M QUANTUM HD
PUBLICATION
NOTES:
1. Refer to motor nameplate for correct motor connection.
2. Separate conduit runs for control voltage wiring and motor
connection wiring.
3. Conduit grounds are not acceptable.
4. All wiring must be per latest edition of the NEC and local codes.
*Additional information is available in the "Installation of Electronic Equip-

ment" section of this publication.
Current transformer (CT) ratios
The CT ratio for various motor sizes (with a 5 amp
6. One each normally open compressor motor and oil secondary) is given in the following table:
pump motor starter auxiliary contact should be supplied.
In addition to the compressor and oil pump motor starter Table 7: CT ratios by motor HP
coils, the CT and CPT secondaries should be wired as
HP Voltage
shown on the starter package wiring diagram. The load
200 230 380 460 575 2300 4160
on the control panel for the compressor motor starter coil
20 100:5 100:5 50:5 50:5 50:5 - -
should not exceed a 2 amp load. For larger starters, an
25 100:5 100:5 50:5 50:5 50:5 - -
interposing relay must be used to switch the compressor 30 200:5 100:5 100:5 50:5 50:5 - -
motor starter coil(s). 40 200:5 200:5 100:5 100:5 50:5 - -
50 200:5 200:5 100:5 100:5 100:5 - -
NOTICE 60
75
300:5
300:5
200:5
300:5
200:5
200:5
100:5
200:5
100:5
100:5
-
-
-
-
Do not install a compressor HAND/OFF/AUTO switch 100 400:5 300:5 200:5 200:5 200:5 - -
in the starter package as this would bypass the com- 125 500:5 400:5 300:5 200:5 200:5 - -
pressor safety devices. 150 600:5 500:5 300:5 300:5 200:5 - -
200 800:5 600:5 400:5 300:5 300:5 100:5 50:5
7. The compressor motor Current Transformer (CT) is 250 800:5 800:5 500:5 400:5 300:5 100:5 50:5
300 1000:5 1000:5 600:5 500:5 400:5 100:5 50:5
installed on any one phase of the compressor leads.
350 - 1000:5 800:5 500:5 500:5 100:5 100:5
400 - - 800:5 600:5 500:5 200:5 100:5
NOTICE 450
500
-
-
-
-
1000:5
1000:5
800:5
800:5
600:5
600:5
200:5
200:5
100:5
100:5
The CT must see all the current of any one phase, 600 - - 1200:5 1000:5 800:5 200:5 100:5
therefore in wye-delta applications both leads of any 700 - - - 1200:5 1000:5 200:5 200:5
one phase must pass through the CT. 800 - - - - 1000:5 300:5 200:5
900 - - - - 1200:5 300:5 200:5
1000 - - - - - 300:5 200:5
1250 - - - - - 400:5 200:5
1500 - - - - - 500:5 300:5
Minimum burden ratings Installation of electronic equipment

The following table gives the minimum CT burden ratings. in an industrial environment
This is a function of the distance between the motor start-
In today’s refrigeration plants, electronic controls are part
ing package and the compressor unit. of almost every aspect of refrigeration control. Electronic
controls have brought to the industry more precise con-
Table 8: Burden rating and maximum panel distance trol, improved energy savings, and operator conveniences.
Electronic control devices have revolutionized the way
Burden rating Maximum distance from Frick
refrigeration plants operate.
panel
ANSI VA Using # Using # Using # The earlier relay systems were virtually immune to radio
14 AWG 12 AWG 10 AWG frequency interference (RFI), electromagnetic interference
(EMI), and ground loop currents. As a result, installation
B-0.1 2.5 15 ft 25 ft 40 ft
and wiring were of little consequence and the wiring job
B-0.2 5 35 ft 55 ft 88 ft consisted of hooking up the point-to-point wiring and
B-0.5 12.5 93 ft 148 ft 236 ft sizing the wire correctly. In an electronic system, incorrect
installation causes problems that may outweigh the bene-
Control power regulator fits of electronic control. Electronic equipment is suscepti-
Compressor units that will be used in areas that suffer ble to RFI, EMI, and ground loop currents, which can cause
brownouts and other significant power fluctuations can be equipment shutdowns, processor memory and program
loss, and erratic behavior and false readings. Manufactur-
supplied with a control power regulator. See the following
ers of industrial electronic equipment take into consider-
Figure. ation the effects of RFI, EMI, and ground loop currents and
incorporate protection of the electronics in their designs.
Figure 19: Suggested regulator installation However, these design considerations do not make the
equipment immune, so manufacturers require certain
installation precautions, to protect the electronics from
these effects. As a result, view all electronic equipment as
sensitive instrumentation that 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 mini-
mize 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.
With exclusion of the three phase wire sizing, use Frick
drawing 649D4743 as a reference for properly sizing con-
trol 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 instruc-
tions thoroughly before beginning the project. Make
sure you have drawings and instructions with your
equipment. If not, call the manufacturer and re-
quest 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 Figure 20: Voltage source circuit to prevent EMI

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, con-
tactors, and solenoids. These sudden dips in voltage can
cause the electronic control panel, whether it is a micro-
processor, a computer, or a PLC, to malfunction momen-
tarily 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 sup-
ply 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. As a result, 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 instru-
mentation 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 Grounding
panels) subjects the electronic equipment to noise gener- Grounding is the most important factor for successful
ated by other devices connected to the breaker panel. operation and is typically the most overlooked. The NEC
This noise is known as electromagnetic interference (EMI). states that control equipment can be grounded by us-
EMI flows on the wires that are common to a circuit. EMI ing the rigid conduit as a conductor. This worked for the
cannot travel easily through transformers and therefore earlier relay systems, but it is in no way acceptable for
can be isolated from selected circuits. Use a control power electronic control equipment. Conduit is made of steel and
transformer of the proper VA rating, usually provided in is a poor conductor relative to an insulated stranded cop-
the compressor drive motor starter, to isolate the elec- per wire. Electronic equipment reacts to very small cur-
tronic control panel from other equipment in the plant that rents and must have a proper ground in order to operate
generate EMI. See the following Figure. 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. See Figure 21. Driv-
ing 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 three-phase ground point,
yields the best results.
Figure 21: Control power ground circuit Figure 22: Motor And starter grounding
NOTICE
Structural grounding can also result in multiple VFD applications
ground potentials and is also a relatively poor con- The primary ground conductor that accompanies the
ductor. Therefore, this is not an acceptable method three-phase supply must be stranded copper, insulated
for proper operation of electronic equipment. and two sizes larger than the minimum required by the
NEC or any other applicable codes. This is necessary due
There must be a ground for the three-phase power wir- to the increased generation of EMI, which is a character-
ing. This must be sized in accordance to the NEC and any istic of a VFD output to the motor when compared to a
local codes relative to the highest rated circuit overload conventional starter.
protection provided in the circuit. The manufacturer may
require a larger ground conductor than what is required by For VFD applications, isolation of the control power,
the NEC for proper steering of EMI from sensitive circuits. analog devices, and communications ground from the
This conductor must also be insulated to avoid inadvertent three-phase ground within the starter and the electronic
contact at multiple points to ground, which could cre- control panel may be necessary. This is due to the higher
ate Ground Loops. In many installations that are having noise (RFI/EMI) levels generated between the VFD output
electronic control problems, this essential wire is usually and the motor, relative to a conventional starter. If these
missing, is not insulated, or improperly sized. grounds are left coupled by a common back-plate in the
starter/drive, this noise can be direct coupled to the con-
NEC size ratings are for safety purposes and not neces- trol power, analog device, and communications grounding
sarily for adequate relaying of noise (EMI) to earth ground and may cause unexplained behavior and possible damage
to avoid possible interference with sensitive equipment. to components.
Therefore sizing this conductor 1 – 2 sizes larger than
required by code will provide better transfer of this noise. To install correctly, run a separate, properly sized (10 or 8
AWG typically) insulated ground along with and taken to
Johnson Controls-Frick requires that the ground conductor ground with, the three-phase ground at the three-phase
meet the following: supply transformer (plant). This will require that the three-
• Stranded copper phase ground and the control power ground be electri-
• Insulated cally isolated except for the connection at the plant supply
transformer.
• One size larger than NEC requirements for conventional
starters This style of grounding should steer the noise (EMI/RFI)
• Two sizes larger than NEC requirements for VFD starters to earth ground, reducing the potential for it to affect the
• Conduit must be grounded at each end sensitive equipment, which could occur if the grounds
• This circuit must be complete from the motor to the were left coupled.
starter continuing in a seamless manner back to the
plant supply transformer (power source). NOTICE
For Direct Coupled, Package Mounted Starters, the ground If all other recommendations for grounding are fol-
between the motor and the starter may need to be made lowed, this process should not be necessary.
externally. See Figure 22. 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 con-
nection at each end will maximize metal to metal contact.
Conduit Wiring practices

All national and local codes must be followed for conduit Do not mix wires of different voltages in the same conduit.
with regard to materials, spacing and grounding. In addi- An example of this would be the installation of a screw
tion, Johnson Controls-Frick requirements must be fol- compressor package where the motor voltage is 480 V
lowed where they exceed or match national or local codes. and the electronic control panel power is 120 V. The
Conversely, there is no allowance for any practices that are 480 V circuit must be run from the motor starter to the
substandard to what is required by national or local codes. motor in its own conduit. The 120 V circuit must be run
Johnson Controls-Frick conduit requirements: from the motor starter control transformer to the elec-
tronic control panel in its own separate conduit. If the two
• For variable frequency drives (VFDs) of any type, thread- circuits are run in the same conduit, transients on the 480
ed metallic or threaded PVC-coated metallic is required V circuit will be induced onto the 120 V circuit causing
for both the power feed (line side) from the source and functional problems with the electronic control panel. Me-
between the VFD output and the motor (load side). tallic dividers must be used in wire way systems (conduit
• PVC conduit is acceptable only when VFD rated cable trays) to separate unlike voltages. The same rule applies
of the proper conductor size and ground is used. This for 120 V wires and 220 V wires. Also, never run low volt-
applies to both the line side and load side of the drive. age wires for DC analog devices or serial communications
When VFD rated cable is not used, threaded metallic or in the same conduit with any AC wiring including 120 V
threaded PVC-coated metallic must be used. wires. See the following figure.
• When threaded metallic or threaded PVC-coated metal-
lic is used, it must be grounded at both ends. Figure 23: Separation of different voltage circuits
• When not required to be in metal or other material by

national or local codes, conduits for the power feed
(three-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 (three-phase) may be PVC.
• Any unshielded control voltage, signal, analog, or com-
munication wiring that does not maintain 12 inches of
separation from any three-phase conductors for every
33 feet (10 meters) of parallel run must be in metal con-
duit which will be grounded.
Separation:
Distance interval Spacing Never run any wires through an electronic control panel
0 ft to 33 ft (0 m to 10 m) 12 in. (0.3 m) that do not relate to the function of the panel. Elec-
33 ft to 66 ft (10 m to 20 m) 24 in. (0.6 m) tronic control panels should never be used as a junction
• Because PVC conduit does absolutely nothing to protect box. These wires may be carrying large transients that
lower voltage lines from the magnetic field effects of will interfere with the operation of the control panel. An
extreme example of this would be to run 480 V from
higher voltage conductors, running either the lower or
the starter through the electronic control panel to an
the higher voltage lines in PVC, does not reduce these oil pump motor.
requirements on separation. Only running in metal con-
duit can relieve these requirements. When running conduit to the electronic control panel,
• Due to the level of EMI that can be induced onto lower use the access holes (knockouts) provided by the manu-
voltage lines when running multiple feeders in a trench, facturer. These holes are strategically placed so that the
control power, communications, analog, or signal wiring field wiring does not interfere with the electronics in the
cannot be run in trenches that house multiple conduits/ panel. Never allow field wiring to come in close proximity
electrical ducts carrying three-phase power to starters, with the controller boards because this will almost always
VFD, or motors. cause problems.
• Control power, communications, analog, or signal wir- Do not drill into an electronic control panel to locate con-
ing should be run overhead (preferred) or in a separate duit connections. You are probably not entering the panel
trench. If these lines are not in threaded metallic or where the manufacturer would like you to since most
threaded PVC-coated metallic, abiding by the separation manufacturers recommend or provide prepunched conduit
requirements noted above is necessary. connections. You may also be negating the NEMA rating
of the enclosure. Drilling can cause metal filings to land on
• Though not recommended, if cable trays are used, me- the electronics and create a short circuit when powered
tallic dividers must be used for separation of conductors is applied. If you must drill the panel, take the following
of unlike voltages and types (AC or DC). precautions:
NOTICE
When in doubt contact the factory or use threaded
metallic or threaded PVC coated metallic conduit.
• First, call the panel manufacturer before drilling into ground wires back to the power source (Plant Transform-
the panel to be sure you are entering the panel at the er). Multiple electronic control panels on the same power
right place. wires create current surges in the supply wires, which
may cause controller malfunctions. Daisy-chaining ground
• Take measures to avoid ESD (electrostatic discharge) to
wires, taking them to ground at each device, allows
the electronics as you prep the inside of the Electronic
ground loop currents to flow between electronic control
control panel. This can be done by employing an anti-
panels which also causes malfunctions. See the following
static wrist band and mat connected to ground.
Figure.
• Cover the electronics with plastic and secure it with
masking or electrical tape. Figure 24: Electronic control panel power supplies
• 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 contact-
ing 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.
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
Communications UPS power and Quantum HD panels

The use of communications such as serial and ethernet Johnson Controls does not advise nor support the use
in industrial environments are commonplace. The proper of uninterrupted power supply systems for use with the
installation of these networks is as important to the proper Quantum™ HD panel. With a UPS system providing shut-
operation of the communications as all of the preceding down protection for a Frick Quantum panel, the panel may
practices are to the equipment. not see the loss of the three-phase voltage on the motor
because the UPS may prevent the motor starter contactor
Serial communications cable needs to be of the proper
from dropping out. With the starter contactor still ener-
gauge based on the total cable distance of the run.
gized, the compressor auxiliary will continue to feed an
Daisy-chaining is the only acceptable style of running the
Okay signal to the Quantum™ HD panel. This may allow
communications cable. While Star Networks may use less
the motor to be subjected to the fault condition on the
cable, they more often than not cause problems and inter-
three-phase bus.
ruptions in communications, due to varying impedances
over the varying lengths of cable. Ground or drain wires of A number of fault scenarios are:
the communications cable are to be tied together at each
• T
he three-phase bus has power On and Off in a
daisy-chain connection and only taken to ground in the
continuous cycle manner which may cause the motor
central control system panel.
to overheat due to repeated excessive in-rush current
It is important to carefully consider the type of cable to experiences.
be used. Just because a cable has the proper number of • T
he motor cycling may damage the coupling or cause
conductors and is shielded does not mean it is an accept- other mechanical damage due to the repeated high
able cable. Johnson Controls-Frick recommends the use torque from rapid sequential motor bumps.
of Belden #9829 for RS-422 communications and Belden #
9841 for RS-485 up to 2000 ft (600 m) total cable length. • P
rolonged low voltage may cause the motor to stall
Refer to Frick drawing 649D4743 for more detail and possibly overheat before the motor contactor is
manually turned off.
Comm Port Protection: Surge suppression for the comm
Under normal conditions, the loss of three-phase power
ports may not be the best method, since suppression
will shut down the Quantum™ HD panel and it will reboot
is required to divert excess voltage/current to ground.
upon proper power return. If the panel was in Auto, it
Therefore, the success of these devices is dependent on a
will come back and return to running as programmed. If
good ground (covered earlier in this section). This excess
the unit was in Remote, the external controller will re-
energy can be quite high and without a proper ground, it
initialize the panel and proceed to run as required. If the
will access the port and damage it.
panel was in Manual mode, the compressor will have to
Isolation or optical isolation is the preferred comm port be restarted manually after the three-phase bus fault/in-
protection method. With optical isolation, there is no con- terruption has been cleared / restored.
tinuity between the communications cable and the comm
If the local power distribution system is unstable or prone
port. There is no dependence on the quality of the ground.
to problems there are other recommendations to sat-
Be sure to know what the voltage isolation value of the
isfy these problems. If power spikes or low or high line
optical isolator is before selecting it. These may range
voltages are the problem, then a constant voltage (CV)
from 500 V to 4000 V.
transformer with a noise suppression feature is recom-
Frick Optical Isolation Kits are offered under part number mended. Johnson Controls, Inc. can provide these types of
639C0133G01. One kit is required per comm port. 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 facility’s power supply quality may be
necessary.
NOTICE
It is very important to read the installation instructions thoroughly before begin-
ning 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.
This page is intentionally left blank.

Operation Page 23
11. Shaft rotation clockwise facing compressor, suitable for

Operation all types of drives. See the following warning.
Operation and startup instructions
The Frick RWF II Rotary Screw Compressor Unit is an inte-
WARNING
grated system consisting of seven major subsystems: Compressor rotation is clockwise when facing the
compressor drive shaft. See Figure 25. The compres-
1. Quantum™ HD Control Panel sor should never be operated in reverse rotation as
(See publications 090.040-O, -M, and -CS) bearing damage will result.
2. Compressor
3. Compressor Lubrication System Figure 25: Shaft rotation direction
4. Compressor Oil Separation System
5. Compressor Hydraulic System
6. Compressor Oil Cooling System
7. Compressor Easy-Start System
The information in this section of the manual provides the
logical step‑by‑step instructions to properly start up and
operate the RWF II Rotary Screw Compressor Unit.
NOTICE
The following subsections must be read and under- 12. Dual compressor casing design for very low airborne
stood before attempting to start or operate the unit. noise transmission.
13. Suction flange is 300 psig ANSI type.
14. Integral suction strainer is provided on models 100 –
SGC compressor 480 and 546. Models 496, 676, 856, and 1080 have external
The Frick RWF II rotary screw compressor utilizes mating strainer.
asymmetrical profile helical rotors to provide a continuous 15. "D" Flange adapter for bolting directly to motor.
flow of refrigerant vapor and is designed for both high-
pressure and low-pressure applications. The compressor
incorporates the following features:
Compressor lubrication system
The lubrication system on an RWF II screw compressor
1. High-capacity roller bearings to carry radial loads at unit performs several functions:
both the inlet and outlet ends of the compressor.
1. Provides lubrication to bearings and seal.
2. Heavy‑duty, four-point angular-contact ball bearings
to carry axial loads are mounted at the discharge end of 2. Provides a cushion between the rotors to minimize
compressor. noise and vibrations.
3. Balance pistons located in the inlet end of the 3. Helps keep the compressor cool and prevents
compressor to reduce axial loads on the axial load bear- overheating.
ings and increase bearing life. 4. Provides an oil supply to hydraulically actuate the slide
4. Movable slide valve to provide fully modulating capac- valve and slide stop.
ity control from 100% to approximately 10% of full load 5. Provides oil pressure to the balance pistons to help
capacity. increase bearing life.
5. Volume ratio control to allow infinitely variable volume 6. Provides an oil seal between the rotors to prevent ro-
ratio from 2.2 to 5.0 during compressor operation for all tor contact or gas bypassing.
models.
The compressor unit may be equipped with either a no
6. A hydraulic unloader cylinder to operate the slide stop pump or a demand pump lubrication system. Addition-
and slide valve. ally, either system may contain dual oil filters and liquid
7. Bearing and casing design for 400 PSI discharge pres- injection, water-cooled, or thermosyphon oil cooler for
sure. This psi rating applies only to the compressor and compressor oil cooling.
does not reflect the design pressure of the various system
components. No pump oil system
8. All bearing and control oil vented to closed thread in The RWF II screw compressor unit is designed to be
the compressor instead of suction port to avoid perfor- self‑lubricating. Oil being supplied to the compressor from
mance penalties from superheating suction gas. the oil separator is at system head pressure. Within the
compressor, oil porting to all parts of the compressor is
9. Shaft seal design to maintain operating pressure on
vented back to a point in the compressor’s body that is at
seal well below discharge pressure, for increased seal life.
a pressure lower than compressor discharge pressure. The
10. Oil injected into the rotors to maintain good volumetric compressor’s normal operation makes the compressor unit
and adiabatic efficiency even at very high compression operate essentially as its own oil pump. All oil entering the
ratios.
Page 24 Operation
compressor is moved by the compressor rotors out the Figure 26: Oil separation system
compressor outlet and back to the oil separator.
For normal high-stage operation, an oil pump is not
required.
Demand pump oil system

This system is designed to provide adequate compres-
sor lubrication when there is low differential oil pressure
across the compressor suction and discharge for some
high stage applications and booster applications as re-
quired.
On start-up, Quantum™ HD will calculate the pressure dif-
ferential 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. Cold-start system
The RWF II package is equipped with a special "cold-start"
WARNING discharge check valve (see Figure 27) on the gas outlet
connection of the oil separator. This valve causes the oil
The oil pump relief valve is not intended to be ad- separator to develop oil pressure rapidly on initial start in
justed. Do not attempt to remove or unscrew the order to lubricate the compressor without requiring an oil
relief valve bonnet. Removal of the bonnet will result pump, even in cold ambient temperatures with all pres-
in major oil or refrigerant loss. sures equalized.
For high-stage packages, the cold-start valve is equipped
NOTICE with a large spring that creates 30 psi of pressure in the
For alarm descriptions and shutdown or cutout pa- oil separator (above suction pressure), for lubrication of
rameters, see publication 090.040-O. the compressor.
Once the compressor is running it will begin to force gas
to the condenser at connection P2. As the condenser
Compressor oil separation system heats up it will begin to rise in pressure as the compres-
The RWF II is an oil flooded screw compressor. Most of sor suction pulls down in pressure. As soon as differential
the oil discharged by the compressor separates from the pressure is developed between the condenser and suction,
gas flow in the oil charge reservoir. Some oil, however, these pressures act across a piston inside the cold-start
is discharged as a mist which does not separate readily valve to partially overcome the spring force. When the dif-
from the gas flow and is carried past the oil charge reser ferential pressure reaches and exceeds 30 psi, the piston
voir. One or more coalescer filter elements then coalesce fully overcomes the spring force and powers the valve fully
the oil mist into droplets which fall to the bottom of the open for very low operating pressure drop.
coalescer section of the oil separator. See Figure 26. The
return of this oil to the compressor is controlled by a For booster applications, the valve is equipped with a
throttling valve on both high stage and booster applica- lighter spring which produces 7 psi oil pressure above suc-
tions. tion pressure before it fully powers open. An oil pump is
required to ensure compressor lubrication.
NOTICE The RWF II package is also equipped with a suction check
valve bypass. The oil separator will slowly bleed down
Open throttling valve only enough to keep coalescer
to approximate system suction pressure when the unit is
end of separator free of oil.
stopped. This allows the compressor drive motor to have
an easier start, and the discharge check valve will seat
The sight glass located near the bottom of the coalescer
more tightly. See Suction check valve bypass for opera-
section of the oil separator should remain empty during
tion.
normal operation. If an oil level develops and remains in
the sight glass, a problem in the oil return separation sys-
tem or compressor operation has developed. See Mainte- NOTICE
nance for information on how to correct the problem. For alarm descriptions and shutdown or cutout pa-
rameters, refer to publication 090.040-O.
NOTICE
The normal operating level is midway between the two
sight glasses located midway along the oil separator
shell.
Operation Page 25
Figure 27: Cold-start valve

NOTICE
To control the rate of loading and unloading, change
cycle time, proportional band, and dead band
setpoints with Quantum control. If additional control
is needed, throttle SC2 or BP.
Double-acting mode - booster

Open valve at SC2
Close valve at BP (bypass)
Booster compressor loading: The compressor loads when
MSV solenoid YY2 is energized and oil flows from the oil
manifold through valve ports P and B to cylinder port SC2
and enters the load side of the cylinder. Simultaneously,
oil contained in the unload side of the cylinder flows out
cylinder port SC1 through valve ports A and T to com
pressor suction.
Booster compressor unloading: The compressor unloads
when MSV solenoid YY1 is energized and oil flows from
the oil manifold through valve ports P and A to cylin-
Compressor hydraulic system der port SC1 and enters the unload side of the cylinder.
The compressor hydraulic system moves the movable Simultaneously, oil contained in the load side of the cylin-
slide valve (MSV) to load and unload the compressor. It der flows out of compressor port SC2 through valve ports
also moves the movable slide stop (MSS) to increase or B and T to compressor suction.
decrease the compressor’s volume ratio (Vi).
The hydraulic cylinder located at the inlet end of the SGC
NOTICE
compressor serves a dual purpose. It is separated by a To control the rate of loading and unloading, change
fixed bulkhead into two sections. The movable slide valve cycle time, proportional band, and dead band
(MSV) section is to the left of the bulkhead and the mov- setpoints with Quantum control. If additional control
able slide stop (MSS) to the right. Both sections are con- is needed, throttle SC2 or BP.
sidered double-acting hydraulic cylinders as oil pressure
moves the pistons in either direction. Figure 28: Solenoid valves and cylinder
Both sections are controlled by double‑acting, four‑way SEE HYDRAULIC
solenoid valves which are actuated when a signal from the SCHEMATIC
appropriate microprocessor output energizes the solenoid FOR FUNCTIONAL
VIEW OF VALVE
valve. Valves V1, V2, SC1, SC3, and SC4 are always open. OPERATION
NOTICE
SC1 SC3
The solenoid coils can be serviced or replaced with-

out evacuating the package. However, if the hydraulic
solenoid valves or manifold block needs to be serviced
or replaced, then the compressor package must be
evacuated.
Single-acting mode - high stage
Close valve at SC2
Open valve at BP (bypass)
High stage compressor loading: The compressor loads WARNING
when MSV solenoid YY2 is energized and oil flows from NEVER open valve BP and valve SC2 at the same time
the unload side of the cylinder out port SC1, through valve during compressor operation.
ports A and T to compressor suction. Simultaneously,
discharge pressure loads the slide valve. Volume ratio control
High stage compressor unloading: The compressor See Figure 29 for port references.
unloads when MSV solenoid YY1 is energized and oil Open valve at SC3
flows from the oil manifold through valve ports P and A to Open valve at SC4 (not used on models 496, 676, 856,
cylinder port SC1 and enters the unload side of the cylin- 1080)
der. Simultaneously, gas on the load side of the cylinder
is vented through port SC2 and valve BP to compressor Compressor Vi increase: The volume ratio Vi is increased
suction. when MSS solenoid valve YY3 is energized and oil flows
Page 26 Operation
Figure 29: Hydraulic schematic - all package sizes

SC1 SC2 SC3 SC4 SC1 SC2 SC3
SC 4 NOT USED
2 2 2 2 2 2 2
DIRECTION
SC1 SC2 SC3 SC4 CONTROL SC1 SC2 SC3 SC4 DIRECTION
2 VALVE 2 CONTROL VALVE
1 1 1 1 1 1 1
BP BP
A B A B A B A B
YY1 YY2 1
YY3 YY4 YY1 YY2 1
YY3 YY4
P T P T P T P T
SV-2 SV-3 SV-2 SV-3

P T P T
SCREW IN FLOW SCREW IN FLOW
DIRECTION REGULATING REGULATING
CONTROL VALVE NEEDLE VALVE NEEDLE VALVE
HYDRAULIC SCHEMATIC HYDRAULIC SCHEMATIC

SIZES: 100-480, 546 SP-1 SIZES: 496, 676, 856, 1080
Valve 1
SC4 SC3
Valve 1 P
T
Valve 2 BP COMPRESSOR TOP VIEW
(INCREASE VI) YY3 YY4 (DECREASE VI) SC2 SC1
(UNLOAD) YY1 YY2 (LOAD)
COMPRESSOR TOP VIEW
SC-5 Valve 2
(INCREASE VI) YY3 YY4 (DECREASE VI)

(UNLOAD) YY1 YY2 (LOAD)
from the oil manifold through valve ports P and A to com- Single-port liquid injection
pressor port SC3, enters the increase side of the cylinder
The single-port liquid injection system is designed to per-
and overcomes the decrease spring tension. Simultane-
mit liquid refrigerant injection into one port on the com-
ously, oil flows from SC4 port through valve ports B and T
pressor at any given moment and operates as outlined.
to compressor suction. On models 496, 676, 856, and 1080
the SC4 port does not exist. The inboard side of the slide The liquid injection solenoid valve is energized by the
stop piston is at suction pressure. microprocessor when the temperature sensor, installed in
the compressor discharge, exceeds the setpoint. High-
Compressor Vi decrease: The volume ratio Vi is de-
pressure liquid refrigerant is then supplied to the tempera
creased when MSS solenoid valve YY4 is energized and
ture control valve (TCV). See Figure 61 to Figure 65 for
oil flows from the oil manifold through valve ports P and
piping and instrumentation drawings.
B to compressor port SC4, enters the decrease side of the
cylinder. Simultaneously, oil flows form SC3 port through
valve ports A and T to compressor suction. On models Dual-port liquid injection
496, 676, 856, and 1080 the SC4 port does not exist. On The dual-port liquid injection system is designed to obtain
these models, YY4 is energized which permits oil to vent the most efficient compressor performance at high and
from port A to T with assistance from the unloader spring. low compression ratios by permitting injection of liquid
refrigerant into one of two ports optimally located on
Note: T
o control the rate of Vi change, throttle the needle the compressor. This minimizes the performance penalty
valve at SC3 port. incurred with liquid injection oil cooling.
Compressor oil cooling systems The dual-port system contains all the components of the
single-port system with the addition of a 3-way motorized
The RWF II unit can be equipped with one of several sys-
valve and operates as outlined.
tems for controlling the compressor oil temperature. They
are single or dual-port liquid injection and thermosyphon or The liquid injection solenoid valve is energized by the
water-cooled oil coolers. Each system is automatically con- microprocessor when the temperature sensor, installed
trolled, independentof compressor loading or unloading. in the compressor discharge, exceeds the setpoint. Then,
liquid refrigerant flows through the motorized expansion
Oil cooling systems should maintain oil temperature within
valve to the 3-way motorized valve. Depending on the
the following ranges for R-717:
compressor’s operating volume ratio (Vi), the micropro-
Liquid injection External* cessor will select the flow of the liquid refrigerant to the
Oil cooling Oil cooling optimum compressor port.
130°F to 170°F 120°F to 160°F
* Thermosyphon oil cooling (TSOC) or water-cooled oil
cooling (WCOC).
Operation Page 27
Quantum HD EZ-COOL Liquid injection adjustment procedure

Figure 30: Liquid injection
adjustment screen
ACCESSING:
Package
Liquid Injection LIOC
Description: This screen allows the user to enter and view EZ-Cool status
the operating parameters related to EZ-Cool LIOC PI control. Discharge Temperature - The actual discharge temperature
The following are the EZ-Cool LIOC Setup screen selections is shown here.
available on this screen: Control Output - The value of the output signal as con-
Liquid Injection Oil Cooling trolled by the PI. This is not a setpoint value.
Valve Type Valve Position - The value shown here represents the posi-
• Analog Modulating - This selection is used to control tion of the valve with relationship to the Control Output.
a modulating valve that requires an analog output (4-10
EZ COOL PI Control
mA) signal. This is the standard valve type for Frick
packages and includes valves like the Danfoss modulat- [Setpoint] - Enter the value that you wish to control to.
ing valve for LIOC. [Proportional Band] – This setpoint determines the size of
• Digital PWM - This selection is used to control a a region either above or below the control setpoint. Within
modulating valve that requires a digital PWM signal. This this region, the proportional component of the PI Output
includes valves like the Yosaku LIOC valve. value is the number between 0% and 100% that directly
corresponds to the difference between the control input
The PWM signal is controlled from the LIOC PWM Digital
(actual) and the control setpoint (setpoint). Outside of this
Output. To use this selection, the LIOC PWM Digital
region, the proportional component is either 100% or 0%.
Output must be configured in the Digital I/O section.
If the PI’s action is forward, the Proportional Band extends
The PWM cycle time is 20 seconds. The Control Output above the Control Setpoint. If the PID’s Action is Reverse,
corresponds to the PWM output On time. For example, the Proportional Band extends below the Control Setpoint.
if the Control Output value is calculated to be 75%, then [Integration Time] - This setpoint controls the influence
the PWM output will cycle On for 15 seconds and then that the Integral component exerts on the PI Output value.
Off for 5 cycles. It will continue to repeat this cycle if the The Integral component works to push the Control Input
Control Output is greater than 0%. toward the Control Setpoint by tracking the difference be-
Solenoid control tween the Control Input and the Control Setpoint over time.
An output is provided for an optional liquid injection sole- High Limit - The highest value that the output can be.
noid valve. The function of this output is only available if the Low Limit - The lowest value that the output can be.
compressor has liquid injection oil cooling and it has been I/O Board - Select from one of the following:
enabled. Liquid injection controls the supply of liquid refrig- • None
erant to the compressor. Liquid injection is off (the solenoid • Analog Board 1
is closed) if the compressor is off. • Analog Board 2
I/O Channel - Select the output channel that will be used.
[On When Above] - When the Discharge Temperature is Port Multiplier – This setpoint is used for the Liquid Injec-
above this setpoint, the Liquid Injection solenoid output will tion Closed Warning safety. See this safety description in the
energize, until the Discharge Temperature drops below this Warnings/Shutdowns Messages section. The port multiplier
setpoint. represents the internal pressure at this port divided by the
[Off When Below] - When the Discharge Temperature is suction pressure based on the compressor design.
below this setpoint, the Liquid Injection solenoid output will
de-energize, until the Discharge Temperature raises above
this setpoint.
Page 28 Operation
Operation of Danfoss liquid Figure 33: ICAD parameter list display example
injection valve
Figure 31: ICAD MMI
• Acknowledge and save change of value of a parameter.

• To exit from the Parameter list and return to the
display of opening degree (OD), keep the push button
activated for 2 seconds.
Display
Normally for the OD, 0% to 100% of the ICM valve is
displayed. No activation of push buttons for 20 seconds
means that the display will always show OD. See the fol-
lowing Figure.
Figure 34: ICAD opening degree

ICAD (industrial control actuator with display) is equipped
with an MMI (man-machine interface) from which it is possi-
ble 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 inte-
grated ICAD MMI (Figure 31 and Figure 32) and consists of
the following buttons:
Down arrow
• Decreases parameter number by 1 at each activation
Up arrow • Displays the parameter.
• Increases parameter number by 1 at each activation • Displays the actual value of a parameter.
Figure 32: ICAD MMI display • Displays the function status by means of text. See Fig-
ure 31.
• Mod represents that ICAD is positioning the ICM
valve according to an analog input signal (Current or
Voltage).
• Low represents that ICAD is operating the ICM valve
like an ON/OFF solenoid valve with low speed accord-
ing to a digital input signal.
• Med represents that ICAD is operating the ICM valve
like an ON/OFF solenoid valve with medium speed ac-
cording to a digital Input signal.
• High represents that ICAD is operating the ICM valve
like an ON/OFF solenoid valve with high speed accord-
ing to a digital input signal. See the following Figure.
Enter
• Gives access to the Parameter list by keeping the push
button activated for 2 seconds. A Parameter list ex-
ample is shown below (parameter i08, Figure 33).
• Gives access to change a value once the Parameter list
has been accessed.
Operation Page 29
Figure 35: ICAD "high" function status Suction check valve bypass
The RWF II unit is equipped with a low-pressure-drop
suction check valve bolted directly to the compressor
housing. Valve NV-2 must be open in most systems at all
times. It should normally be cracked open to allow the
oil separator to slowly bleed down to approximately
system suction pressure when the unit is stopped (hav-
ing this valve cracked open allows the compressor drive
motor to have an easier start, and the discharge check
valve will seat more tightly). If the drive coupling back-
spins, start closing the valve until the backspin stops. If
the separator oil level foams excessively on shutdown,
Alarms - ICAD can handle and display different alarms.
NV-2 should be closed slightly. If the separator takes more
than 20 min to 30 min to equalize to suction pressure after
Table 9: ICM alarms shutdown, NV-2 can be opened slightly. See Figure 36.
Description ICM alarm Comments
Check valve CV-4 is installed on all RWF II packages. On
text
high-stage systems, check valve CV-4 is installed with a
No valve type A1 At start-up A1 and CA will be
45 psi spring to avoid the possibility of back-feeding to a
Selected displayed
shut-down compressor from a common economizer ves-
Controller fault A2 Internal fault inside electronics
sel.
All input error A3 Not active if i01 = 2 or i02 = 2
When i03 = 1 and AI A > 22 mA On booster systems, check valve CV-4 is installed with a
When i03 = 2 and AI A > 22 mA 25 psi spring to avoid the possibility of air ingress into the
Or Al A < 2 mA system, if the system suction pressure is below atmo-
When i03 = 3 and AI A > 12 V spheric.
When i03 = 4 and Al A > 12 V or
Figure 36: Suction check valve bypass
Al A < 1 V
Low voltage of A4 If 5 VDC < Fail-safe supply
SUCTION GAS
TO THE COMPR
fail-safe supply < 18 VDC PE PI PAL PALL PIC

Check Supply A5 If supply voltage < 18 VDC 4 4 4 4 4
to ICAD
If an alarm has been detected the ICAD display (see Figure
31) will alternate between showing actual alarm and pres-
ent OD. SC-14 SC-5
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, A5 the lowest.
NV-2
Any active alarm will activate the Common Digital Alarm CV-4 FROM
output (Normally Open). SEPARATOR
COLD-START
All alarms will automatically reset themselves when they SE-1 VALVE
physically disappear.
COMPRESSOR END VIEW
Old alarms (alarms that have been active, but have physi-
cally disappeared again) can be found in parameter i11.
Reset to factory setting:

Low ambient operation
It is recommended that oil separators be insulated as a
1. Remove the power supply.
minimum requirement to preserve the heat generated by
2. Activate down arrow and up arrow push buttons at the
the oil heaters. It is important that the coalescer end of
same time.
the separator be insulated to prevent refrigerant conden-
3. Connect the power supply.
sation.
4. Release down arrow and up arrow push buttons.
5. When the display on ICAD (see Figure 31) is alternating On systems located outdoors or in unheated buildings
between showing: CA and A1 the factory resetting is where the ambient temperature could drop below +40°F,
complete. insulating and/or heat tracing of the compressor lube oil
systems is highly recommended.
When low ambient temperatures (below +20°F) are a pos-
sibility, it is recommended that lube oil lines, oil filters, oil
pumps, and oil coolers be heat traced and insulated.
Freeze-up protection must also be provided for all water-
cooled equipment
Page 30 Operation
Table 10: Parameter list

Description Display Min. Max. Factory Unit Comments (standard setting)
name setting
ICM OD ICM valve Opening Degree is displayed during normal operation.
- 0 100 - %
(Opening degree) Running display value (see j01, j05).
Internal main switch
1: Normal operation
Main Switch j01 1 2 1 - 2: Manual operation. Valve Opening Degree will be flashing. With the
down arrow and the up arrow push buttons the OD can be entered
manually.
Operation mode
1: Modulating - ICM positioning according to Analogue input (see j03)
Mode jo2 1 2 1 - 2: ON/OFF - operating the ICM valve like an ON/OFF solenoid valve
controlled via Digital Input. See also j09.
Type of Analog input signal from external controller
1: 0-20mA
Analog input signal j03 1 4 2 - 2: 4-20mA
3: 0-10V
4: 2-10V
Speed can be decreased. Max. speed is 100 %
Not active when j01 = 2
Speed at ON/OFF If j02 = 2, the display will indicate speed in display. Low, Med, and
and Modulating j04 1 100 100 % High also means ON/OFF operation.
Mode If j04 < = 33, Low is displayed
33 < If j04 < = 66, Med is displayed
If j04 > = 67, High is displayed
Not active before j26 has been operated.
Automatic calibration j05 0 1 0 - Always auto reset to 0.
CA will flash in the display during calibration.
Type of A0 signal for ICM valve position
0: No signal
Analog output signal j06 0 2 2 -
1: 0 - 20mA
2: 4 - 20mA
Define condition at power cut when fail-safe is installed.
1: Close valve
Fail-safe j07 1 4 1 - 2: Open valve
3: Maintain valve position
4: Go to OD given by j12
Define function when Dl is ON (short circuited Dl terminals) when j02 = 2
Digital input function j09 1 2 1 1: Open ICM valve (Dl = OFF = > Close ICM valve)
2: Close ICM valve (Dl = OFF = > Open ICM valve)
Enter number to access password protected parameters:
Password j10 0 199 0 -
j26
Old alarms will be listed with the latest shown first. Alarm list can be
Old Alarms j11 A1 A99 - - reset by means of activating down arrow and up arrow at the same
time for 2 seconds.
Only active if j07 = 4
OD at powercut j12 0 100 50 - If fail-safe supply is connected and powercut occurs, ICM will go to
entered OD.
NB: Password protected. Password = 11
At first start-up, A1 will flash in display. Enter valve type.
0: No valve selected. Alarm A1 will become active.
}
1: ICM20 with ICAD 600
ICM configuration j26 0 6 0 2: ICM25 with ICAD 600
You must get number off Valve Body
OD% j50 0 100 - % ICM valve Opening Degree is displayed during normal operation.
AI [mA] j51 0 20 - mA Analog input signal
AI [V] j52 0 10 - V Analog input signal
AO [mA] j53 0 20 - mA Analog output signal
Digital Input function j54 0 1 - - Digital Input signal
DO Close j55 0 1 - - Digital Output Closed status. ON when OD < 3%
DO Open j56 0 1 - - Digital Output Open status. ON when OD > 97%
DO Alarm j57 0 1 - - Digital Output alarm status. ON when an alarm is detected
MAS mP SW ver. j58 0 100 - - Software version for MASTER Microprocessor
SLA mP SW ver. j59 0 100 - - Software version for SLAVE Microprocessor
Operation Page 31
Suction check valve power assist kit Solenoid valve: Energizing, or opening, the solenoid valve
pressurizes the balance piston with full oil pressure from
Low temperature booster compressor applications require
the oil manifold, bypassing the A4ALE Pressure Regulating
hot gas to assist the suction check valve closure for RWF II
Valve. De-energizing, or closing, the solenoid valve pres-
models 496, 676, 856, and 1080. This is accomplished by
surizes the balance piston with oil pressure regulated by
using the high pressure discharge gas from the high pres-
the A4ALE Pressure Regulating Valve.
sure side of the system (power assist kit).
Signals from the control panel operate the solenoid valve
The power assist kit (see Figure 37) is factory installed (output module 12 on micro panel). The solenoid valve
with the discharge gas pressure being supplied from the should open when the slide valve position is 70% or
high stage discharge gas. Running piping, rather than tub- greater, and close when the slide valve position is 65% or
ing, to supply high pressure gas to the unit is recommend- less.
ed. The piping should be at least 3/4 in. in diameter, and
should be insulated and heat traced to prevent internal Orifice: The orifice ensures oil supply to the inlet end
condensation. bearings during upset conditions such as start-up.
The power assist kit consists of a strainer, mounted and
wired solenoid valve, timer, and metering valve. The timer Initial start-up
limits the high pressure gas feed to the suction check Initial start‑up must be performed under the supervision of
valve to thirty seconds via the solenoid valve. This is suf- a Johnson Controls-Frick authorized start‑up representa-
ficient time to warm the suction check valve piston and tive to prevent voiding the compressor warranty. Before
provide proper operation. The metering valve is provided the start‑up, complete the prestart check. See the RWF II
for use as a service valve and to allow discharge gas flow Compressor prestart checklist in the Forms section.
regulation to prevent excessive force and resulting closure
"hammering". The valve should be adjusted accordingly to Initial start-up procedure
prevent such an occurrence.
Having performed the checkpoints on the prestart check
Figure 37: Power assist kit list (see Forms), the compressor unit is ready for start‑up.
It is important that an adequate refrigerant load be avail-
3/8 OD YY POWER ASSIST TO BE CONNECTED TO
S
7 CONN IN CENTER OF MV END PLATE able to load test the unit at normal operating conditions.
The following points should be kept in mind during initial
1/2 STR-4 1/2 3/8
start‑up.
HIGH PRESSURE GAS FROM HIGH
SIDE COMPRESSOR DISCHARGE
1. 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 adequate oil flow.
There is still an orifice installed in the compressor to con-
trol 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
Balance piston pressure regulator correct adjustment of this valve.
A Balance Piston Pressure Regulator may be required on
The best method to determine target discharge tempera-
Models 496 to 1080 to reduce the extended overbalance
ture is to run CoolWare™ with the operating conditions
from the thrust balance piston at part load.
of the compressor. The program will give you a theoreti-
Figure 38 shows the three additions described below ar- cal discharge temperature of the compressor. Once this
ranged in parallel. temperature is known, you may adjust the hand expansion
valve. The ideal discharge temperature is within 5°F + or –
Figure 38: High-stage SB-2 oil supply line diagram of the theoretical discharge temperature. Adjust the valve
954A0014H01 PRESSURE-REGULATING VALVE (A4ALE)
to achieve the theoretical discharge temperature. If you
FROM do not have access to CoolWare™, 180°F is a good target
TO SB-2 COMPRESSOR discharge temperature for a high stage ammonia compres-
COMPRESSOR DISCHARGE OR
PORT OIL MANIFOLD
sor. Booster applications and compressors using HFC and
HCFC refrigerants may run cooler. Compressors with high
951A0007H01 (OR H03) discharge pressure may run hotter.
SOLENOID VALVE
The first method is used for compressors with external oil
534B0325H01 1/8" RESTRICTION ORIFICE FROM OIL cooling (thermosyphon, water cooled, and glycol cooled).
MANIFOLD Before the initial startup of the compressor close the hand
BLPSPREG
expansion valve completely. Open the valve back up and
count the turns that it takes to fully open the valve. After
Pressure-regulating valve: Discharge pressure determines the initial startup close the valve to achieve approximately
compressor thrust balance. The proper setting for the 180°F discharge temperature or the theoretical tempera-
pressure-regulating valve is 50 psi (±15) below discharge ture from CoolWare. Do not fully close the valve at any
pressure when slide valve is less than 65%. time while the compressor is running.
Page 32 Operation
The second method is used for compressors with Liquid until full range is accommodated. Also refer to 070.902-IB
Injection Oil Cooling. Because the discharge temperature is for acceptable package vibration readings.
controlled by the Liquid Injection Thermal Expansion Valve
Review skip frequencies as shown in the Maintenance
you will not be able adjust for the correct oil flow by using
schedule.
the discharge temperature. Before the initial startup of the
compressor, close the main oil injection hand expansion
valve completely. Open the valve back up and count the Normal start-up procedure
turns that it takes to fully open the valve. After the initial 1. Confirm system conditions permit starting the compres
startup, close the valve until it is two turns open. The sor.
valve may need to be closed further to reduce excessive
2. Press the [RUN] key.
noise and vibration. However, do not fully close the valve.
3. Allow the compressor to start‑up and stabilize. Press
WARNING the [AUTO] key immediately below the V ratio label
on the operating display screen. Press the [AUTO] key
Failure to properly adjust this valve can lead to immediately below the SV POS label on the operating
excessive noise and vibration of the compressor and display. The compressor is now operating in the automatic
package, premature failure of the bearings, liquid mode.
loading of the rotors, liquid starvation of the rotors
and catastrophic failure of the compressor. 4. Observe the compressor unit for mechanical tightness
of the external piping, bolts and valves. Ensure that the
2. For proper and safe operation, the compressor must be machine is clean from oil and refrigerant leaks. If any of
run at the proper speed and discharge pressure. Exceeding these occur, shut down the compressor and correct the
design conditions creates a potential hazard. problem as necessary using good safety precautions.
3. Rotate and lubricate motor bearings according to 5. Ensure manway bolts remain finger tight after the
manufacturer’s recommendations before initial start-up as compressor unit is in operation, as the manway bolts
required. will loosen as a result of pressurization.
4. After running the unit for approximately three hours,

adjust liquid injection oil cooling if applicable. If unit has WARNING
water cooled oil cooling, adjust water control valve to Overtightening components could result in a fire,
cooler. serious injury or property damage.
5. The compressor slide valve and slide stop linear trans- Do not apply the manway bolt torque specified for
mitters should be calibrated. an unpressurized unit while the unit is pressurized.
Applying this torque when the manway is pressur-
6. Perform baseline vibration analysis. Required!
ized can overstress the manway gasket. Overstressing
7. For VFD applications, skip frequencies must be identified the gasket can lead to gasket failure and/or a system
and entered. leak.
Trained technicians are required for servicing.
VFD skip frequencies
WARNING Restarting the compressor unit after a control
Failure to enter skip frequencies could cause cata- power interruption (plant power failure)
strophic compressor failure or severe compressor 1. Check variable setpoints.
damage and result in serious injury or death. 2. Follow normal start‑up procedure.
Criteria for identifying elevated energy on VFD
packages and establishing skip frequencies
With the RWF II 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 ener-
gy 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
Maintenance Page 33
Maintenance 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
General information cases can cause complete failure.
This section provides instructions for normal maintenance,
5. Protect the compressor during long periods of shut
a recommended maintenance program, troubleshooting and
down. If the compressor will be sitting for long periods
correction guides, and typical P and I diagrams. For typical without running it is advisable to evacuate to low pressure
wiring diagrams and information about the Quantum™HD and charge with dry nitrogen or oil. This is particularly true
control panel, refer to 090.040-M. on systems known to contain water vapor.
WARNING 6. Preventive maintenance inspection is recommended

any time a compressor exhibits a noticeable change in
This section must be read and understood be- vibration level, noise or performance.
fore attempting to perform any maintenance or
service to the unit. Compressor shutdown and start-up
For seasonal or prolonged shutdowns the following proce-
Normal maintenance operations dure should be followed:
When performing maintenance you must take several 1. Reduce the system pressure to the desired condition.
precautions to ensure your safety: 2. Press [STOP] key to cease operation of the compressor.
WARNING 3. Open disconnect switches for compressor motor and oil

pump starters.
1. If unit is running, press [stop] key. 4. Turn on oil heater circuit breaker.
2. Disconnect power from unit before performing any
5. Close suction and discharge service valves, also liquid
maintenance. injection and economizer service valves, if applicable.
3. Wear proper safety equipment when compressor Attach CLOSED TAGS.
unit is opened to atmosphere. 6. Shut off cooling water supply valve to oil cooler, if ap-
4. Ensure adequate ventilation. plicable. Attach CLOSED TAG.
5. Take necessary safety precautions required for the 7. Protect oil cooler from ambient temperatures below
refrigerant being used. freezing or remove water heads.
WARNING To start up after a seasonal or prolonged shutdown the fol-

lowing procedure should be followed:
Close all compressor package isolation valves prior 1. Any water necessary for the operation of the system
to servicing the unit. Failure to do so may result in that may have been drained or shut off should be restored
serious injury. and turned on.
2. Open suction and discharge service valves, also liquid
General maintenance injection and economizer service valves, if applicable. Remove
Proper maintenance is important in order to assure long tags.
and trouble-free service from your screw compressor unit.
Some areas critical to good compressor operation are: 3. Close disconnect switches for compressor, motor and oil
pump starters.
1. Keep refrigerant and oil clean and dry, avoid mois-
ture contamination. After servicing any portion of the 4. Turn off oil heater circuit breaker.
refrigeration system, evacuate to remove moisture before 5. Perform checkpoints on prestart check list, then start
returning to service. Water vapor condensing in the com- unit.
pressor while running, or more likely while shut down, can
cause rusting of critical components and reduce life.
2. Keep suction strainer clean. Check periodically, par
General instructions for replacing
ticularly on new systems where welding slag or pipe scale compressor unit components
could find its way to the compressor suction. Excessive
dirt in the suction strainer could cause it to collapse, NOTICE
dumping particles into the compressor. See Publication 070.660-SM for procedures covering
3. Keep oil filters clean. If filters show increasing pressure replacement motor and compressor mounting.
drop, indicating dirt or water, stop the compressor and
When replacing or repairing components which are ex-
change filters. Running a compressor for long periods with
high filter pressure drop can starve the compressor for oil posed to refrigerant pressure (including suction strainer)
and lead to premature bearing failure. proceed as follows:
4. Avoid slugging compressor with liquid refrigerant. While 1. Push [STOP] key on control panel to shut down unit.
screw compressors are probably the most tolerant to in- 2. Open disconnect switches for compressor and pump
gestion of some refrigerant liquid of any compressor type
motor starters.
available today, they are not liquid pumps. Ensure to maintain
adequate superheat and properly size suction accumulators 3. Close suction and discharge service valves, also liquid
to avoid dumping liquid refrigerant into compressor suction. injection and economizer service valves, if applicable.
Page 34 Maintenance
4. Slowly vent separator to low-side system pressure us- 3. Open bleed valve and purge pressure from the oil filter
ing the bypass line on the suction trap. cartridge.
NOTICE NOTICE
Recover or transfer all refrigerant vapor, in accordance Recover or transfer all refrigerant vapor, in ac-
with local ordinances, before opening to atmosphere. cordance with local ordinances, before opening to
The separator must be equalized to atmospheric pres- atmosphere.
sure.
4. Remove the plug from the bottom of the filter canister
WARNING and drain the oil. Remove the canister cover and discard
the gasket. Remove the screws securing the filter assem-
Oil-entrained refrigerant may vaporize, causing a bly. Pull the filter assembly from the canister and discard
separator pressure increase. Repeat venting and re- the gasket and the element.
covery procedure, if necessary.
5. Flush the canister with clean compressor oil; wipe dry
5. Make replacement or repair. with a clean, lint‑free cloth; and replace the plug.
NOTICE 6. Install a new one-piece filter element*. Tighten the six

3/8 in. hex head cap screws to 10 ft-lb torque.
Replace all gaskets and O-rings with new ones. Suction
Strainer: remove, inspect and clean as necessary and Figure 39: SuperFilter II - current design
replace using a new gasket.
6. Isolate the low pressure transducer, PE-4, to prevent
damage during pressurization and leak test.
7. Pressurize unit and leak test.
8. Evacuate unit to 29.88 in. Hg (1000 microns).
9. Open suction and discharge service valves, low pres- *Before January 2010, the SuperFilter™ II elements were
sure transducer, and also liquid injection and economizer separate pieces. Follow step 6a in lieu of step 6 for this
service valves, if applicable. design. After January 2010, the rod and nuts were elimi-
10. Close disconnect switches for compressor and oil pump nated and the end plate and gasket became part of the
motor starters. filter. Refer to the Oil Filter page in the 070.610-SPL for a
detailed graphic.
11. Unit is ready to put into operation.
6a. Install the new element(s) on the rod with all neces-
12. Perform checkpoints on prestart checklist, then start
unit. sary hardware. Tighten the nut on the end plate to 10 ft-lb
torque. Then, while holding the nut with a wrench, apply
a second nut to act as a locknut. Replace the gasket and
Oil filter (OF‑1) cartridge style reinstall the filter assembly into the canister, securing with
RWF II compressor units are furnished with one main screws tightened to 30 ft-lb torque.
oil filter (OF‑1). A second oil filter (OF‑2) is installed as
optional equipment to facilitate the changing of the filter Figure 40: SuperFilter II - design pre-2010
element(s) without unit shutdown.
NOTICE
Use of filter elements other than Frick may cause
warranty claim to be denied.
The procedure to change filter cartridge(s) is as follows:

1. If a single oil filter is installed, push [STOP] key on mi-
croprocessor panel to shut down unit, then open discon
nect switches for compressor and oil pump motor starters.
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 WARNING
pressure drop which could cause an oil filter differen- Do not mix oils of different brands, manufacturers, or
tial alarm. types. Mixing of oils may cause excessive oil foaming,
2. Close outlet then inlet service valves of filter being ser- leakage and catastrophic compressor failure.
viced.
Maintenance Page 35
Replace the gasket and reinstall the canister cover. Torque 9. Screw out manual solenoid valve stem.
cover bolts first to finger tight, then 65 ft-lb, then 130 10. Carefully open liquid supply service valve.
ft-lb. 11. Leak test.
7. Evacuate (pull a vacuum on) the filter canister to elimi- 12. Close disconnect switches for compressor and oil pump
nate non-condensibles. motor starters.
13. Start unit.
8. Fill the canister with new Frick refrigeration oil as
needed. Coalescer filter element
9. Open outlet service valve and leak test. When changing the coalescer filter element(s) it is recom
mended that the oil be changed, cartridge(s) in oil filters
10. Filter is ready to place in service. OF‑1 and OF‑2 if applicable be changed and the following
applicable strainer elements be removed and cleaned.
Strainer – demand oil pump
To clean the demand oil pump strainer, the unit must be
shut down. The procedure is as follows:
NOTICE
1. Push [STOP] key on microprocessor panel to shutdown Use of filter elements other than Frick may cause
unit, then open disconnect switches for compressor and warranty claim to be denied.
oil pump motor starters.
1. See Changing oil, Steps 1 through 8.
2. Close strainer inlet service valve.
3. Open drain valve located in the strainer cover and 2. Loosen manway cover retainer bolts, remove retainers,
drain oil into a container. manway cover and cover gasket. Discard cover gasket.
4. Remove capscrews securing strainer cover, strainer 3. Remove and retain nut securing coalescer filter re-
cover, gasket and element. Retain gasket. tainer.
5. Wash element in solvent and blow clean with air. 4. Remove retainer, coalescer filter element and 2
6. Wipe strainer body cavity clean with a lint-free clean O‑rings. Discard filter elements.
cloth.
5. Install new coalescer filter element(s).
7. Replace cleaned element, gasket and reattach cover
using retained capscrews.
8. Close drain valve and open strainer inlet service valve. NOTICE
9. Check for leakage. Frick SuperCoalescer™ element (with drain feature) must
10. Close disconnect switches for compressor and oil pump be installed with the "DRAIN DOWN" tag on the bottom
motor starters. at the 6 o'clock position.
11. Start the unit.
Strainer – liquid injection

CAUTION
To clean the liquid injection strainer the unit must be shut Seat element in center of locating tabs on separator
down. The procedure is as follows: bulkhead.
1. Push [STOP] key on microprocessor panel to shut 6. Replace coalescer filter retainer and nut. Tighten the
down unit, then open disconnect switches for compressor nut to 21 ft-lb torque. Do not overtighten nut. Excessive
and oil pump motor starters. torque can damage the element and result in oil car-
2. Close liquid supply service valve located before liquid ryover. Install jam nut and tighten.
solenoid. 7. Install new manway gasket and replace manway cover.
WARNING 8. While unit is at atmospheric pressure, tighten the two

12 in. x 16 in. elliptical head manway bolts to 180 ft-lb.
Excessive pressure from expanding refrigerant
9. Ensure manway bolts remain finger tight after the
trapped between stop valve and solenoid may cause compressor unit is in operation, as the manway bolts
gasket and O-ring failure and uncontrolled refrigerant will loosen as a result of pressurization.
release.
3. Close service valve located between the compressor
and the liquid injection thermovalve.
WARNING
Overtightening components could result in a fire,
4. Carefully loosen capscrews securing the strainer cover
serious injury or property damage.
to the strainer. Allow pressure to relieve slowly.
Do not apply the manway bolt torque specified for
5. When all entrapped refrigerant has been relieved,
an unpressurized unit while the unit is pressurized.
carefully remove loosened capscrews (as liquid refriger
ant is sometimes caught in the strainer), strainer cover and Applying this torque when the manway is pressur-
strainer basket. ized can overstress the manway gasket. Overstressing
the gasket can lead to gasket failure and/or a system
6. Wash the strainer basket and cover in solvent and blow
leak.
clean with air.
Trained technicians are required for servicing.
7. Reassemble strainer.
8. Open service valve between compressor and liquid 10. See Changing oil, Steps 9 through 14.
injection thermovalve and check for leakage.
Page 36 Maintenance
Changing oil 12. Open the suction and discharge service valves, and
also the liquid injection and economizer service valves, if
WARNING applicable.
Do not mix oils of different brands, manufacturers, or 13. Close the disconnect switch for compressor motor
types. Mixing of oils may cause excessive oil foaming, starter.
nuisance oil level cutouts, oil pressure loss, gas or oil 14. Start the unit.
Shut down the unit when changing oil. At the same time Demand pump disassembly
all oil filter cartridges must be changed and all oil strainer
elements removed and cleaned. The procedure is as fol-
lows:
DANGER
Before opening any viking pump liquid chamber
1. Press the [STOP] key on the microprocessor panel to (pumping chamber, reservoir, jacket, etc.) Ensure:
stop the compressor unit.
1. That any pressure in the chamber has been com-
2. Open the disconnect switch for the compressor motor
starter. pletely vented through suction or discharge lines or
other appropriate openings or connections.
3. Close the suction and discharge service valves; also
close the liquid-injection and economizer service valves, if 2. That the driving means (motor, turbine, engine,
applicable. etc.) has been locked out, or made non-operational
4. Slowly vent separator to low-side system pressure us- so that it cannot be started while work is being done
ing the bypass line on the suction trap. on the pump.
Failure to follow above listed precautionary measures
NOTICE may result in serious injury or death.
Recover or transfer all refrigerant vapor, in ac- 1. Mark head and casing before disassembly to ensure
cordance with local ordinances, before opening to proper reassembly. The idler pin, which is offset in the
atmosphere. The separator must be equalized to pump head, must be positioned up and equal distance
atmospheric pressure. between port connections to allow for proper flow of liquid
through the pump.
WARNING 2. Remove the head capscrews.
Oil-entrained refrigerant may vaporize, causing a 3. Tilt top of head back when removing to prevent idler
separator pressure increase. Repeat venting and re- from falling off idler pin.
covery procedure, if necessary.
4. Remove idler and bushing assembly. If idler bushing
5. Open the drain valve(s) located on the underside of the needs replacing, see Installing carbon graphite bushings.
separator and drain the oil. 5. Insert a brass bar or piece of hardwood in the port
6. Drain the oil filter(s) OF‑1 and, if applicable, the oil opening and between rotor teeth to keep shaft from
coolers and filter OF‑2. turning. Turn the locknut counterclockwise and remove
7. Remove the old filter cartridges, then install new ones locknut. See the following Figure.
(as previously described in the section oil filter (OF-1)
main single/dual). Figure 41: Thrust-bearing assembly (GG, HJ, HL)
8. Remove, clean, and reinstall strainer elements in the
strainers.
9. Evacuate unit to 29.88 in. Hg (1000 microns) vacuum.
10. Open the 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 under the separator. Using a
pressure-type oil pump and recommended Frick oil, open
the drain valve and fill the separator until the oil level is
midway in the top sight glass.
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.
Refer to the table in the oil charge section for approxi-
mate oil charge quantities.
Maintenance Page 37
Figure 42: Thrust-bearing assembly (AS, AK, AL) and replace if necessary. Check all other parts for nicks,
burrs, excessive wear and replace if necessary.
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 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
bearings if bearings 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.
6. Loosen two setscrews in face of bearing housing and Demand pump assembly
turn thrust bearing assembly counterclockwise and remove Assembly notes on standard mechanical seal, synthetic
from casing. See Figure 41 or 30. rubber bellows type.
7. GG, HJ, HL: Remove snap ring from shaft. See Figure 41.
AS, AK, AL: Remove bearing spacer from shaft. See Figure NOTICE
42.
Read carefully before reassembling pump:
8. Remove brass bar or piece of hardwood from port The seal used in this pump is simple to install and
opening. good performance will result if care is taken during
installation.
9. The rotor and shaft can now be removed by tapping
on end of shaft with a lead hammer or, if using a regu- The principle of mechanical seal is contact between
lar hammer, use a piece of hardwood between shaft and the rotary and stationary members. These parts are
hammer. lapped to a high finish and their sealing effectiveness
depends on complete contact.
The rotary member of the seal will come out with rotor Prior to installing rotary portion of mechanical seal,
and shaft. prepare and organize rotor shaft, head and idler as-
10. AS, AK, AL: Remove bearing retainer washer. The semblies and appropriate gaskets for quick assembly
washer may have stayed with rotor and shaft when re- Once rotary portion of mechanical seal is installed
moved or is against ball bearing. See Figure 42. on rotor shaft, it is necessary to assemble parts as
quickly as possible to ensure that the seal does not
11. Remove the mechanical seal rotary member and spring stick to shaft in wrong axial position. The seal will
from rotor and shaft assembly. stick to the shaft after several minutes setting time.
12. GG, HJ, HL: Remove inner snap ring and single-row Never touch sealing faces with anything except clean
ball bearing from casing. hands or clean cloth. Minute particles can scratch the
seal faces and cause leakage.
AS, AK, AL: Remove single-row ball bearing from casing.
13. Remove seal seat or stationary part of seal from cas- 1. Coat idler pin with refrigeration oil and place idler and
ing. bushing on idler pin in head. If replacing a carbon-graphite
bushing, see Installing carbon graphite bushings.
14. Disassemble thrust-bearing assembly.
2. Clean rotor hub and casing seal housing bore. Make
GG, HJ, HL: Remove outer snap ring from bearing housing sure both are free from dirt and grit. Coat outer diameter
and remove ball bearing. See Figure 41. of seal seat and inner diameter of seal housing bore with
AS, AK, AL: Loosen two set screws in flange outside di- refrigeration oil.
ameter. Rotate end cap and lip seal counterclockwise and 3. Start seal seat in seal housing bore. If force is neces-
remove. Remove ball bearing. See Figure 42. sary, protect seal face with a clean cardboard disc and
The casing should be examined for wear, particularly in gently tap it in place with a piece of wood. Be sure seal
the area between ports. All parts should be checked for seat is completely seated in the bore.
wear before pump is put together. 4. Place tapered installation sleeve on shaft. Refer to
When making major repairs, such as replacing a rotor and Figure 43. Sleeve is furnished with GG, AS, AK, and AL
shaft, it is advisable to also install a new mechanical seal, replacement mechanical seals. Coat rotor shaft, tapered
head and idler pin, idler, and bushing. See Installing carbon installation sleeve, and inner diameter of mechanical seal
graphite bushings. rotary member with a generous amount of refrigeration
oil. Petrolatum may be used but grease is not recom-
Clean all parts thoroughly and examine for wear or dam- mended.
age. Check lip seals, ball bearings, bushing, and idler pin
Page 38 Maintenance
Figure 43: Shaft with sleeve 12. GG, HJ, HL: Install shaft snap ring in groove in the
shaft. See Figure 41.
AS, AK, AL: Install bearing spacer over shaft and against
single row ball bearing. See Figure 42.
13. Pack lubrication chamber between inner ball bear-
ing and double-row ball bearing in the thrust-bearing
assembly approximately one‑half full of multipurpose
grease, NLGI #2. The thrust-bearing assembly will take the
remaining space. See Figure 41 and Figure 42.
14. Pack double-row ball bearing with multipurpose
grease, NLGI #2.
GG, HJ, HL: Install ball bearing into bearing housing with
shield side toward coupling end of shaft. See Figure 42.
5. Place seal spring on shaft against rotor hub. See fol- Install snap ring into bearing housing to retain ball bearing.
lowing Figure. This snap ring has a tapered edge to fit tapered groove in
Figure 44: Shaft with seal spring bearing housing. The tapered edge is located away from
ball bearing.
AS, AK, AL: Install ball bearing into bearing housing. In
stall lip seal in bearing housing end cap. The lip should
face towards end of shaft. Put bearing spacer collar in lip
seal and install in bearing housing and tighten setscrews
securely. See Figure 42.
15. Insert brass bar or hardwood through port opening
between rotor teeth to keep shaft from turning.
16. Start thrust-bearing assembly into casing. Turn by hand
until tight. This forces rotor against head. Replace and
tighten locknut or shaft.
17. Remove brass bar or hardwood from port opening.
6. Slide rotary member, with lapped contact surface 18. Adjust pump end clearance.
facing away from spring, over installation sleeve on shaft
until just contacting the spring. Do not compress spring.
Remove installation sleeve.
DANGER
Before starting pump, ensure that all drive equipment
7. Coat rotor shaft with refrigeration oil. Install shaft guards are in place. Failure to properly mount guards
slowly pushing until the ends of rotor teeth are just below may result in serious injury or death.
the face of the casing.
8. Leave the rotor in this position. Withdrawal of rotor
and shaft may displace the carbon seal rotating face and
Thrust bearing adjustment
result in damage to the seal. See Figure 41 and Figure 42. Loosen two screws in face of
thrust-bearing assembly. If shaft cannot be rotated freely,
9. Place O‑ring gasket on head and install head and idler turn thrust-bearing assembly counterclockwise until shaft
assembly on pump. Pump head and casing were marked can be turned easily.
before disassembly to ensure proper reassembly. If not, be
sure idler pin, which is offset in pump head, is positioned 1. While turning rotor shaft, rotate thrust-bearing assem-
up and equal distance between port connections to allow bly clockwise until noticeable drag occurs. This is zero end
for proper flow of liquid through pump. clearance.
10. Tighten head capscrews evenly 2. Mark position of bearing housing with respect to the
casing.
11. Pack inner ball bearing with multipurpose grease, NLGI
#2. 3. Rotate thrust-bearing assembly counterclockwise the
distance listed below as measured on outside of bearing
GG, HJ, HL: Install bearing in casing with sealed side to- housing.
wards head end of pump. Drive the bearing into the bore.
Tap the inner race with a brass bar and lead hammer to 4. Tighten two setscrews in face of bearing housing after
position bearing. Install inner snap ring. adjustment is made to secure thrust-bearing assembly
position.
AS, AK, AL: Install bearing retainer washer over the shaft
before installing ball bearing. Install ball bearing in casing For viscosities above 2500 SSU, add additional end clear-
with sealed side towards head end of pump. Drive the ance (0.004 in. for GG, HJ and HL size pumps and 0.005 in.
bearing into the bore. Tap the inner race with a brass bar for AS, AK and AL size pumps).
and lead hammer to position bearing.
Maintenance Page 39
Table 11: Thrust bearing assembly adjustment c. Pump is worn.

Pump Distance (in.) on O.D. End clearance d. Pump is dry - should be primed.
size of bearing housing (in.) 3. Fluttering, jumping, or erratic reading:
GG 7/16 0.003 a. Liquid vaporizing.
HJ, HL 9/16 0.003 b. Liquid coming to pump in slugs - possibly an air leak
AS, AK, AL 1/2 0.003 or insufficient liquid above the end of the suction pipe.
c. Vibrating from cavitation, misalignment, or damaged
Installing carbon graphite bushings parts.
When installing carbon graphite bushings, extreme
care must be taken to prevent breaking. Carbon graph-
Pressure gauge - discharge port
ite is brittle and easily cracked. If cracked, the bushing 1. High reading would indicate:
will quickly disintegrate. Using a lubricant and adding a a. High viscosity and small and/or long discharge line.
chamfer on the bushing and the mating part will help in b. Gate valve partially closed.
installation. The additional precautions listed below must c. Filter plugged.
be followed for proper installation: d. Vertical head did not consider a high specific gravity
1. A press must be used for installation. liquid.
e. Line partially plugged from buildup on inside of pipe.
2. Be certain bushing is started straight. f. Liquid in pipe not up to temperature.
3. Do not stop pressing operation until bushing is in prop- g. Liquid in pipe has undergone a chemical reaction and
er position. Starting and stopping will result in a cracked has solidified.
h. Relief valve set too high.
bushing.
2. Low reading would indicate:
4. Check bushing for cracks after installation. a. Relief valve set too low
b. Relief valve poppet not seating properly.
Troubleshooting the demand pump c. Too much extra clearance.
d. Pump worn.
DANGER 3. Fluttering, jumping, or erratic reading:
a. Cavitation.
Before opening any pump liquid chamber (pumping b. Liquid coming to pump in slugs.
chamber, reservoir, jacket etc.) Ensure: c. Air leak in suction line.
d. Vibrating from misalignment or mechanical problems.
1. That any pressure in chamber has been completely
vented through suction or discharge lines or other Some of the following may also help pinpoint the
appropriate openings or connections. problem:
2. That the driving means (motor, turbine, engine, 1. Pump does not pump.
etc.) has been locked out, or made nonoperational so a. Lost its prime - air leak, low level in tank.
that it cannot be started while work is being done on b. Rotating in wrong direction.
pump. c. Motor does not come up to speed.
d. Suction and discharge valves not open.
Failure to follow above listed precautionary measures e. Strainer clogged.
may result in serious injury or death. f. Relief valve set too low, relief valve poppet stuck open.
g. Pump worn out.
Mark valve and head before disassembly to ensure proper h. Any changes in the liquid system, or operation that
reassembly. would help explain the trouble, e.g. new source of
supply, added more lines, inexperienced operators, etc.
If trouble does develop, one of the first steps toward find- i. Tighten end clearance.
ing the difficulty is to install a vacuum gauge in the suction j. Head position incorrect.
port and a pressure gauge in the discharge port. Readings 2. Pump starts, then loses its prime.
on these gauges often will give a clue as to where to start a. Low level in tank.
looking for the trouble. b. Liquid vaporizing in the suction line.
c. Air leaks or air pockets in the suction line; leaking air
Vacuum gauge—suction port through packing or mechanical seal.
d. Worn out.
1. High reading would indicate:
a. Suction line blocked - foot valve stuck, gate valve 3. Pump is noisy
closed, strainer plugged. a. Pump is being starved (heavy liquid cannot get to
b. Liquid too viscous to flow through the piping. pump fast enough). Increase suction pipe size or
c. Lift too high. reduce length.
d. Line too small. b. Pump is cavitating (liquid vaporizing in the suction
line). Increase suction pipe size or reduce length; if
2. Low reading would indicate -
pump is above the liquid, raise the liquid level closer
a. Air leak in suction line.
to the pump; if the liquid is above the pump, increase
b. End of pipe not in liquid.
the head of liquid.
Page 40 Maintenance
c. Check alignment. evidence of drag or contact in pump and increase

d. May have a bent shaft or rotor tooth. Straighten or clearance where necessary
replace.
6. Rapid Wear.
e. May be a foreign object trying to get into the pump
a. Examination of a pump that has gradually lost its
through the suction port.
ability to deliver capacity or pressure would show a
4. Pump not up to capacity smooth wear pattern on all parts. Rapid wear shows
a. Starving or cavitating - increase suction pipe size or up as heavy grooving, galling, twisting, breaking, or
reduce length. similar severe signs of trouble.
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
Preventive maintenance
is it wired up correctly Performing a few preventive maintenance procedures will
e. Relief valve set too low or stuck open. extend the life of your pump and reduce the cost per gal-
f. Pump worn out. lon pumped.
g. Tighten end clearance.
h. Head position incorrect. 1. Lubrication - Grease all zerks after every 500 hours of
operation or after 60 days, whichever occurs first. If ser-
5. Pump takes too much power. vice is severe, grease more often. Do it gently with a hand
a. Running too fast - is correct motor speed, reducer gun. Use #2 ball bearing grease for normal applications.
ratio, sheave size, etc. being used. For hot or cold applications, use appropriate grease.
b. Liquid more viscous than unit sized to handle - heat
the liquid, increase the pipe size, slow the pump down, 2. Packing adjustment - Occasional packing adjust-
or get a bigger motor. ment may be required to keep leakage to a slight weep; if
c. Discharge pressure higher than calculated - check impossible to reduce leakage by gentle tightening, replace
with pressure gauge. Increase size or reduce length packing or use different type. See Technical Service
of pipe, reduce speed (capacity), or get bigger motor. Manual on particular model series for details on repacking.
d. Pump misaligned.
e. Extra clearance on pumping elements may not be 3. End clearance adjustment - After long service the
sufficient for operating conditions. Check parts for running clearance between the end of the rotor teeth and
Maintenance schedule
Follow this schedule to ensure trouble-free operation of the compressor unit.
Table 12: Maintenance schedule
Frequency or hours of operation (maximum)
40,000
80,000
60,000
90,000
30,000
20,000
50,000
70,000
10,000
45,000
85,000
65,000
95,000
35,000
25,000
55,000
75,000
15,000
8000
5000
1000
Task description
200
Change oil As directed by oil analysis

Oil analysis n Every 6 months
Replace oil filters (g) n As directed by oil analysis
Clean oil strainers n n n n n n n n n n n
Clean liquid strainers n n n n n n n n n n n
Replace coalescers n n n
Check and clean suction strainer n n n n n n n n n n n
Check coupling (a) n Annually regardless of operating hours
Check alignment (h) n n n n n n n n n n n
Suction and discharge flange bolts (d) n n n n n n n n n n n n n n n n n n n n n n
Vfd units check skip freq. (f) Check annually
Check electrical connections (b) n n n n n n n n n n n n n n n n n n n n
Check sensor calibration (c) n n n n n n n n n n n n n n n n n n n n n
Test high pressure cut-out Test annually
Vibration analysis (e) Every 6 months, more frequently if levels increase
Motor grease See motor grease section. Follow motor manufacturers recommendation.
Replace shaft seal When leak rate exceeds 7 to 8 drops a minute
a. Check bolts, shim packs, center inserts, keys, and all bolt torques.
b. Check and torque all terminals in the processor and starter panel per the specification posted in the enclosure.
c. Check calibration of slide valve, slide stop, pressures and temperatures. Calibration should be conducted with NIST certified devices.
d. Verify tightness of bolts on suction and discharge flanges. See Table 13 for torque requirements.
e. 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 Maintenance program section below.
f. Units with variable speed drives - check for excess vibration and skip frequencies anytime unit operating conditions change.
g. The filter may need to be changed more frequently based on differential pressure or as directed by oil analysis.
h Refer to 070.210-IB for foot mounting alignment.
Maintenance Page 41
the head may have increased through wear to the point Vibration analysis
where the pump is losing capacity or pressure. Resetting
Periodic vibration analysis can be useful in detecting
end clearance will normally improve pump performance.
bearing wear and other mechanical failures. If vibration
See Technical Service Manual on particular model series
analysis is used as a part of your preventive maintenance
for procedure on adjusting end clearance for the pump
program, take the following guidelines into consideration.
involved.
1. Always take vibration readings from exactly the same
places and at exactly the same percentage of load.
Maintenance program
To obtain maximum compressor unit performance and 2. Use vibration readings taken from the new unit at
ensure reliable operation, follow a regular maintenance start-up as the base line reference.
program. 3. Evaluate vibration readings carefully as the instrument
range and function used can vary. Findings can be eas-
Check the compressor unit daily for leaks, abnormal vibra-
ily misinterpreted.
tion, noise, and proper operation. A log should also be
maintained. Initial oil analysis and vibration analysis should 4. Vibration readings can be influenced by other equip
be done at start-up and continued per the maintenance ment operating in the vicinity or connected to the
schedule. same piping as the unit.
Vibration analysis is recommended every 6 months to Figure 45: Multivalve Arr. - 496, 676, 856 and 1080
ensure that the internal components of the screw com-
pressor 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, the 6 month vibration analysis is not re-
quired. Frick PhD provides continuous vibration monitoring
that fulfills the maintenance requirement. If the Frick PhD
has 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 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.
Table 13: RWF II bolt sizes and torque values

RWF II Compressor Disch. flange to separator flange Compressor suction flange Strainer trap Multi-valve inlet
model model Bolt size (mm) Torque* (ft-lb) Bolt size (mm) Torque* (ft-lb) Torque* (ft-lb) Torque* (ft-lb)
100/119 SS SGC 1913 M20 X 2.5 180 M20 X 2.5 180 180 —
134/159 SS SGC 1918 M20 X 2.5 180 M20 X 2.5 180 180 —
177/209 SS SGC 2313 M20 X 2.5 180 M20 X 2.5 180 180 —
222/264 SS SGC 2317 M20 X 2.5 180 M22 X 2.5 280 280 —
270 SGC 2321 M20 X 2.5 180 M22 X 2.5 280 280 —
316/375 SS SGC 2813 M22 X 2.5 280 M22 X 2.5 280 280 —
399/472 SS SGC 2817 M22 X 2.5 280 M24 X 3.0 300 300 —
480 SGC 2821 M22 X 2.5 280 M24 X 3.0 300 300 —
546 SGC 2824 M22 X 2.5 280 M24 X 3.0 300 300 —
496 SGCB/H 3511 M24 X 3.0 300 M30 X 3.5 350 250 250
676 SGCB/H 3515 M24 X 3.0 300 M30 X 3.5 350 250 250
SGCB/H 3519
856 M24 X 3.0 300 M30 X 3.5 350 250 250
SGXB/H 3519
1080 SGXB 3524 M24 X 3.0 300 M30 X 3.5 350 250 250
* Based on: Gaskets-Garlock® Blue-Gard® 3300; Bolts-class 8.8 or stronger hex head bolts, lightly oiled and clean
Page 42 Maintenance
Oil quality and analysis 2. Unthread the bottle cap and carefully position under
the oil sampling valve spout. Place the spout inside the
High quality refrigeration oil is necessary to ensure
bottle.
compressor longevity and reliability. Oil quality will rapidly
deteriorate in refrigeration systems containing moisture 3. Push the oil sampling valve to open and release to
and air or other contaminants. In order to ensure the qual- close (spring actuated, see Figure 46, inset). Fill the bottle
ity of the refrigeration oil in the compressor unit. 3/4 full.
4. Retighten bottle cap, sampling valve cap and locknut.
WARNING Please note that the locknut prevents accidental release of
oil.
Do not mix oils of different brands, manufacturers, or
5. Record all necessary sample data and identification on
types. Mixing of oils may cause excessive oil foaming,
forms and labels and send promptly to the lab for results.
Operating log
NOTICE The use of an operating log as included in this manual (see
Table of Contents) permits thorough analysis of the opera-
The Frick oil charge shipped with the unit is the best tion of a refrigeration system by those responsible for its
suited lubricant for the conditions specified at the maintenance and servicing. Continual recording of gauge
time of purchase. If there is any doubt due to the re- pressures, temperatures, and other pertinent information,
frigerant, operating pressures, or temperatures, refer enables the observer and serviceman to be constantly
to Frick Oil publication 160.802-SPC for guidance. familiar with the operation of the system and to recognize
Only use Frick oil filter elements or warranty claim immediately any deviations from normal operating condi-
may be denied. tions. It is recommended that readings be taken at least
every four hours.
1. Participate in a regular, periodic oil analysis program
to maintain oil and system integrity. Oil analysis kit part
number: 333Q0001853.
Motor bearings
Follow the motor manufacturer’s maintenance
2. Oil samples for analysis should be taken after the oil recommendations for lubrication. See Table 14 and Table
filter. A 1/4 in. purge valve is provided in the oil filter can- 15 for WEG and Marathon.
ister head.
Figure 46: Oil sampling valve
WARNING
Make sure the motor bearings are properly lubricated
Locknut before start-up as required by the motor manufacturer.
Valve Cap
DO NOT & Spout
UNTHREAD
VALVE!
Oil sampling procedure

WARNING
Exercise extreme caution in the vicinity of operating
equipment. Skin contact with lube oil or inhalation
of vapors can cause serious injury or death, consider
gloves and eye protection.
Sample hot, active fluid while the equipment is operating.
Sample after 30 min of compressor operation.
1. Unthread the oil sampling valve cap and locknut
(see Figure 46).
CAUTION
Do not unthread the valve from the filter housing or
piping or uncontrolled release of oil will result.
Maintenance Page 43
Relubrication interval and instructions – WEG electric motor

Table 14: Motor lubrication schedule. For WEG Electric Motors only. For other manufacturers, follow their schedule
WEG relubrication interval

W40 platform and ODP NEMA premium motors. Excludes W50 and W60 platforms
Sync. Service cycle - ball bearings
Amount Interval
Drive Speed Frame size Grease
(g) (h) 8 hr/day operation 24 hr/day operation
(rpm)
1500 & 284 - 326 15 10800 1350 days (10,800 hr) 450 days (10,800 hr)
1800 364 & 365 27 10800 1350 days (10,800 hr) 450 days (10,800 hr)
284 - 326 15 10800 1350 days (10,800 hr) 450 days (10,800 hr)
SSS¹
364 – 5010 8 1100 135 days (1100 hr) 45 days (1100 hr)
3600
L5010 Polyrex 15 1100 135 days (1100 hr) 45 days (1100 hr)
L5809 EM 19 1100 135 days (1100 hr) 45 days (1100 hr)
284 - 326 15 8800 1100 days (8,800 hr) 366 days (8,800 hr)
≤ 4200
364 - 5010 16 1100 135 days (1100 hr) 45 days (1100 hr)
VSD²
L5010 15 1100 135 days (1100 hr) 45 days (1100 hr)
≤ 3600
L5809 19 1100 135 days (1100 hr) 45 days (1100 hr)
L5010 17 1100 135 days (1100 hr) 45 days (1100 hr)
VSD2,3 > 3600 Isoflex
L5809 21 1100 135 days (1100 hr) 45 days (1100 hr)
1: Solid State Starter / 2: Variable Speed Drive
3: L5010-L5809 frames intended for operation above 3600 rpm on VSD must be reviewed and approved by WEG
4: 364-L5809 frames: Bearing caps should be removed and cleaned of excess grease after 8800 hr
Procedure/warning:
- With the motor shutdown, inject approximately half of the total grease quantity to be used and operate the motor for approxi-
mately one (1) minute in full rotation speed.
- Shutdown the motor and inject the remaining grease. The injection of the entire amount of grease in an idle motor may cause
part of the lubricant to penetrate into the inner part of the motor through the internal sealing of the bearing cap.
- The lubrication intervals specified consider an absolute temperature on the bearing of 149°F (65°C) the motor running at rated
speed, a motor mounted in horizontal position and greased with appropriate grease based on table above. Any variation of the
parameters listed above must be evaluated by WEG engineering.
- For each increment of 27°F (15°C) above the bearing temperature, the relubrication intervals given in the Table must be halved.
For special applications such as: high and low temperatures, aggressive environments, vertical mounting position, etc., please
contact WEG about the required amount of grease and the relubrication intervals.
Relubrication interval and instructions – Marathon

Table 15: Motor Lubrication schedule. For Marathon* Motors only. For other manufacturers, follow their schedule
*Previously Regal, Ram, Schneider Electric

Page 44 Maintenance
Grease compatibility Abnormal operation analysis and

The motor nameplate will list the manufacturer’s recom- correction
mended grease. Use of grease other than recommended Four logical steps are required to analyze an operational
by the manufacturer may result in premature motor failure problem effectively and make the necessary corrections:
and denied warranty claims. The proper grease is available
through the Baltimore Parts Center or motor supplier. 1. Define the problem and its limits.
2. Identify all possible causes.
3. Test each cause until the source of the problem is
Troubleshooting guide found.
Successful problem solving requires an organized approach 4. Make the necessary corrections.
to define the problem, identify the cause, and make the
The first step in effective problem solving is to define the
proper correction. Sometimes it is possible that two
limits of the problem. If, for example, the compressor pe-
relatively obvious problems combine to provide a set of
riodically experiences high oil temperatures, do not rely on
symptoms that can mislead the troubleshooter. Be aware
this observation alone to help identify the problem. On the
of this possibility and avoid solving the wrong problem.
basis of this information the apparent corrective measure
Table 16: Pressure transducer voltage-psi conversion would appear to be a readjustment of the liquid injection
system. Lowering the equalizing pressure on the thermal
Sensor 200 psi 500 psi expansion valve would increase the refrigerant feed and
Voltage Range - psig* Range - psig*
the oil temperature should drop.
Low High Low High
1.0 29.92" 9.57" 29.92" 4.1 If the high oil temperature was the result of high suction
1.1 29.92" 0.3 29.92" 16.6 superheat, however, and not just a matter of improper
1.2 29.92" 5.3 17.10" 29.1 liquid injection adjustment, increasing the liquid feed could
1.3 19.74" 10.3 4.1 41.6 lead to other problems. Under low load conditions the
1.4 9.57" 15.3 16.6 54.1 liquid injection system may have a tendency to overfeed.
1.5 0.3 20.3 29.1 66.6 The high suction superheat condition, moreover, may only
1.6 5.3 25.3 41.6 79.1
be temporary. When system conditions return to normal
1.7 10.3 30.3 54.1 91.6
1.8 15.3 35.3 66.6 104.1 the unit’s liquid injection will overfeed and oil temperature
will drop. In solving the wrong problem a new problem
1.9 20.3 40.3 79.1 116.6
was created.
2.0 25.3 45.3 91.6 129.1
2.1 30.3 50.3 104.1 141.6 When an operating problem develops, compare all
2.2 35.3 55.3 116.6 154.1 operating information on the main operating screen with
2.3 40.3 60.3 129.1 166.6 normal operating conditions. If an Operating Log has been
2.4 45.3 65.3 141.6 179.1 maintained the log can help determine what constitutes
2.5 50.3 70.3 154.1 191.6 normal operation for the compressor unit in that particular
2.6 55.3 75.3 166.6 204.1 system.
2.7 60.3 80.3 179.1 216.6
2.8 65.3 85.3 191.6 229.1
The following list of abnormal system conditions can cause
2.9 70.3 90.3 204.1 241.6 abnormal operation of the RWF II compressor unit:
3.0 75.3 95.3 216.6 254.1 1. Insufficient or excessive refrigeration load.
3.1 80.3 100.3 229.1 266.6 2. Excessively high suction pressure.
3.2 85.3 105.3 241.6 279.1 3. Excessively high suction superheat.
3.3 90.3 110.3 254.1 291.6
4. Excessively high discharge pressure.
3.4 95.3 115.3 266.6 304.1
3.5 100.3 120.3 279.1 316.6 5. Inadequate refrigerant charge or low receiver level.
3.6 105.3 125.3 291.6 329.1 6. Excessively high or low temperature coolant to the oil
3.7 110.3 130.3 304.1 341.6 cooler.
3.8 115.3 135.3 316.6 354.1 7. Liquid return from system (slugging).
3.9 120.3 140.3 329.1 366.6 8. Refrigerant underfeed or overfeed to evaporators.
4.0 125.3 145.3 341.6 379.1 9. Blocked tubes in water-cooled oil cooler from high
4.1 130.3 150.3 354.1 391.6 mineral content of water.
4.2 135.3 155.3 366.6 404.1
10. Insufficient evaporator or condenser sizing.
4.3 140.3 160.3 379.1 416.6
4.4 145.3 165.3 391.6 429.1 11. Incorrect refrigerant line sizing.
4.5 150.3 170.3 404.1 441.6 12. Improper system piping.
4.6 155.3 175.3 416.6 454.1 13. Problems in electrical service to compressor unit.
4.7 160.3 180.3 429.1 466.6 14. Air and moisture present in the system.
4.8 165.3 185.3 441.6 479.1
Make a list of all deviations from normal plant operation
4.9 170.3 190.3 454.1 491.6
5.0 175.3 195.3 466.6 504.1 and normal compressor unit operation. Delete any items
At 0 psig 1.094 V 1.494 V 0.968 V 1.268 V which do not relate to the symptom and separately list
* Below 0 psig measured in inches of mercury.
Maintenance Page 45
those items that might relate to the symptom. Use the list The spring is compressed with a large bolt (7). If it is nec-
as a guide to further investigate the problem. essary to repair the valve, it can be dismantled as follows:
The second step in problem solving is to decide which 1. To manually open the valve, mount the hexagon screw
items on the list are possible causes and which items are (29), the hexagon flange nut (28) and the nylon ring (27) as
additional symptoms. High discharge temperature and high shown. Tighten the nut (28) a few turns, in order to redraw
oil temperature readings on a display may both be symp- the valve cone from the seat.
toms of a problem and not casually related. High suction
superheat or a low receiver level, however, could cause
both symptoms.
NOTICE
The third step is to identify the most likely cause and take Step 1 is not strictly necessary when dismantling the
action to correct the problem. If the symptoms are not valve, but will prevent the valve seat gasket from
relieved move to the next item on the list and repeat the being exposed to a shear load, and it will keep all
procedure until you have identified the cause of the prob- internal valve parts together as a unit.
lem. Once the cause has been identified and confirmed
2. Loosen the screws (24) by 0.315 in (8 mm), and ensure
make the necessary corrections.
that the bonnet (2) is not under pressure from the spring.
Servicing the cold-start valve If the bonnet is under pressure from the spring (15)
after all the screws have been loosened by 0.315 in (8
Figure 47: Cold-start valve mm), there is a damage inside the valve. In this case, it is
important to remove only two screws, one from each side.
In the threaded holes from which the two screws have
been removed, insert studs with nuts (see table for size)
and turn the nuts down to meet the bonnet (2). Studs
must be about the same length as the valve body. Then
remove the remaining two screws (24), loosen the nuts on
the studs, and carefully ease off the bonnet. All internal
parts can then be safely removed.
NOTICE
If step 1 was followed, loosen the hexagon nut (28)
carefully, holding the hexagon screw (29) in place.
If the bonnet is not under pressure from the spring, all

screws (24) can be removed. The bonnet and all internal
parts can now be removed from the valve body.
When internal parts have been taken out of the valve
body, the spring can be removed by unscrewing the spring
bolt (7).
Before beginning to disassemble the valve, the refrigerant
must be removed from all associated piping.
NOTICE
Start room ventilation and put on a safety mask.
When assembling the valve, the bonnet gasket (17)
must be captured in the groove in the bonnet (2).
WARNING
Be extremely careful when dismantling the cold-start After the bonnet assembly is mounted into the valve
valve on the discharge side of the unit, as condensed housing (1), install and tighten bonnet cap screws (24). The
refrigerant often is trapped between the cold-start required torque is shown for each valve size in the table
valve and the stop valve. A bleed valve on the side below.
of the check valve is used to vent the space between
the check valve and stop valve. Exposure to refriger- Table 17: Bonnet cap screw torque values
ant fumes can cause injury or death. Valve Torque Valve Torque Screw
size (N.m) size (lb-ft) size
DN (mm) ANSI (in.) (mm)
WARNING 65 74 2 1/2 54 M12
Inside the valve (see Figure 47) there is a very heavy, 80 44 3 32 M10
tight spring (15). Provided the valve is intact, the 100 74 4 54 M12
spring presents no danger when dismantling. 125 183 5 134 M16
150 183 6 134 M16
200 370 8 271 M20
Page 46 Maintenance
EZ-CAL High pressure cut-out check Pressure transducers – testing

valve test block 1. Shut down the compressor and allow pressures to
The optional Frick EZ-CAL™ test block may be installed on equalize.
the package and can be used for the periodic testing and 2. Isolate suction transducer PE-4 from the unit and
calibration of the high discharge pressure limiting device depressurize. Ensure that the transducer has proper volt-
(High Pressure Cut-out, or HPCO). age for excitation. Measure across the red and black wires
This block is installed near the Quantum HD electronic (power and DC common) of the transducer. Voltage should
controller and contains the discharge pressure transducer be 11.8 VDC to 15 VDC.
(connected to the electronic controller as a HPCO). This
block is factory installed on the package, the pressure NOTICE
transducer is wired to the Quantum HD controller and
Recover or transfer all refrigerant vapor, in ac-
tubing is run to the compressor discharge connection (See
cordance with local ordinances, before opening to
pages 51 and 54 for diagrams). atmosphere.
The block can be locked in the RUN position during normal 3. Measure the voltage of PE-4 on connector P6A (ter-
operation, but the compressor is still protected from a minals WHT and BLK) on the Analog Board with a digital
high pressure event in either operational position. voltmeter.
EZ-Cal principles of operation 4. The voltage reading should be 1.48 VDC to 1.72 VDC at
standard atmospheric pressure (14.7 psia or 0 psig). When
The test block functions as a low pressure drop check checking transducers at higher elevations, an allowance
valve, not a stop valve, in the line from the discharge in the readings must be made by subtracting approxi-
pressure source to the HPCO. In the RUN position the mately 0.02 VDC per 1000 ft of elevation above sea level.
HPCO is fully open to the discharge pressure source. Therefore, if PE-4 is measured at 5000 ft elevation under
In the TEST position an external pressure source is con- relatively normal weather conditions, the output voltage
nected to the test connection quick connect and when the should differ by 0.10 VDC to read between 1.38 VDC and
valve is switched to TEST position, the external source is 1.62 VDC.
connected directly to the HPCO. This allows the func- 5. Isolate the oil pressure transducer PE-1 from the pack-
tion of the HPCO and pressure setting to be confirmed age and open it to atmosphere.
by application of external pressure while comparing the
compressor discharge pressure reading to a master gauge. 6. Measure the voltage of PE-1 on connector P5A (termi-
nals WHT and BLK) on the Analog Board.
Once the HPCO is confirmed to trip the compressor at the
correct set point, the valve is switched back to run mode 7. The voltage reading should be between 1.1 VDC and
and any high pressure trapped above the check valve is 1.29 VDC at standard atmospheric pressure. PE-1, PE-2,
relieved back to the system. Should an actual high pres- and PE-3 all have a span of 500 psi as compared to PE-4
sure event occur, even during testing, the check valve in with a span of 200 psi. As a result, atmospheric pres-
the test block will open and expose the HPCO to the high sure changes have a lesser effect which is 0.0067 VDC
pressure level, still allowing protection of the compressor per 1000 ft of elevation and 0.00067 VDC per 0.1 in. Hg
during testing of the HPCO. barometric deviation.
8. Isolate transducer PE‑2 from the package and depres-
NOTICE surize.
Leaving the test block valve in the TEST position af-
ter testing is complete can trap the external pressure NOTICE
between the HPCO and the test port. Recover or transfer all refrigerant vapor, in ac-
cordance with local ordinances, before opening to
Leaving the test block valve in the TEST position after atmosphere.
testing is complete risks trapping the external pres- 9. Measure the voltage of PE‑2 on connector P5B (termi-
sure between the HPCO and the test port. The discharge nals WHT and BLK) on the Analog Board.
pressure reading on the control panel would not see the
decrease in discharge pressure as the system is returned 10. The voltage reading should be between 1.1 VDC and
to normal operation. Returning the test block valve to 1.29 VDC at standard atmospheric pressure (see Step 12).
the RUN position after testing opens a direct two-way
11. Since the discharge pressure, PE‑3, cannot be closed
connection between discharge pressure and the HPCO
off from its sensing point (code requirements), close all
transducer or switch.
transducers from atmosphere and open them to their
Refer to 160.100-IO for the full operation procedure and sensing points so all transducers can equalize to separator
more detail on the EZ-CAL™ Test Block and Test Pump pressure.
Calibration Kit.
12. Measure the voltage of PE‑3 on connector P5B (termi-
13. Measure the voltage of PE‑1 on connector P5A (termi-
Maintenance Page 47
14. These two voltages should be within 0.04 VDC of one Replacement
another. The Capacity Linear Transmitter is located on the end of
15. Test is complete. the compressor unload cylinder, see Figure above.
The linear transmitter with hermetic enclosure is based on
Pressure transducers – replacement the inductive measuring principle. It features removable
1. Shut off control power. electronics (from the sensor well) eliminating the need
2. Close the applicable transducer isolation valve. to evacuate the compressor for replacement. This type
of transmitter is dedicated to capacity control and is not
NOTICE adjustable.
To change the discharge pressure transducer (PE‑3), it 1. Shut off control power.
will be necessary to depressurize the entire compres- 2. Remove DIN connector plug from transmitter.
sor package. Follow "General Instructions For Replac- 3. Loosen cap screws.
ing Compressor Unit Components" before going to
step 3. 4. Remove transmitter unit.
5. Install new transmitter unit.
Figure 48: Pressure transducer color key 6. Tighten cap screws.
7. Apply DIN connector plug to transmitter.
CABLE COLOR CODE 8. Turn on control power.
PIN 1 + SUPPLY
1
PIN 2 DC COMMON
NOTICE
3
For calibration instructions, refer to Quantum™ HD

2 PIN 3 SIGNAL
Operator's Manual, 090.040-O.
CASE GND
Troubleshooting the sensor
3. See the Figiure above to identify wiring harness con- Ensure that the channel is properly configured on the Cali-
nectors.
bration or Analog board setup screen for the type sensor
4. Loosen screw and disconnect wiring harness connector being used.
from transducer.
5. Unscrew the transducer using a wrench on the metal Check that supply voltage to the sensor is 12 VDC to 15
hex at the base of the transducer. Do not attempt to VDC on red and black wire for Channel 14, P7A terminal
loosen or tighten transducers by their top casing. strip of the Analog Board.
6. Install new transducer. Check for a returning signal of:
7. Reconnect the wiring harness to the transducer.
• 1 VDC to 5 VDC for a transducer
8. Reopen the transducer isolation valve.
• 4 mA to 20 mA for a linear transmitter
9. Turn on control power.
• 0 VDC to 5 VDC for a Potentiometer
NOTICE • 0.273 mA for an ICTD at 0C or ice water
The Pressure Transducer is factory set. If calibration

is required, refer to Analog Calibration Instruction in Volume ratio control transmitter –
publication 090.040-M. slide stop
Troubleshooting
Capacity linear transmitter – slide Confirm the setup of channel 15 on the calibration or ana-
valve log board #1 setup screen.
Figure 49: Capacity linear transmitter Troubleshoot the slide stop linear transmitter on chan-
nel 15 of the P7B terminal strip of the analog board in the
SHADED AREA SHOWS same manner as the slide valve transmitter.
END VIEW CAPACITY LINEAR TRANSMITTER
STAINLESS STEEL WELL Replacement

DIN CONNECTOR The volume ratio control transmitter is located on the
right side of the compressor (facing the shaft) at the inlet
end. See Figure below.
the inductive measuring principle. It features removable
HEAT ISOLATOR
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
COMPRESSOR UNLOAD CYLINDER user adjustments.
CAST ALUMINUM HOUSING

Page 48 Maintenance
1. Shut off control power. the wires removed from the board. If this is open, the
2. Remove DIN connector plug from transmitter. shunt is in the sensor. It is always a good idea to physically
3. Loosen set screws. inspect the wiring of the DIN Plug.
4. Remove transmitter unit.
6. Tighten set screws.
WARNING
7. Apply DIN connector plug to transmitter. Be extremely careful not to loosen thermowell while
8. Turn on control power. attempting to remove the temperature sensor.
The use of two wrenches will be necessary to ensure
NOTICE the thermowell remains stationary. Loss of oil and/or
refrigerant could occur. Exposure to refrigerant fumes
For calibration of the volume ratio control unit, refer and/or hot oil can cause injury or death.
to the Calibration Instructions in publication
090.040-O.
Replacement
Figure 50: Volume ratio control transmitter
1. Shut off control power.
2. Remove DIN connector plug from transmitter. See Figure
above.
3. Unscrew knurled ring and remove transmitter unit.
4. Apply thermal compound to new sensor assembly,
insert into thermal well, and tighten knurled ring.
NOTICE
The temperature sensor is factory set. If calibration is
Temperature sensor required, refer to Calibration Instructions in publica-
tion 090.040-O for service technicians.
Troubleshooting
Confirm the setup of the channel on the calibration or Oil level transmitter
analog board #1 setup screen. Is the temperature probe
reading bottom end -459°F or top end +463°F? If reading
bottom end, the probe or wire(s) to the probe are open or
CAUTION
the probe is shorted to ground pulling down the power/ This device is static sensitive. Please follow proper
excitation. Check the power at the analog board between ESD procedures when handling.
the + and – of the channel for that probe. In Example,
discharge temperature would be Channel 2 on the P4A Troubleshooting
terminal strip of the analog board. Is there a signal of Are the red indicator lights on at the sensor? If yes, check
12 VDC to 15 VDC? If yes, the probe is not shorted to that 2CR or OLCR is energized and that module 13 of digi-
ground but is most likely open. Do continuity tests to tal board #1 is energized as well as the status of module
determine if it is the wiring or the sensor that is open. 13 is ON at the service screen for digital board #1. Correct
Correct as necessary. as necessary. If No, is there oil present in the lower sight
glass of the separator? If No, add oil to the separator. If
Figure 51: Temperature transmitter Yes, confirm that 24 VDC is getting to the sensor for exci-
tation. If yes, replace the oil level sensor. If No, check the
fuse of wire 1001. If blown, check for shorts of wire 1001;
correct and replace the fuse. If the fuse is good, check
for 24 VDC immediately upstream of the fuse back to the
power supply. Correct as necessary.
Replacement
The Oil Level Transmitter is located on the front of the
separator near the bottom/center. See Figure below.
the capacitive measuring principle. It features removable
electronics (from the sensor well) eliminating the need to
If reading top end, the sensor is being shunted and full evacuate the compressor for replacement. This transmitter
signal is coming back to the board. Check the wiring by is dedicated to oil level control and has no user adjust-
unplugging the connector at the sensor, disconnecting ments.
from the analog board, and doing a continuity test across
Maintenance Page 49
1. Shut off control power.

2. Remove DIN connector plug from transmitter.
3. Loosen set screws.
4. Remove transmitter unit.
6. Tighten set screws.
Figure 52: Oil level transmitter

Page 50 Maintenance
Troubleshooting the RWF II compressor

Symptom Probable causes and corrections
Excessive noise and vibration Main oil injection valve may be closed. Open valve.
Main oil injection valve may be open too far. Adjust.
Bearing damage or excessive wear. Contact Frick Factor or Frick service.
Slide valve/slide stop out of calibration (over- or undercompression)
Coupling loose on shaft. Tighten coupling. Replace if damaged.
If motor or compressor have been reinstalled, check that installation done according to 070.660-SM
Refrigerant flood-back. Correct system problem.
Slide valve and/or slide stop will not 4-way hydraulic control valve failed. Repair or replace.
move
Slide stop indicator rod stuck. Contact Frick Factor or Frick service for assistance.
Check both S.V. and S.S. feedback devices for wiring and resistance.
Compressor must be running with sufficient oil pressure.
Unloader piston stuck. Contact Frick Factor or Frick service for assistance.
Slipper seals worn out or damaged. Contact Frick Factor or Frick service for assistance.
NOTICE
Troubleshooting the compressor is limited to identifying the probable cause. If a mechanical problem is suspected
contact the Service Department. Do not attempt to disassemble the compressor.
Troubleshooting the demand pump system

pump will not produce enough oil Check pump rotation.
pressure to start compressor
Check that service valves are open.
Filter cartridges may be blocked. Check PSID across filters.
Strainer may be blocked. Clean.
Oil pressure regulator set too low or stuck open. Readjust or repair.
Pump worn out. Repair or replace.
Oil pressure rapidly drops Main oil injection throttling valve too wide open or oil pressure
off when compressor starts regulating valve improperly adjusted. Readjust both valves.
results in compressor
differential alarm
Oil pressure fluctuates Liquid injection overfeeding or refrigerant flood back from system. Make
necessary adjustments or corrections
Noise and vibration Pump strainer blocked. Clean.
Liquid refrigerant overfeed. Adjust liquid injection.
Pump worn out. Repair or replace.
Grease leaks from vent port Normal leakage which will cease after initial operation. Black oil leaking
in the side of the pump body from this vent indicates oil seal wear or failure. If leakage exceeds normal allowable
rate of 7 drops per minute, replace seal.
Oil pressure drops as head Normal behavior. Set main oil injection and oil pressure for maximum head
pressure increases pressure condition.
Main filter psid is too high Filters clogged with dirt. Replace.
Oil is too cold. Allow oil to warm up and check again.
Service valve on filter outlet is partially closed. Open valves fully.
Maintenance Page 51
Troubleshooting the oil separation system

Gradual oil loss with an oil Maintaining too high an oil level, lower level.
level in the coalescer
section sight glass Refrigerant carryover or liquid injection overfeeding, correct operation.
Loss of suction superheat. Adjust evaporator feeds.
Contaminated oil, damaged or not seated coalescer filter elements. Replace
oil charge and coalescers.
Coalescer return valve closed. Open return valve.
Coalescing oil return line strainer blocked. Clean.
Rapid loss with no oil level On shutdown, compressor unit suction check valve did not close. Repair valve.
in the coalescer section
sight glass Suction check valve bypass valve open too far to meter flow. Close valve.
Coalescers loose or not seated properly. Correct or replace.
On economized unit: economizer check valve not working. Repair or replace.
Economizer check valve not in automatic position or manually opened. Place in auto position.
Shaft seal leakage If leakage exceeds normal allowable rate of 7 drops per minute, replace seal.
Troubleshooting the hydraulic system

Slide valve will not load or Solenoid coils may be burned out. Test and replace if necessary.
unload
Valve may be closed. Open hydraulic service valves.
Solenoid spool may be stuck or centering spring broken. Replace.
Check outputs 2 and 3 and fuses.
Check LED on coil. If lit, there is power to the coil. Check coil.
Solenoid may be actuated mechanically by inserting a piece of 3/16 in. rod
against armature pin and pushing spool to opposite end. Push A side to
confirm unload capability. If valve works, problem is electrical.
Slide valve will load but A side solenoid coil may be burned out. Test and replace if necessary.
will not unload
Dirt inside solenoid valve preventing valve from operating both ways. Clean.
Check LED on coil. If lit, valve is functioning mechanically. Problem is electrical.
Slide valve will unload but A side solenoid coil may be burned out. Test and replace if necessary.
will not load
Dirt inside solenoid valve preventing valve from operating both ways. Clean.
Check LED on coil. If lit, valve is functioning mechanically. Problem is electrical.
Slide stop will not function Solenoid coils may be burned out. Test and replace if necessary.
either direction
Solenoid service valves may be closed. Open.
Manually actuate solenoid. If slide stop will not move mechanical problems
are indicated. Consult Frick factor or Frick service.
Page 52 Maintenance
Motor and bare compressor SAE straight thread o-ring fittings

replacement assembly procedure
Refer to publication 070.660-SM. When performing maintenance or replacing the compres-
sor, the hydraulic tubing may need to be removed and
re-installed. The following procedure outlines the proper
Shutdown due to improper oil installation of SAE straight thread fittings to SAE straight
pressure (high stage and booster) thread ports.
The compressor must not operate with incorrect oil The male and female ends of SAE straight thread O-ring
pressure. ports have UN/UNF straight threads. An elastomeric O-ring
is fitted to the male end. On assembly, the O-ring is firmly
1. Refer to Control setup - Oil setpoints display in pub-
sandwiched between the angular sealing surface of the
lication 090.040-O.
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 following table.
Table 18: SAE port adjustable fitting or plug torque

Straight and adjustable fittings or plugs (steel)
Fitting size SAE port thread size Assembly torque
in.-lb ft-lb
2 5/16 – 24 65 ± 5 5.5 ± 0.5
3 3/8 – 24 130 ± 10 11 ± 1.0
4 7/16 – 20 170 ± 10 14 ± 1.0
5 1/2 - 20 260 ± 15 22 ± 1.0
6 9/16 – 18 320 ± 20 27 ± 2.0
8 3/4 - 16 500 ± 25 42 ± 2.0
10 7/8 – 14 720 ± 30 60 ± 2.5
12 11⁄16 – 12 960 ± 50 80 ± 5.0
16 15⁄16 – 12 1380 ± 75 115 ± 6.0
20 15⁄8 – 12 2700± 150 225 ± 12.0
24 17⁄8 - 12 3000 ± 160 250 ± 12.0
Compressor port locations

Maintenance Page 53
Figure 53: Compressor port locations - RWF II 100, 119 SS, 134, 159 SS
Port Thread size O-ring

SB-3 11⁄16-12 UN-2B 980A0012K66
SC-5 9/16-18 UNF-2B 980A0012K60
SC-6 9/16-18 UNF-2B 980A0012K60
SC-8 11⁄16-12 UN-2B 980A0012K66
SC-9 9/16-18 UNF-2B 980A0012K60
SC-13 9/16-18 UNF-2B 980A0012K60
SC-14 9/16-18 UNF-2B 980A0012K60
SD-1 11⁄16-12 UN-2B 980A0012K66
SL-1 11⁄16-12 UN-2B 980A0012K66
SL-2 11⁄16-12 UN-2B 980A0012K66
SM-1 11⁄16-12 UN-2B 980A0012K66
Page 54 Maintenance
Figure 54: Compressor port locations - RWF II 177, 209 SS, 222, 264 SS, 270

SB-3 11⁄16-12 UN-2B 980A0012K66
SC-5 9/16-18 UNF-2B 980A0012K60
SC-6 9/16-18 UNF-2B 980A0012K60
SC-8 11⁄16-12 UN-2B 980A0012K66
SC-9 9/16-18 UNF-2B 980A0012K60
SC-11 15⁄16-12 UN-2B 980A0012K69
SC-13 9/16-18 UNF-2B 980A0012K60
SC-14 9/16-18 UNF-2B 980A0012K60
SD-1 11⁄16-12 UN-2B 980A0012K66
SL-1 11⁄16-12 UN-2B 980A0012K66
SL-2 11⁄16-12 UN-2B 980A0012K66
SM-1 15⁄16-12 UN-2B 980A0012K69
Maintenance Page 55
Figure 55: Compressor port locations - RWF II 316, 375 SS, 399, 472 SS

SC-5 3/4-16 UNF-2B 980A0012K62
SC-6 9/16-18 UNF-2B 980A0012K60
SC-8 15⁄16-12 UN-2B 980A0012K69
SC-9 9/16-18 UNF-2B 980A0012K60
SC-13 9/16-18 UNF-2B 980A0012K60
SC-14 9/16-18 UNF-2B 980A0012K60
SD-1 11⁄16-12 UN-2B 980A0012K66
SL-1 15⁄16-12 UN-2B 980A0012K69
SL-2 15⁄16-12 UN-2B 980A0012K69
SM-1 15⁄16-12 UN-2B 980A0012K69
Page 56 Maintenance
Figure 56: Compressor port locations - RWF II 480/546

SC-5 3/4-16 UNF-2B 980A0012K62
SC-6 9/16-18 UNF-2B 980A0012K60
SC-8 15⁄16-12 UN-2B 980A0012K69
SC-9 9/16-18 UNF-2B 980A0012K60
SC-13 9/16-18 UNF-2B 980A0012K60
SC-14 9/16-18 UNF-2B 980A0012K60
SD-1 11⁄16-12 UN-2B 980A0012K66
SL-1 15⁄16-12 UN-2B 980A0012K69
SL-2 15⁄16-12 UN-2B 980A0012K69
SM-1 15⁄8,-12 UN-2B 980A0012K71
Maintenance Page 57
Figure 57: Compressor port locations - RWF II 496
Port Size
SB-2 3/4-14 NPTF
SB-3 1½-11½ NPTF
SC-3 1/2-14 NPTF
SC-4 1/2-14 NPTF
SC-5 3/8-18 NPTF
SC-6 3/8-18 NPTF
SC-7 1/8-27 NPTF
SC-8 1¼-11½ NPTF
SC-9 1½-11½ NPTF
SC-10 1½-11½ NPTF
SD-1 1/2-14 NPTF
SL-1 1¼-11½ NPTF
SL-2 1¼-11½ NPTF
SM-1 2 in. Sq. flange
ST-1 3/4-14 NPTF
SV-1 3 in. Sq. Flange
TW-1 3/4-14 NPTF
SP-1 3/4-14 NPTF
Page 58 Maintenance
Port Size
SB-2 3/4-14 NPTF
SB-3 1½-11½ NPTF
SC-3 1/2-14 NPTF
SC-4 1/2-14 NPTF
SC-5 3/8-18 NPTF
SC-6 3/8-18 NPTF
SC-7 1/8-27 NPTF
SC-8 1¼-11½ NPTF
SC-9 1½-11½ NPTF
SC-10 1½-11½ NPTF
SD-1 1/2-14 NPTF
SL-1 1¼-11½ NPTF
SL-2 1¼-11½ NPTF
ST-1 3/4-14 NPTF
SV-1 3 in. Sq. flange
TW-1 3/4-14 NPTF
SP-1 3/4-14 NPTF
Maintenance Page 59
Port Size
SB-2 3/4-14 NPTF
SB-3 1½-11½ NPTF
SC-3 1/2-14 NPTF
SC-4 1/2-14 NPTF
SC-5 3/8-18 NPTF
SC-6 3/8-18 NPTF
SC-7 1/8-27 NPTF
SC-8 1¼-11½ NPTF
SC-9 1½-11½ NPTF
SC-10 1½-11½ NPTF
SD-1 1/2-14 NPTF
SL-1 1¼-11½ NPTF
SL-2 1¼-11½ NPTF
ST-1 3/4-14 NPTF
TW-1 3/4-14 NPTF
SP-1 3/4-14 NPTF
*RWF II 856 models using SGXB/H 3519 com-

pressors will have an additional SB-4 port.
Refer to page 49 for SC-5 and SB-4 port
locations.
Page 60 Maintenance
SM-1: MAIN OIL SL-1: LOW Vi

SC-3: INJECTION LIQUID INJECTION
MOVEABLE
SLIDE SV-1: VAPOR
STOP INJECTION
SC-9: CLOSED
THREAD
DRAIN
SC-8: CLOSED TW-1:
SC-9: CLOSED SC-6: DISCHARGE SC-10:
THREAD DRAIN THERMOWELL
THREAD DRAIN PRESSURE OIL DRAIN
DISCHARGE
SC-7: SEAL
SC-4: INLET WEAPAGE
OIL DRAIN
Port Size
SB-2 3/4-14
SB-3 1½-11½
SB-4 1-11½
SC-3 1/2-14
SC-4 1/2-14
SC-5 3/8-18
SC-6 3/8-18
SC-7 1/8-27
SUCTION PORT SC-8 1¼-11½
SD-1: COALESCER BLEED 14” CLASS 300 FLANGE SC-9 1½-11½
SP-1: HIGH SC-10 1½-11½
PRESSURE SD-1 1/2-14
OIL SL-1 1¼-11½
SB-3: SL-2 1¼-11½
DISCHARGE SM-1 2 in. Sq. flange
BEARINGS SP-1 3/4-14
ST-1 3/4-14
TW-1 3/4-14
SB-4: DAMPER SC-5: INLET

SL-2:
ST-1: THERMOWELL SUCTION OIL FEED PRESSURE
HIGH Vi LIQUID
INJECTION SB-2: INLET
BEARINGS AND
BALANCE
PISTON
DISCHARGE PORT
10” CLASS 300 FLANGE
Piping and instrumentation diagrams
Maintenance Page 61
Figure 61: Piping and instrumentation diagram
EZ-CAL™
PORT CONNECTIONS FOR DIRECTION CONTROL VALVES PE PI PAL PALL PIC
TO THE COMPR
4 4 4 4 4
SUCTION GAS
CONNECTION TAHH
DESIGNATION SIZE DESCRIPTION 1
P SAE #6 PRESSURE SUPPLY TAH
REDUCER AND 1
T SAE #6 RELIEF TO TANK DIRECTION CONTROL VALVE SUCTION VALVE
SC-1 5/16 SCREW IN FLOW REGULATING NEEDLE VALVE SHIPPED LOOSE TI
1
SC-2 5/16 SCREW IN FLOW REGULATING NEEDLE VALVE
SC-3 5/16 SCREW IN FLOW REGULATING NEEDLE VALVE SC-14 SC-5
SC-4 5/16 SCREW IN FLOW REGULATING NEEDLE VALVE TE
1
CONNECTION NV-2
DESIGNATION SIZE DESCRIPTION
SB-3 1 1/4 SQ. FLG. COMPRESSOR OIL SUPPLY
3/8 - 18 NPTF SLIDE VALVE - UNLOAD CV-4
3/8 - 18 NPTF SLIDE VALVE - LOAD ZT ZI
3/8 - 18 NPTF MOVEABLE SLIDE STOP ZI ZT 2 2
1 1 SE-1
3/8 - 18 NPTF MOVEABLE SLIDE STOP
SC-5 9/16-18UNF-2B INLET PRESSURE, STR THD O-RING
SC-6 9/16-18UNF-2B DISCHARGE PRESSURE, STR THD O-RING
COMPRESSOR END VIEW
SC-7 1/8 - 27 NPTF SEAL WEEPAGE
SC-8 1 5/16-12UN-2B CLOSED THREAD DRAIN, STR THD O-RING
SC-9 9/16-18UNF-2B INLET HOUSING OIL DRAIN, STR THD O-RING NV-1
SC-13 9/16-18UNF-2B OIL DRAIN CYLINDER, STR THD O-RING (OPTIONAL) SUCTION GAS
SM-1 1 5/16-12UN-2B MAIN OIL INJECTION, STR THD O-RING ECONOMIZER KIT TO THE COMPR
SV-1 2 1/2 SQ. FLG. VAPOR INJECTION TONGUE & GROOVE IS SHIPPED LOOSE.
SE-1 1/2 - 14 NPTF ELECTRICAL CONNECTOR THE ISOLATION
AND CHECK VALVES
SD-1 1 1/16-12UN-2B COALESCER BLEED STR THD O-RING PORT AND STRAINER
SC-14 9/16-18UNF-2B LIQUID INJECTION BLEED SHOULD BE LOCATED CV-3 STR-5
SL-1 1 5/16-12UN-2B LOW VI LIQUID INJECTION AS CLOSE AS POSSIBLE
SD-1
SL-2 1 5/16-12UN-2B HIGH VI LIQUID INJECTION TO THE COMPRESSOR,
PREFERABLY WITHIN SB-3 M-1
TE-1 3/4-14 NPTF SUCTION GAS TEMPERATURE ELEMENT S S
A FEW FEET. SV-1
MICROPROCESSOR NOTES: SM-1
SL-1
1. PRESSURE TRANSDUCERS INDICATE: SEE HYDRAULIC
SC-13
SC-13
PE-1 OIL PRESSURE (MANIFOLD) 0-500 PSIA C-1 SL-2
PIC PI PE SCHEMATIC HTR-3
PE-2 OIL PRESSURE BEFORE FILTER 0-500 PSIA 7 7 7 (Fig. 19) SC-6
PE-3 DISCHARGE PRESSURE 0-500 PSIA
PE-4 SUCTION PRESSURE 0-200 PSIA
PE-7 ECONOMIZER PRESSURE 0-500 PSIA
2. TEMPERATURE PROBES INDICATE: POWERMIZER TEST PORT
TE-1 SUCTION GAS TEMPERATURE (OPTIONAL)
TE-2 DISCHARGE GAS TEMPERATURE
TE-3 LUBE OIL TEMPERATURE
TE-4 SEPARATOR OIL TEMPERATURE
PE PI PAH PAHH
3 3 3 3
CV
RWF II 399 PACKAGE SHOWN FOR REFERENCE
1 PSIG
8
EZ-CAL VALVE ASSEMBLY
DISCHARGE GAS
PSV
(OPTIONAL)
DISCHARGE
FROM UNIT
1
STOP/CHECK TE TI TAH TAHH
VALVE 2 2 2 2
ASSEMBLY
HAND PURGE/VENT
EXPANSION
VALVE
PI
1
LG
1
PV-1 PUMPOUT
LG LG
PAL PALL PI PE
3 2
1 1 1 1
HTR-1 HTR-2
TAHH TAH TI TE
3 3 3 3
LS LSLL
1 1
STR-1
TALL TAL TI TE
4 4 4 4
B
A TCV
OF-1
SAMPLING C 1
OUTLET
VALVE
REMOVE EVAC/CHARGE KIT C

PDAH PDI PE BEFORE PIPING
2 2 2
F
OIL COOLER
DRAIN F
CUSTOMER IS RESPONSIBLE FOR PROVIDING AND INSTALLING
RELIEF PROTECTION IF COOLER IS ISOLATED
C
INLET
See Legend next page.

Page 62 Maintenance
Figure 62: P and I diagram - optional dual oil filters and demand oil pump
REFRIGERANT OUT - OR -
WATER OR GLYCOL IN
OIL COOLER
TSOC / WCOC / GCOC
REFRIGERANT IN - OR -
WATER OR GLYCOL OUT
LEGEND (Covers all P and I diagrams in this manual)

C COMPRESSOR TSH TEMPERATURE SWITCH HIGH ALARM
CV CHECK VALVE TW THERMOWELL
DP DISCHARGE PRESSURE VI VI CONTROL
FG FLOW GLASS SB-2 INLET BEARING & BALANCE PISTON
HV HAND VALVE SB-3 DISCHARGE BEARINGS & SEAL
HTR HEATER SC-1 SLIDE VALVE - UNLOAD
LG LEVEL GLASS SC-2 SLIDE VALVE - LOAD
LSLL SEPARATOR LOW OIL LEVEL SHUTDOWN SC-3 MOVEABLE SLIDE STOP
M MOTOR SC-4 MOVEABLE SLIDE STOP
1MC MOTOR CONTROL CENTER SC-5 INLET PRESSURE
2MC MOTOR CONTROL CENTER SC-6 DISCHARGE PRESSURE
NOS NO OIL SWITCH SC-7 SEAL WEEPAGE
NV NEEDLE VALVE SC-8 OIL DRAIN CONNECTION
OF OIL FILTER SC-9 INLET HOUSING OIL DRAIN
OP OIL PRESSURE SC-13 OIL DRAIN CYLINDER
P DEMAND PUMP SE-1 ELECTRICAL CONNECTION
PAH HIGH DISCHARGE PRESSURE ALARM SE-2 ELECTRICAL CONNECTION
PAHH HIGH DISCHARGE PRESSURE SHUTDOWN SL-1 LIQUID INJECTION LOW VI
PAL LOW PRESSURE ALARM SL-2 LIQUID INJECTION HIGH VI
PALL LOW PRESSURE SHUTDOWN SM-1 MAIN OIL INJECTION
PDAH HIGH PRESSURE DIFFERENTIAL ALARM SV-1 VAPOR INJECTION TONGUE & GROOVE
PDI PRESSURE DIFFERENTIAL INDICATOR SD-1 COALESCER BLEED STR THD O-RING PORT
PDSLL COMPRESSOR LOW DIFFERENTIAL PRESSURE CUTOUT TW-1 THERMOWELL
PE PRESSURE TRANSDUCERS PRESSURE TRANSDUCERS INDICATE:
PI PRESSURE INDICATOR PE-1 OIL PRESSURE (MANIFOLD)
PIC PRESSURE INDICATION CONTROLLER PE-2 OIL PRESSURE BEFORE FILTER
PM PUMP MOTOR PE-3 DISCHARGE PRESSURE
PS PRESSURE SWITCH CONTROL PE-4 SUCTION PRESSURE
PSV HIGH PRESSURE SAFETY VALVE TEMPERATURE PROBES INDICATE:
SP SUCTION PRESSURE TE-1 SUCTION GAS TEMPERATURE
STR STRAINER TE-2 DISCHARGE GAS TEMPERATURE
TAH HIGH TEMPERATURE ALARM TE-3 LUBE OIL TEMPERATURE
TAHH HIGH TEMPERATURE SHUTDOWN TE-4 SEPARATOR OIL TEMPERATURE
TAL LOW OIL TEMPERATURE ALARM SOLENOID VALVE FUNCTION:
TALL LOW OIL TEMPERATURE SHUTDOWN YY-1 ENERGIZE UNLOAD SLIDE VALVE
TC TEMPERATURE CONTROLLER YY-2 ENERGIZE LOAD SLIDE VALVE
TCV THERMAL CONTROL VALVE YY-3 ENERGIZE INCREASE VOLUME RATIO
TE TEMPERATURE ELEMENT YY-4 ENERGIZE DECREASE VOLUME RATIO
TI TEMPERATURE INDICATOR YY-9 DUAL-PORT LIQUID INJECTION SOLENOID
TS TEMPERATURE SWITCH
Maintenance Page 63
Figure 63: P and I diagram, liquid injection – single port
COMPRESSOR LOW VI,

HIGH VI, ECONOMIZER,
OR CLOSED THREAD
TUBING LINE
SIGHT
SOLENOID GLASS
VALVE MOTORIZED
STRAINER EXPANSION
S VALVE
LIQUID REFRIGERANT
FROM RECEIVER
LIQUID LINE
Figure 64: P and I diagram, liquid injection – dual port (new design)
3-WAY
MOTORIZED
VALVE
COMPRESSOR COMPRESSOR
LOW VI HIGH VI
M
TUBING LINE
SOLENOID
VALVE MOTORIZED
EXPANSION
STRAINER VALVE
S
LIQUID REFRIGERANT
FROM RECEIVER
LIQUID
LINE SIGHT
GLASS
Figure 65: P and I diagram, liquid injection – dual port (old design)
YY
9
COMPRESSOR COMPRESSOR
SUCTION PRESS. S
LOW VI
COMPRESSOR
HIGH VI TUBING LINE
TO SEPARATOR
SOLENOID
VALVE MOTORIZED
EXPANSION
STRAINER VALVE
S
LIQUID REFRIGERANT
FROM RECEIVER
LIQUID
LINE SIGHT GLASS
Page 64 Maintenance
Figure 66: EZ-CAL High-pressure cut-out calibration diagram
SUCTION
HIGH PRESSURE CUT-OUT CALIBRATION DIAGRAM
COMPRESSOR MOTOR
DISCH PRESSURE
DISCHARGE PRESSURE & HPCO
DISCHARGE
PE
TRANSDUCER
EZ-CAL™ HPCO
CALIBRATION BLOCK
TEST PORT CONNECTION
R
LOCKABLE '2' POSITION C

PERMANENTLY CONNECTION HOSE
INSTALLED VALVE (RUN/CALIBRATE)
TO TEST PORT
TEMPORARILY INSTALLED
FOR FIELD CALIBRATION MASTER GAUGE
PI
RUN POSITION
HAND OIL PUMP
CALIBRATE POSITION
REFRIGERATION
OIL SUMP
Installation - Operation - Maintenance Page 65

Page 66 Forms
Forms
Operating log sheet
Forms Page 67
RWF II compressor prestart checklist

The following items must be checked and completed by the installer before 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 Electrical checks

__ Package installed according to Frick publication __ Package installed according to Frick publication
070.210-IB, Screw Compressor Foundations. 090.400-SB, Proper Installation of Electrical
__ Confirm that motor disconnect is open Equipment In An Industrial Environment.
__ Isolate suction pressure transducer __ Confirm that main disconnect to motor starter and micro
__ Pressure test and leak check unit is open
__ Evacuate unit __ Confirm that electrical contractor has seen this sheet,
__ Remove compressor drive coupling guard all pertinent wiring information, and drawings
__ Remove coupling center and do not reinstall __ Confirm proper power supply to the starter package
(motor rotation must be checked without center) __ Confirm proper motor protection (breaker sizing)
__ Check for correct position of all hand, stop, and check __ Confirm that all wiring used is stranded copper and is
valves before charging unit with oil or refrigerant 14 AWG or larger (sized properly)
__ Check oil level for oil pre-charged packages __ Confirm all 120 V control wiring is run in a separate
__ Charge unit with correct type and quantity of oil conduit from all high voltage wiring
__ Lubricate electric drive motor bearings before __ Confirm all 120 V control wiring is run in a separate
checking motor rotation conduit from oil pump and compressor motor wiring
__ Check oil pump alignment and rotation (if applicable) __ Confirm no high voltage wiring enters the micro panel
__ Check for correct economizer piping (if applicable) at any point
__ Check separate source of liquid refrigerant supply (if __ Check current transformer for correct sizing and instal-
applicable, liquid injection oil cooling) lation
__ Check water supply for water-cooled oil cooler (if ap- __ Check all point-to-point wiring between the micro and
plicable, water cooled oil cooling) motor starter
__ Check thermosyphon receiver refrigerant level (if ap- __ Confirm all interconnections between micro, motor
plicable, thermosyphon oil cooling) starter, and the system are made and are correct
__ Check for proper pipe supports and correct foundation __ Ensure all electrical panels are free from installation
__ Check to ensure all piping including relief valves is debris, metal particles, and moisture
completed
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 6. Verify and finalize alignment (if applicable)
2. Verify all wiring connections 7. Calibrate slide valve and slide stop
3. Verify compressor motor rotation 8. Calibrate temperature and pressure readings
4. Verify oil pump motor rotation 9. Correct any problem in the package
5. Verify the % of FLA on the micro display 10. Instruct operation personnel
Note: C
ustomer 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:_______________________ Print Name:____________________________________
Compressor Model Number:______________________ Company:______________________________________
Unit Serial Number:_____________________________ Job Site Contact:________________________________
End User Name:________________________________ Contact Phone Number:_________________________
Address of Facility:______________________________
City, State, Zip: _________________________________ Signed: _______________________________________
Page 68 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 Model#______________________________________ Separator National Board #_________________________________
Compressor Serial #______________________________________
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 RTD’s Setup Coolant Loop Temp Setup
All wiring connections Motor Bearing RTD’s 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 Direction Package
Mode 1______________ ___________ ____________ Compressor _______________
Mode 2______________ ___________ ____________ Pump _______________
Mode 3______________ ___________ ____________ Dual Pump _______________
Mode 4______________ ___________ ____________ Drive ____________________________
VFD Hi & Low PI Control ___________ ____________ Refrigerant ___________ K-Factor__________
Miscellaneous Filter______________________________
Sequencing ________________ PowerPac_____________
Condenser ________________
Screen Saver ________________
Forms Page 69
Page 2 Unit Serial #______________________________ Frick Order No:_____________________________

Mode___________________ Capacity Control Setpoints Mode___________________
Setpoint_________ Regulation Safeties Setpoint_________ Regulation Safeties
High Low Load Inhibit_________ High Low Load Inhibit__________
Prop. Band _________ ________ Force Unload_________ Prop. Band ________ _________ Force Unload__________
Dead Band _________ ________ Warning___________ Dead Band ________ _________ Warning____________
Cycle Time _____ Sec _____ Sec Warning Delay____ Sec Cycle Time _____Sec _____ Sec Warning Delay_____ Sec
VFD Prop Band _________ ________ Shutdown__________ VFD Prop Band ________ _________ Shutdown___________
VFD Integ. Time _____ Sec _____ Sec Shutdown Delay____ Sec VFD Integ. Time _____Sec _____ Sec Shutdown Delay_____ Sec
Channel _________________________ Channel __________________________
Auto Cycle Low Suction Auto Cycle Low Suction
Start _________ Load Inhibit ___________ Start __________ Load Inhibit ___________
Start Delay _____ Min Force Unload ___________ Start Delay ______ Min Force Unload ___________
Stop _________ Warning ___________ Stop __________ Warning ___________
Stop Delay _____ Min Warning Delay _______ Sec Stop Delay ______ Min Warning Delay _______ Sec
Shutdown ___________ Shutdown ___________
Shutdown Delay _______ Sec 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 ________ _________ 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 Pull Down _______________________
Warning ___________ Delay ______ Sec Capacity Position _________ %
Shutdown ___________ Delay_______ Sec Amount of Time __________ Sec
High Compressor Oil Temperature Pump Down _____________________
Warning _______ Delay________ Sec On When Suction Above _____ PSIG Delay______ Min
Shutdown _______ Delay________ Sec DX Circuit
Low Compressor Oil Pressure #1 Action________________________
Warning _________ PSI Delay_________ Sec Off When Below ________ %
Shutdown _________ PSI Delay_________ Sec On When Above ________ %
High Filter Pressure #2 Action _______________________
Warning _________ PSI Delay_________ Min Off When Below__________ %
Shutdown _________ PSI Delay_________ Min On When Above__________ %
Main Oil Injection________________________ Liquid Injection __________________
Shutdown _________ PSI Delay_________ Sec On When Above ___________ Delay________ Sec
Oil Heater Off Above_________ Dual Port Transition _________
High Level Shutdown Delay_________ Sec
Low Oil Level Delay_________ Sec Hot Gas Bypass __________ %
Oil Pump Lube Time Before Starting_________ Sec Power Assist __________ Sec
Dual Pump Transition Time_________ Sec
Page 70 Forms
Page 3 Unit Serial #______________________________ Frick Order No:_____________________________
Compressor Motor Setpoints and Information

Motor Name Plate VFD Manufacturer_________________
Motor Amps ____________ Maximum Drive Output____ % Frame Size_______________
Volts ____________ Minimum Drive Output ____ % H.P._____________________
Service Factor ____________ Remote Control RPM ____________________
Horsepower ____________ Rate Of Increase_________ % Delay_____ Sec Serial #__________________
CT Factor ____________ Rate Of Decrease________ % Delay_____ Sec Service Factor____________
Recycle Delay___________ Min Capacity Control Voltage__________________
High Motor Amps When Slide Valve Reaches_________ % Hz______________________
Load Inhibit______________ Drive Speed Reaches _________ % Design __________________
Force Unload__________ Variable Speed Min. Slide Valve Position ________ % Code____________________
Warning________ Delay____ Sec Skip Frequency Bands Bearing Type_________________
Shutdown________ Delay____ Sec Bottom Top Motor Coupling ______________
________ ______
Low Motor Amps ________ ______
Shut Down_________ Delay_______ Sec ________ ______
Confirmed Running Motor Amps________ ________ ______
Starting Motor Amps Ignore Period _________ Sec ________ ______
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 Discharge End Delay Digital Controls Step Order
High Warning_______ gF______ Sec High Warning______ gF______ Sec Module A ________
High Shutdown_____ gF______ Sec High Shutdown_____ gF______ Sec Module B ________
Module C ________
Motor Bearing _______________ Module D ________
Shaft Side Delay Opposite Shaft Side Delay Step Up Dead Band _________ PSI
High Warning________ F______ Sec High Warning_______ F______ Sec Step Up Delay ________ Sec
High Shutdown______ F______ Sec High Shutdown______ F______ Sec Step Down Dead Band _________ PSI
Step Down Delay ________ Sec
Motor Stator__________________ High Pressure Override _________ PSI
High Pressure Override Delay______ Sec
Stator 1 Delay Stator 2 Delay
High Warning_______F_______ Sec High Warning______F_______ Sec Analog Controls Analog Output A ____________
High Shutdown_____F_______ Sec High Shutdown_____F_______ Sec Analog Output B ____________
Proportional Band _________ PSI
Stator 3 Delay Integration Time ________ Sec
High Warning_______F_______ Sec High Limit _________ PSI
High Shutdown_____F_______ Sec Low Limit ________ Sec
Miscellaneous
Remote Capacity Deadband________ % Max Slide Valve Timer________ 1/10 Sec
High Compressor Oil Pressure _________________ Max Discharge Pressure ____________ PSI
Shutdown______PSI Delay _____ Sec Max Discharge and Oil Temp_________°F
Forms Page 71
Page 4 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 Comm 2 Comm 3
Baud Rate__________ Baud Rate ___________ Baud Rate____________
Data Bits __________ Data Bits_____________ Data Bits_____________
Stop Bits __________ Stop Bits ____________ Stop Bits_____________
Parity _____________ Parity _______________ Parity_______________
RS 485 Connection________ RS 485 Connection________ RS 485 Connection________
Protocol ___________ Protocol __________ Protocol ___________ Use Map File_________
Ethernet
IP Data Naming Data Protocols
Address Type __________ Host Name___________ ModBus TCP_________
IP Address __________ Work Group__________ Ethernet I/P__________
Gateway Address __________ Comments___________ Profinet______________
Subnet Mask __________
Web Server Port __________
Compressor Operating Log Sheet Starter Operating Log Sheet

Date Average Current
Time Current Phase A
Hour Meter Reading Current Phase B
Equip. Room Temp. Current Phase C
Suction Pressure Full Load Amps
Suction Temperature Output Frequency
Suction Superheat Output Voltage
Discharge Pressure DC Bus Voltage
Discharge Temperature Input Power kW
Corresponding Temperature Actual Speed
Oil Pressure Speed Command
Oil Temperature Ambient Temp F.
Oil Filter Pressure Drop Convert Heatsink Temp. F.
Separator Temperature Baseplate Temp. F.
Slide Valve Position VSD Operating Mode
Volume Ratio (VI) Harmonic Filter Present
Motor Amps / FLA % Harmonic Filter Mode
Capacity Control Setpoint Water Pump Energized
Oil Level Precharge Relay Energized
Oil Added Trigger SCR’s Energized
Seal Leakage (Drops/Min.) DC Inverter Link Current
Evaporator. EWT F. Motor Winding Temp. F.
Evaporator LWT F. Humidistat % RH
Condenser EWT F. Vyper Coolant Temp. F.
Condenser LWT F. Total kWh
Page 72 Forms
Vibration data sheet

Date: ___________________________________________ Sales Order Number:_________________________________
End User: ________________________________________ Installing Contractor:_________________________________
Address: ___________________________________________ Service Technician:___________________________________
___________________________________________________
___________________________________________________

Equipment ID (As in Microlog): _____________________________
Compressor Model 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 Slide valve position %

Press # Press # Press # Temperature °F V.I. Ratio
Temperature °F Temperature °F Temperature °F F.L.A. %
Compressor Inboard
Compressor Inboard (Coupling End Male) Motor Inboard (Coupled End)
(Coupling End) Axial Direction Horizontal _______ . ______ IPS Overall
Vertical Direction ____.____ IPS Overall Vertical _______ . ______ IPS Overall
____.____ IPS Overall Axial _______ . ______ IPS Overall
Compressor Outboard Compressor Inboard

(Coupling End Female) Motor Outboard (Noncoupled End)
(Nondrive End) Horizontal _______ . ______ IPS Overall
Vertical Direction Axial Direction
____.____ IPS Overall Vertical _______ . ______ IPS Overall
____.____ IPS Overall Axial _______ . ______ IPS Overall
Index Page 73
Index
Symbols compressor port locations, 50 dual-port liquid injection, 26
compressor prestart checklist, 64 dual-setpoint, 13
three-phase ground, 18 condenser, 24 DX economizer, 11
three-phase supply, 18 condenser inlet, 9 DX vessel, 12
condensing pressure, 9
A condensing temperature, 10 E
abnormal operation conduit, 19
economizer
analysis and correction, 44 cone/button, 9
back-pressure regulator valve, 12
across-the-line, 14 constant speed starters, 19
balancing load, 12
atmospheric pressure, 34,36 control power regulator, 16
BPR valve, 12
axial load bearings, 23 control power transformer, 14
check valve, 12
axial loads, 23 control transformer, 14
DX economizer, 11
coolers, 5
DX vessel, 12
B cooling tower water, 11
economizer port, 11,12
cooling water, 11
back-feeding, 29 economizer vessel, 12
coupling, 14
back flushing, 11 electric shutoff option, 12
coupling data table, 7
back-pressure regulator, 13 flash economizer system, 12
coupling hubs, 6
back-pressure regulator valve, 12 flash gas, 13
CPT, 15
balance piston, 23,31 flashing liquid, 11
crane, 6
balance piston pressure regulator, 41 flash tank, 11
CT, 15
balancing load, 12 flash vapor, 13
CT ratio, 15
bleed valve, 34 heat exchanger, 11
current transformer, 15
booster application, 14,24 isolation valve, 12
cutout parameters, 24
booster compressor, 31 liquid feed solenoid, 12
cycle time, 25
booster systems, 29 liquid solenoid, 11
BP, 25 D microprocessor, 11
BP coupling data table, 7 outlet pressure regulator, 12
BPR valve, 12 Daisy-chaining, 21 overpressurizing, 12
brownouts, 16 dead band, 25 Packaged refrigerant
demand oil pump strainer, 35 recirculation unit, 12
C demand pump, 23,24 partial load, 12
Demand pump port pressure, 12
cable trays, 19 Carbon-graphite bushings, 36,37,39 strainer, 12
check valve, 12,29 Thrust-bearing assembly, 38 subcooled liquid, 12
chemical cleaning process, 11 Troubleshooting subcooling, 11
circuit breaker, 14 Grease leaks from vent port, 47 suction bypass, 12
circuit breaker disconnect, 14 Insufficient oil pressure, 47 suction pressure, 12
clamping bolts, 7 Main filter psid too high, 47 economizer port, 11,12
closed-loop fluids, 11 Noise and vibration, 47 economizer vessel, 12
closed-loop system, 11 Oil pressure drops as head pressure elastomeric gear, 7
coalescer filter element, 24,35 increases, 47 electric shutoff option, 12
coalescer filter retainer, 35 Oil pressure fluctuates, 47 entrapped refrigerant, 35
codes, 19 Oil pressure rapidly drops, 47 evaporator, 11
cold-start system, 24 Viking pump, 36 external controller, 14
cold-start valve, 24 "D" flange adapter, 23 external oil cooler, 8
comm port protection, 21 disc drive spacer, 6 External Oil Cooling, 31
communications, 21 discharge check valve, 24,29 external strainer, 23
compressor discharge pressure, 23 EZ-CAL™, 46,58,61
compressor, 12 disconnect switches, 33 EZ-COOL™, 27
discharge, 24 disc packs, 6
drive shaft, 23 double-acting hydraulic cylinders, 25 F
hydraulic system, 25 double-acting mode, 25
lubrication, 24 filter assembly, 34
double-acting solenoid valve, 26
motor, 14,15 filter canister, 34
drain valve, 35
oil temperature, 26 filter cartridge, 34
drive coupling, 29
suction, 25 filter elements, 9,34,35
drive hubs, 7
Vi, 25 fixed bulkhead, 25
dry nitrogen, 7,33
compressor operating log sheet, 68 flash economizer system, 12
dual dip tube method, 10
Page 74 Index
flash gas, 13 infinitely variable volume ratio, 23 password, 30

flashing liquid, 11 inlet service valve, 34 parameters, 28
flash tank, 11 solenoid valve, 28
flash vessel, 12 J liquid injection oil cooling, 11
float level control, 11 liquid injection strainer, 35
forklift, 6 jack, 6 liquid injection system, 10
foundation, 5 liquid injection tube, 10
foundation
K liquid injection valves, 33
anchor bolts, 5 keyway setscrews, 7 liquid level, 10
epoxy grout, 5 liquid refrigerant, 26
grout, 5 L liquid solenoid, 11,35
housekeeping pads, 5 liquid supply service valve, 35
I-beams, 5 leak test, 34 locknut, 7
reinforced concrete, 5 level-control method, 11 low differential oil pressure, 24
foundation, 3,5,23 LICO, 26 low pressure transducer, 34
freeze-up protection, 29 liquid feed solenoid, 12 low voltage, 14
frequency range, 32 liquid injection, 23,26 lubrication system, 23
alarms, 29
G analog input signal, 28 M
common digital alarm, 29
gas bypassing, 23 danfoss liquid injection valve magnetic field, 19
gas compression, 5 High, 28 main oil injection port, 24
gas flow, 24 ICAD (industrial control actuator maintenance
gas outlet connection, 24 with display), 28 abnormal operation analysis and cor-
gauges, 8 ICM (motorized industrial control rection, 44
general maintenance, 33 valve), 28 abnormal system conditions, 44
Low, 28 abnormal vibration, 41
H Med, 28 capacity linear transmitter,
MMI (man machine interface), 28 compressor unload cylinder,
hard water conditions, 11
opening degree (OD), 28 condensed refrigerant, 45
heat exchanger, 11
parameter list DIN connector plug,
helical rotors, 23
analog input signal, 30 filter elements, 42
high-frequency vibrations, 5
analog output signal, 30 grease compatibility, 43
high pressure discharge gas, 31
automatic calibration, 30 leaks, 41
high stage applications, 24
digital input function, 30 linear transmitter,
hot oil, 10
fail-safe, 30 lubrication, 42
hydraulic cylinder, 25
ICM configuration, 30 main operating screen, 44
hydraulic System
main switch, 30 maintenance schedule, 40
compressor suction, 25
mode, 30 moisture, 42
compressor Vi, 25
modulating mode, 30 motor bearings, 42
cycle time, 25
old alarms, 30 NLGI grease compatibility chart, 44
dead band, 25
password, 30 noise, 41
double-acting hydraulic cylinders, 25
parameters, 28 oil analysis, 42
double-acting mode, 25
digital input signal, 28 oil level control,
fixed bulkhead, 25
enter push button, 28 oil level transmitter,
hydraulic cylinder, 25
ICAD (industrial control actuator oil quality, 42
microprocessor, 25
with display), 28 operating log, 42
movable slide stop, 25
ICM valve, 28 P and I diagram, 58
MSS, 25
MMI (man machine interface), 28 potentiometer,
MSV, 25
motorized industrial control valve, 28 Pressure transducers
MSV solenoid, 25
opening degree, 28 Discharge pressure, 46
needle valve, 26
parameter list Discharge pressure transducer,
proportional band, 25
analog output signal, 30 Oil pressure transducer, 46
slide valve, 25
automatic calibration, 30 Pressure transducer,
solenoid valve, 25
digital input function, 30 Testing, 46
Vi, 25
fail-safe, 30 Voltage reading, 46
volume ratio, 25
ICM configuration, 30 maintenance program, 41
main switch, 30 refrigeration oil, 42
I
mode, 30 sensor well,
identification data plate, 4 modulating mode, 30 servicing the cold-start valve, 45
old alarms, 30 bonnet, 45
bonnet cap screw torque values, 45
valve body, 45
valve housing, 45
Index Page 75
stop valve, 45 orifice, 31 balance pistons, 23

vibration analysis, 41 outlet pressure regulator, 12 compressor drive shaft, 23
vibration readings, 41 overpressurizing, 12 "d" flange adapter, 23
volume ratio control, discharge pressure, 23
volumizer unit, P external strainer, 23
manual solenoid, 35 helical rotors, 23
packaged refrigerant recirculation
manway bolts, 35 infinitely variable volume ratio, 23
unit, 12
manway cover, 35 movable slide valve, 23
package vibration, 5
microprocessor, 11,13,25,26 roller bearings, 23
partial load, 12
microprocessor control system, 14 rotor contact, 23
pH, 11
mist, 24 self-lubricating, 23
P and I diagram, 58
motor, 14 shaft rotation, 23
pipe hangers, 5
motor and bare compressor replace- single-acting mode, 25
piston, 24
ment, 49 slide valve, 23
plate and shell oil cooler, 9,10
motor contactor, 14 suction flange, 23
plate and shell type thermosyphon oil
motor rotation, 6 suction port, 23
cooler, 10
motor starter coils, 15 volumizer, 23
port pressure, 12
motor starter contactor, 14 shaft rotation, 23
power feed, 19
motor starters, 33 shunting device, 14
power fluctuations, 16
mounting bolts, 6 shutdown, 49
powermizer, 13.see also economizer
movable slide stop, 25 shutdown cycles, 8
premature bearing failure, 33
movable slide valve, 23,25 shutdowns, 33
pressure differential, 24
MSS, 25 sight glass, 8,24,36
pressure limiting device.see high pres-
MSV, 25 single-box control, 13
sure cut-out
MSV solenoid, 25 single-port liquid injection, 26
pressure-regulating valve, 31
skip frequencies, 32
N proportional band, 25
slide stop, 23
no pump, 23
slide stop piston, 26
neoprene drive spacer, 7 PVC conduit, 19
slide valve, 13,23,25
nitrogen charge, 7
slide valve position, 31
Q
slugging, 33
O
Quantum™ HD, 3,13,21,24,33 Sola® constant voltage (CV)
dual oil filters, 23,34 transformer, 14
main oil filter, 34 R solenoid, 13,35
oil, 5 solenoid valve, 11,25,26,31
reboot, 21 solid-state, 14
oil charge, 8
receiver, 10,11 spacer, 6
oil charge reservoir, 24
refrigerant charge, 5 spring isolators, 5
oil-charging valve, 36
refrigerant isolation valves, 10 star networks, 21
oil cooler, 10,23
refrigerant vapor, 36 starter coil, 15
oil-entrained refrigerant, 36
refrigeration oil, 35 starter operating log sheet, 68
oil filter cartridges, 36
regulating control transformer, 14 starter package, 14
oil filters, 33
roller bearings, 23 starter wiring diagram, 14
oil foaming, 8,34,36,42
rotary screw compressor, 5 start-up
oil heaters, 8,14
rotor contact, 23 CoolWare™, 31
oil leakage, 8,34,42
oil level cutout, 8,34,36,42 discharge temperature, 31
S hand expansion valve, 31
oil level transmitter
replacement, safety valve, 10 initial start‑up, 31
troubleshooting, sales order numbers, 3 prestart checklist, 31
DIN plug, sc2, 25 start-up, 8
oil manifold, 25,26,31 scaling, 11 theoretical discharge temperature, 31
oil pressure loss, 8,42 self-lubricating, 23 water control valve, 32
oil pump, 23,24 separator, 6,8,36 stop valve, 35
oil pump coupling, 7 serial number, 4 strainer, 11,12,35
oil pump starter, 14 service valves, 36 strainer basket, 35
oil sampling valve, 42 setpoint, 13,25 strainer cover, 35
oil seal, 23 severe water conditions, 11 strainer elements, 36
oil separator, 13,23,24 SGC compressor, 25 strainer inlet service valve, 35
oil strainer elements, 36 SGC compressor, 23 subcooled liquid, 12
oil temperature, 10 angular-contact ball bearings, 23 subcooling, 11
operating level, 8 axial load bearings, 23 suction, 24
operating log sheet, 63 axial loads, 23 suction accumulators, 33
optical isolation, 21 suction bypass, 12
Page 76 Index
suction check valve, 9,29 troubleshooting the demand pump

suction check valve bypass, 24 system, 47
suction check valve bypass line, 12 troubleshooting the hydraulic system,
suction check valve 48
power assist kit, 31 troubleshooting the oil separation sys-
suction flange, 23 tem, 48
suction isolation valve, 9 troubleshooting the rwf ii compressor,
suction port, 23 47
suction pressure, 12 tunnel, 6
suction strainer, 23,33 turbine drive, 5
suction trap, 34 two-pass oil coolers, 10
superheat, 33
superheating, 23 U
super speed, 4
uninterrupted power supply, 21
surge suppression, 21
unit data plate, 3
system head pressure, 23
unitized flex disc, 6
T unloader spring, 26
unshielded, 19
TCV, 26 UPS, 14,21
temperature control valve, 26
temperature sensor, 26 V
temperature sensor
A4ALE pressure regulating valve, 31
replacement,
valve hv-2, 29
DIN connector plug,
vapor, 9
thermal well,
vapor line, 12
transmitter unit,
variable frequency drives, 19
troubleshooting,
VFD, 32
digital board #1,
VFD applications, 18
thermosyphon, 9,23
VFD output, 18
thermosyphon oil cooling, 9,10
Vi, 25
thermosyphon oil cooling
voltage isolation, 21
condenser inlet, 9
volume ratio, 25
condensing pressure, 9
volume ratio control, 23
condensing temperature, 10
volume ratio control transmitter - slide
operating level, 8
stop,
plate and shell oil cooler, 9
replacement,
receiver, 10
linear transmitter,
thermostatically controlled mixing
troubleshooting,
valve, 10
slide stop linear transmitter,
thermosyphon oil cooling, 9,10
slide valve transmitter,
two-pass oil coolers, 10
vapor, 9
W
threaded metallic, 19
threaded PVC-coated metallic, 19 water-cooled, 23
throttling valve, 24 water-cooled oil cooler, 11
thrust balance piston, 31 Water-Cooled Oil Cooling, 11
torque analysis, 14 water treatment, 11
troubleshooting, 47 water vapor, 33
excessive noise and vibration, 47 wye-delta, 14,15
gradual oil loss, 48
rapid oil loss, 48
shaft seal leakage, 48
slide stop
will not function either direction, 48
will not move, 47
slide valve
will load but not unload, 48
will not load or unload, 48
will not move, 47
will unload but not load, 48
Index Page 77

July 2021 form revisions
Page 16 – Moved Installation of electronic equipment in an industrial
environment to the Installation section
Page 41 – Updated Table 13
March 2020 form revisions

Cover – Updated web address
Page 32
– Added check alignment line item and footnote "h" to mainte-
nance schedule table
Page 34 – Updated relubrication table
Form 070.610-IOM (2021-07) Johnson Controls

Supersedes: 070.610-IOM (2020-03) 100 Cumberland Valley Avenue
Subject to change without notice Waynesboro, PA 17268-1206 USA
Published in USA • 07/21 • PDF Phone: 717-762-2121 • FAX: 717-762-8624
© 2021 Johnson Controls - All Rights Reserved www.johnsoncontrols.com/Frick

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Form 070.

610-IOM (JUL 2021)

This manual contains installation, operation, and maintenance

Check www.FrickCold.com for the latest version of this publication.

General information Job inspection

Proper performance and continued satisfaction with these

Safety precaution definitions

Compressor identification Rotary screw compressor serial numbers are defined by

RPM 3600 PSIG 600 BARG 41 3600 600 41

ASSEMBLED IN USA USA

Installation a combination of both, to prevent the transmission of

Table 3: BP series coupling data table

CH couplings are not to be used over 3600 rpm.

WARNING RWF II models

Compressor unit oil

Oil charge NOTICE

Figure 8: Valve installation

The oil filter(s) and coalescer element(s) shipped with the

Suction valve mounting

Figure 9: Thermosyphon receiver system

Figure 10: TSOC Piping Arrangement

System operation - Liquid refrigerant fills the cooler shell

Figure 11: Dual dip tube Water or glycol oil cooling -

and strainer should be located as closely as possible ECONOMIZER

Heat generated from compression could result in a

Trained technicians are required for servicing. ECONOMIZER

Figure 15: Flash economizer system Economizer Vi control

Economizing with VSDs

Voltage protection Motor starter package

NOTE: REFERENCE 090.040-M QUANTUM HD

OPTIONAL CIRCUIT BREAKER FRICK SUPPLIED COMBINATION

*Additional information is available in the "Installation of Electronic Equip-

Minimum burden ratings Installation of electronic equipment

Wire sizing Figure 20: Voltage source circuit to prevent EMI

Conduit Wiring practices

• When not required to be in metal or other material by

Never add relays, starters, timers, transformers, etc.

Communications UPS power and Quantum HD panels

This page is intentionally left blank.

11. Shaft rotation clockwise facing compressor, suitable for

Demand pump oil system

Figure 27: Cold-start valve

Double-acting mode - booster

The solenoid coils can be serviced or replaced with-

Figure 29: Hydraulic schematic - all package sizes

SV-2 SV-3 SV-2 SV-3

HYDRAULIC SCHEMATIC HYDRAULIC SCHEMATIC

COMPRESSOR TOP VIEW

(INCREASE VI) YY3 YY4 (DECREASE VI)

Quantum HD EZ-COOL Liquid injection adjustment procedure

Liquid Injection LIOC

• Acknowledge and save change of value of a parameter.

Figure 34: ICAD opening degree

fail-safe supply < 18 VDC PE PI PAL PALL PIC

Reset to factory setting:

Table 10: Parameter list

1. It is imperative that during the initial start-up of the

4. After running the unit for approximately three hours,

Maintenance Keep liquid injection valves properly adjusted and in good

Page 2 Unit Serial #__ Frick Order No:_

Page 3 Unit Serial #__ Frick Order No:_

Page 4 Unit Serial #_ Frick Order No: __________________________