Professional Documents
Culture Documents
070.450-Iom XJF
070.450-Iom XJF
XJF
ROTARY SCREW COMPRESSOR
MODELS XJF 95, 120, 151
Contents
GENERAL Information
PREFACE ........................................................................... 3
DESIGN LIMITATIONS ........................................................ 3
JOB INSPECTION ............................................................... 3
STANDARD BARE COMPRESSOR ...................................... 3
TRANSIT DAMAGE CLAIMS ............................................... 3
COMPRESSOR IDENTIFICATION . ....................................... 3
LONG TERM STORAGE....................................................... 4
PREPARING COMPRESSOR FOR STORAGE......................... 5
MAINTAINING COMPRESSOR.............................................. 5
DESCRIPTION..................................................................... 5
XJF COMPRESSOR ........................................................ 5
COMPRESSOR LUBRICATION SYSTEM .......................... 5
OIL PUMP....................................................................... 5
Construction details................................................... 6
INSTALLATION
DESIGN LIMITS................................................................... 7
OUTLINE DIMENSIONS....................................................... 7
XJF 95 DIMENSIONS........................................................... 8
XJF 120 DIMENSIONS......................................................... 9
XJF 151 DIMENSIONS....................................................... 10
XJF 95 COMPRESSOR PORT LOCATIONS..........................11
XJF 120 COMPRESSOR PORT LOCATIONS........................12
XJF 151 COMPRESSOR PORT LOCATIONS.........................13
SAE STRAIGHT THREAD O-RING FITTINGS - ASSEMBLY
PROCEDURE FOR RXF 58 - 101.................................... 14
HOLDING CHARGE AND STORAGE................................... 14
RIGGING AND HANDLING...................................................15
FOUNDATION ...................................................................15
CUSTOMER CONNECTIONS...............................................15
COMPRESSOR OIL.............................................................15
OIL PUMP..........................................................................15
COMPRESSOR...................................................................16
MOUNTING...................................................................16
COMPRESSOR/MOTOR COUPLING REQUIREMENTS......16
COUPLING ALIGNMENT REQUIREMENTS
(FOOT MOUNTED ONLY)...........................................16
WARNING
Indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
Indicates a potentially hazardous situation or practice which, if not avoided, will result in death or
serious injury.
CAUTION
Indicates a potentially hazardous situation or practice which, if not avoided, will result in damage
to equipment and/or minor injury.
NOTICE
Indicates an operating procedure, practice, etc., or portion thereof which is essential to highlight.
DANGER
GENERAL Information
PREFACE
All claims must be made by consignee. This is an ICC requirement. Request immediate inspection by the agent of
the carrier and be sure the proper claim forms are executed. Report damage or shortage claims immediately to
Johnson Controls-Frick Sales Administration Department,
in Waynesboro, PA.
It is most important that these compressors be properly applied to an adequately controlled refrigerant or gas system.
Your authorized Johnson Controls-Frick representative should
be consulted for his expert guidance in this determination.
Proper performance and continued satisfaction with these
units is dependent upon:
CORRECT INSTALLATION
PROPER OPERATION
REGULAR, SYSTEMATIC MAINTENANCE
To ensure correct installation and application, the equipment
must be properly selected and connected to a properly
designed and installed system. The Engineering plans,
piping layouts, etc. must be detailed in accordance with the
best practices and local codes, such as those outlined in
ASHRAE literature.
COMPRESSOR IDENTIFICATION
Each compressor has an identification data plate, containing
compressor model and serial number mounted on the
compressor body.
NOTICE
When inquiring about the compressor or unit, or
ordering repair parts, provide the MODEL, SERIAL, and
JOHNSON CONTROLS - FRICK SALES ORDER NUMBERS
from the data plate. See Figure 1.
NOTICE
It is required that the discharge temperature be kept
high enough to prevent condensation of any moisture
in the compressor and oil separator.
DESIGN LIMITATIONS
XJF compressors are designed for operation within the
pressure and temperature limits which are specified by
Johnson Controls-Frick and the Johnson Controls-Frick
selection software COOLWARE. They are primarily used for
compressing refrigerant gas and most hydrocarbon gasses.
If your application is for sour gas, there are special requirements
to protect the compressor. Contact Johnson Controls - Frick
Compressor Engineering for application details.
JOB INSPECTION
Immediately upon delivery examine all crates, boxes and
exposed compressor and component surfaces for damage.
Unpack all items and check against shipping lists for any
discrepancy. Examine all items for damage in transit.
DECADE
0
MONTH
A
YEAR
9
GLOBAL ADDITIONAL
SEQ NO.
REMARKS
0000015
Z
Rotor
Diameter
mm
95
95
95
120
120
120
151
151
151
151
Rotor
L/D
1.4
1.4
1.4
1.4
1.4
1.4
1.6
1.6
1.6
1.6
Max
Speed
Rpm
5,772
4,661
3,600
5,772
4,661
3,600
6,297
5,332
4,306
3,600
Geometrical
Swept Volume
Drive Shaft End
Ft/ Rev
0.02513
0.03112
0.04086
0.05065
0.06272
0.08234
0.09623
0.11366
0.14075
0.16833
M/Rev
0.000711
0.000881
0.001156
0.001433
0.001775
0.002330
0.002723
0.003217
0.003983
0.004764
Cfm
3550 Rpm
89
110
145
180
223
292
342
403
500
598
M/H
2950 Rpm
126
156
205
254
314
412
482
569
705
843
for storage of less than six (6) months if the storage area is
subject to unusual environment such as high humidity, large
changes in temperature, dusty atmosphere, etc.
The standard Johnson Controls-Frick Warranty for an XJF
screw compressor covers twelve (12) months from start-up
or 18 months from shipment, whichever comes first. It is
recommended that arrangements be made with the local
Johnson Controls-Frick service organization (arranged
through factory service) regarding surveillance and
maintenance during the storage period. It will be the
customers responsibility to submit a monthly report
showing the condition of the unit and noting any
discrepancies to the guidelines listed herein. Failure to
comply with this Long Term Storage Recommendation may
void the warranty.
Model
Serial No.
Long term storage of equipment may lead to the deterioration of components over the period of time. Synthetic components in the compressor may deteriorate over time even
if they are kept flooded with oil. A warm and dry environment is essential to minimize environmental and corrosion
damage. Long term storage of the affected equipment at a
customers site may involve additional requirements and
interested parties should refer to the Johnson Controls web
site, www.jci.com/frick, for specific instructions (Location:
Checked By
Date
MAINTAINING COMPRESSOR
Ensure that the 5-15 psig nitrogen charge is maintained
with 15 psig preferred.
Rotate the male rotor shaft every two weeks. Mark the
shaft to ensure the rotor does not return to the original
position.
The compressor must be stored inside a dry building
environment.
Grease the male rotor shaft to prevent rust.
Record all information in a Compressor Long Term Storage
Log. See bottom of page 4.
Contact Johnson Controls-Frick Service with any
questions regarding long term storage.
DESCRIPTION
XJF COMPRESSOR
The Frick XJF rotary screw compressor utilizes mating
asymmetrical profile helical rotors to provide a continuous
flow of vapor and is designed for both high-pressure and
low-pressure applications. The compressor incorporates
the following features:
1. High-capacity roller bearings to carry radial loads at both
the inlet and outlet ends of the compressor.
2. Heavyduty angular contact ball bearings to carry axial
loads are mounted at the discharge end of compressor.
3. Moveable slide valve to provide fully modulating capacity
control from 100% to 25% of full load capacity.
4. VOLUMIZER II volume ratio control adjusts the compres
sor volume ratio during operation to the most efficient of
three possible volume ratios, 2.2, 3.5, 5.0, depending upon
system requirements.
WARNING
It is mandatory that the coupling center be removed
and the direction of motor rotation be confirmed before running the compressor. Proper rotation of the
compressor shaft is clockwise looking at the end of the
compressor shaft. Failure to follow this step could result in backward compressor rotation which can cause
compressor failure or explosion of the suction housing.
COMPRESSOR LUBRICATION SYSTEM
The XJF screw compressor unit is designed to be selflubricating. Oil being supplied to the compressor from the oil
separator is at system head pressure. Within the compressor,
oil porting to all parts of the compressor is vented back to
a point in the compressors body that is at a pressure lower
than compressor discharge pressure. The compressors normal operation makes the compressor unit operate essentially
as its own oil pump. All oil entering the compressor is moved
by the compressor rotors out the compressor outlet and back
to the oil separator. For normal high-stage operation an oil
pump is not required.
Construction details
Housing: All XJF screw compressor castings are close
grain, pressure tight, grey cast iron, to ensure structural,
mechanical, and thermal stability under all operating
conditions. Ductile iron is also available for special
applications. Contact Johnson ControlsFrick Sales for
additional information.
Rotors: The rotors are made from the highest quality
rolled steel to exacting tolerances of the latest industry
standard asymmetric profile. The five-lobed male rotor is
directly connected to the internal gear. The seven-lobed
female rotor is driven by the male on a thin oil film.
GEAR: The compressor has an internal gear to speed up
the rotors. Each model has 3 or 4 gear ratios.
Bearings: Antifriction bearings with L10 rated life in
excess of 50,000 hours (using the Frick Superfilter) at
design conditions are used for reduced frictional
horsepower and superior rotor positioning, resulting in
reduced power consumption, particularly at higher
pressure ratios. Cylindrical roller bearings are provided to
handle the radial loads and the thrust loads are absorbed
by four point contact or angular contact bearings. In
addition, thrust balance pistons are provided to reduce the
thrust load and improve bearing life.
Shaft Seal: The compressor shaft seal is a single-face
type with a spring-loaded carbon stationary surface riding
against a cast iron rotating seat. The seal is capable of
withstanding static pressure up to 400 psig. During
operation it is vented to low pressure to provide extended
life.
Volumizer II ADJUSTABLE VOLUME RATIO CONTROL:
The Frick XJF compressor adjusts to the most efficient of
three volume ratios (2.2, 3.5 or 5.0) depending upon system
INSTALLATION
DESIGN LIMITS
General information for all of the models is provided below.
Please see CoolWare to determine the limits for a specific
application.
XJF compressors are primarily designed for connecting to
an electric drive motor using a tunnel mount. If the application requires it, the compressor can also be driven with
a foot-mounted motor. The tunnel mount ensures proper
alignment of the compressor and motor so that the shaft
seal and coupling will operate properly. The rotor and
bearing design set limitations must not be exceeded (See
Frick Selection Program, CoolWare). Pressure and temperature limits are shown in Frick publication 070.410SED. Refer to Johnson Controls-Frick Compressor Control
Panel instruction 090.040-O for additional information on
setpoint limits.
OUTLINE DIMENSIONS
Drawings for reference only can be found on the following
pages. Complete dimensions and access connections can
be found on the outline drawings.
XJF 95
DWG# 534E0458
XJF 120
DWG# 534E0299
XJF 151
DWG# 534E0539
If you do not have these drawings, please request any you
require by contacting Johnson Controls-Frick sales.
XJF 95 DIMENSIONS
CL SUCTION
SUCTION FLANGE
FABRICATED SQUARE FLANGE
2" (95S & 95M), 3" (95L)
4.82
(122.4)
10.88
(276.3)
2.50 (63.5)
CL COMPRESSOR
8.45
(214.5)
0.94
(23.9)
6.94
(176.2)
CL ROTORS
18.75
(476.3)
6.84
(173.9)
3.66 (92.9)
2.72
(69)
0.75 (19.1)
SEAL WEEPAGE
DRAIN TUBE
TO BE PULLED
THROUGH THIS HOLE
5.19
(131.8)
2.81
(71.4)
2.43 (61.7)
1.94 (49.3)
AVAILABLE SHAFT
FOR COUPLING
.719 (18.3)
DISCHARGE FLANGE
2" SOCKET WELD
5.31
(134.9) 2.56
(65)
10.62
(269.7)
CL DRIVE SHAFT
2.00 (50.8)
MIN DIST REQ'D
FOR SHAFT
SEAL REMOVAL
CL
3.75 (95.3)
CL
DISCHARGE
COMPRESSOR
1.85
(46.9)
7.56
(192)
10.69 (271.5 )
0.50 (12.7 )
6.94
(176.3 )
LIFTING
M20 X 2.5-6H
1.31 DP
8.13 (206.4)
5.21 (132.3)
4.34 (110.4)
CL COMPRESSOR
TOP
5.27 (133.8)
16.81 (427.1)
6.06
(153.9)
9.38 (238.3)
4.00
(101.6)
2.00 (50.8)
1.56 (39.6)
8.13
(206.6)
3.50
(88.9)
SOL-3
SEE NOTE 3
8.25
(209.6)
1.20 (30.4)
2.13 (54)
6.84
3.19 (81) (173.9) 2.75
(69.9)
.3951 (10.035)
.3937 (10.000)
SOL-4
SEE NOTE 3
4.81
(122.2)
11.62
(295.1)
2.66 (67.6)
OUT
OUT
CL
DRIVE SHAFT
CL SUCTION
6.38
(162.1)
2.06
(52.3)
4.06
(103.1)
6.56
(166.6)
5.12
(130)
12.25 (311.1)
25.63 (651.1)
VIEW A-A
6.18
(157)
10
1.182 (30.02)
1.174 (29.82)
1.3785 (35.014)
1.3781 (35.004)
1.71 (43.4)
3.13
(79.5)
CL SUCTION
6.75
(171.5)
4.25
(108)
11.76
(298.8)
2.00 (50.8)
CL COMPRESSOR
21
IMPORTANT
REMOVE SEALING DISC FROM
SUCTION FLANGE BEFORE
PUTTING PACKAGE IN
OPERATION.
10.72
272.2)
9.72
(246.8)
21.73
(551.9)
CL ROTORS
8.12
(206.3)
2.81 (71.4)
1.61
(41)
5.62
(142.7)
4.03 (102.5)
9.50 (241.4)
DISCHARGE FLANGE
3" SOCKET WELD
2.58 (65.6)
CL DRIVE SHAFT
.75 (19.1)
SEAL WEEPAGE DRAIN TUBE TO
BE PULLED THROUGH THIS HOLE
2.38 (60.5)
AVAILABLE SHAFT FOR COUPLING
3.25
(82.6)
2.75 (69.9)
2.50 (63.5)
2.13 (54.1)
MINIMUM DISTANCE REQUIRED
FOR SHAFT SEAL REMOVAL
6.38
(162.1)
DISCHARGE
CL
3.12 (79.4)
IMPORTANT
REMOVE SEALING DISC FROM
SUCTION FLANGE BEFORE
PUTTING PACKAGE IN
OPERATION.
11.24 (285.5)
13.24
(336.3)
2.59 (65.8)
5.62
(142.7)
CL COMPRESSOR
3.69 (93.7)
CL DISCHARGE
10.13 (257.3)
13.00 (330.3)
.718
(18.2)
6.88
(174.8)
7.94 (201.7)
13.81 (350.8)
LIFTING
M20X2.5-6H
1.62 DP
7.95
(202)
5.88 (149.4)
4.96 (126.1)
CL COMPRESSOR
TOP
17.19 (436.8)
6.00 (152.4)
9.20 (233.7)
7.95 (202)
.4741 (12.042)
.4724 (11.999)
6.56
(166.7)
1.378 (35.0)
1.370 (34.8)
VIEW A-A
6.62
(168.1)
4.25
(108)
4.18
(106.2)
3.25
(82.6)
1.5753 (40.013)
1.5749 (40.002)
SOL-3
SEE NOTE 3
9.57
(243.1)
A
SUCTION CL
7.69
(195.2)
0.50
(12.7)
1.56 (39.6)
1.68 (42.7)
OUT
2.78 (70.6)
CL
DRIVE
SHAFT
3.90
(99.1)
6.00
(152.4)
5.25
(133.4)
1.18 (29.9)
2.56 (65)
3.50 (89)
3.38
(85.8)
4.88
(124)
13.69
347.7)
OUT
SOL-4
SEE NOTE 3
3.50
(88.9)
3.54
(90)
4.75
(120.7)
30.03 (762.7)
1.83 (46.5)
MAIN OIL INJECTION
ORIFICE PLUG LOCATION
3.65 (92.7)
2.59 (65.8)
3.75 (95.3)
8.26
(209.8)
3.37
(85.6)
SOL-4
SEE NOTE 3
5.63
(143)
10.70
(271.8)
2.57
(65.3)
2.60
(66)
COMPRESSOR
4.98 (126.5)
DRIVE SHAFT
OUT
8.50
(215.9)
OUT
.500/.502
(12.70/12.75)
1.703/1.718
(43.25/43.63)
SEE DETAIL A
DETAIL A
1.999/2.000
(50.77/50.80)
SOL-3
SEE NOTE 3
11.84 (300.7)
13.17 (334.5)
15.73 (399.5)
19.04 (483.6)
11.31
(287.3)
LIFTING HOLE
M20 X 2.5-6H
1.56 DP
FRICK FABRICATED
SUCTION FLANGE 5"
15.73
(399.5)
4.57
(116.1)
DRIVE SHAFT
COMPRESSOR
1.25
(31.8)
TOP
1.31
(33.3)
1.25
(31.8)
15.79 (401.1)
43.79 (1112.3)
19.04 (483.6)
3.00
(76.2)
7.50
(190.5)
4.75
(120.7)
5.75
(146.1)
8.25
(209.6)
4.00
(101.6)
3.25
(82.6)
1.13
(28.7)
1.88
(47.8)
0.77
(19.6)
1.88
(47.8)
0.75
(19.1)
SUCT
9.50
(241.3) 8.38 7.38 7.13
(212.9) (187.5)
(181.1)
8.10
6.73 (205.7)
(170.9)
4.00
(101.6)
3.00
(76.2)
20.25 (514.35)
9.56 (242.8)
8.25
(209.6)
4.00
(101.6)
2.00
(50.8)
FORGED 4"
SOCKET WELD FLANGE
11.88
(301.8)
5.77
(146.6)
21.38
(543.1)
3.56
(90.4)
9.50
(241.3)
2.39
(60.7)
3.50
(88.9)
8.25
(209.6)
15.73
(399.5)
VIEW B-B
7.50
(190.5)
12.06
(306.3)
MINIMUM DISTANCE
REQUIRED TO
REMOVE SHAFT SEAL
3.25
(82.6)
PORT
1*
2
3
4
5
7
8
10
11
12
16
18**
20
21
22
CONNECTION SIZE
3/4 - 14 NPTF
1/8 - 27 NPTF
3/8 - 18 NPTF
3/8 - 18 NPTF
3/4 - 14 NPTF
1/4 - 18 NPTF
3/8 - 18 NPTF
1/4 - 18 NPTF
1/4 - 18 NPTF
1/4 - 18 NPTF
3/4 - 14 NPTF
1/2 - 14 NPTF
1/8 - 27 NPTF
3/4 - 14 NPTF
1/4 - 18 NPTF
PORT
1
2
3
4
5
6
7
8
10
11
12
15
16
18
19
20
21
22
CONNECTION SIZE
1 - 11 NPTF
1/4 - 18 NPTF
3/8 - 18 NPTF
3/8 - 18 NPTF
1 - 11 NPTF
1/2 - 14 NPTF
1/4 - 18 NPTF
1/4 - 18 NPTF
1/4 - 18 NPTF
1/4 - 18 NPTF
1/4 - 18 NPTF
3/8 - 18 NPTF
3/4 - 14 NPTF
1/8 - 27 NPTF
1/4 - 18 NPTF
1/8 - 27 NPTF
3/8 - 18 NPTF
1/4 - 18 NPTF
O-RING
980A0012K66
980A0012K58
980A0012K66
980A0012K66
980A0012K72
980A0012K60
980A0012K66
980A0012K58
980A0012K60
980A0012K60
N/A
980A0012K66
N/A
N/A
N/A
980A0012K60
980A0012K66
980A0012K60
SAE STRAIGHT THREAD O-RING FITTINGS - ASSEMBLY PROCEDURE FOR RXF 58 - 101
When performing maintenance or replacing the compressor,
the hydraulic tubing may need to be removed and reinstalled. The following procedure outlines the proper
installation of SAE straight thread fittings to SAE straight
thread ports.
The male and female ends of SAE straight thread O-ring
ports have UN/UNF straight threads. An elastomeric O-ring
is fitted to the male end. On assembly, the O-ring is firmly
sandwiched between the angular sealing surface of the
female port and the shoulder of the male end. Sealing is
thus affected and maintained by the O-ring compression
which results from the clamping force generated by the
tightening action. The straight threads do not offer sealing
action; they provide the resistance (holding power) for
service pressure.
Fitting Size
2
3
4
5
6
8
10
12
16
20
24
WARNING
Holding-charge shipping gauges (if mounted) are rated
for 30 psig and are for checking the shipping charge
only. They must be removed before pressure testing
and operating the system. Failure to remove these
gauges may result in catastrophic failure of the gauge
resulting in serious injury or death.
Foot lb
5.5 0.5
11 1.0
14 1.0
22 1.0
27 2.0
42 2.0
60 2.5
80 5.0
115 6.0
225 12.0
250 12.0
WARNING
THIS EQUIPMENT HAS BEEN PRESSURIZED WITH
NITROGEN GAS. TEMPORARY VALVES AND GAUGES
HAVE BEEN INSTALLED.
1. RELIEVE PRESSURE PRIOR TO OPENING LINES OR
MAKING FIELD CONNECTIONS.
2. REMOVE CHARGING VALVES OR GAUGES PRIOR
TO PRESSURIZING SYSTEM.
3. REFER TO THIS MANUAL FOR ADDITIONAL
INFORMATION.
ESCAPING GAS MAY CAUSE INJURY !
package and the rear motor feet and the motor mount have
been bolted into place, the weight of the motor can rest on
the support bracket and the motor mount.
In any screw compressor installation, suction and discharge
lines should be supported in pipe hangers (preferably within
2 feet of vertical pipe run) so that the lines wont move if
disconnected from the compressor. See table for Allowable
Flange Loads.
FOUNDATION
Each XJF Rotary Screw Compressor is shipped mounted on
a wooden skid, which must be removed prior to unit
installation.
CAUTION
Allow proper spacing for servicing (see Dimensional
Outline Drawing).
The first requirement of the compressor foundation is that
it must be able to support the weight.
XJF 95
XJF 120
XJF 151
600 lb
845 lb
1,210 lb
NOZ.
SIZE
NPS
1
1.25
1.5
2
3
4
5
6
8
10
14
CUSTOMER CONNECTIONS
As a minimum you must make oil connections to the
locations shown on the compressor port location drawings
in addition to suction and discharge.
Other connections are available for instrumentation and
service as noted on the Dimensional Outline drawing. The
electrical connections for the slide stop and the slide valve
transmitters and the solenoid valve coils must be connected
to your control system .
The oil supply system for the compressor must be designed
for a total pressure drop of no more than 15 psi with a new
oil filter element. Excessive pressure drop in the oil circuit
can prevent proper operation of the slide valve and slide
stop pistons.
COMPRESSOR OIL
WARNING
DO NOT MIX OILS of different brands, manufacturers, or
types. Mixing of oils can cause excessive oil foaming,
nuisance oil level cutouts, oil pressure loss, gas or oil
leakage and catastrophic compressor failure. CoolWare
will select a specific Frick oil for the refrigerant being
used. Depending on the application, a different oil can be
selected provided it is of the proper viscosity and is compatible with the refrigerant and compressor elastomers.
OIL PUMP
If your XJF compressor application requires an oil pump, it
is recommended that a strainer be mounted upstream to
protect it. Frick supplied pumps are a positive displacement
gear type that must have a safety relief valve to ensure the
oil pressure will not be more than 50 psi above compressor
discharge pressure for all models.
COMPRESSOR
MOUNTING
CAUTION
To prevent injury or damage to components, and for
complete details regarding pressurized refrigerant vapor
transfer and recovery, see the current InstallationOperation-Maintenance Manual for your unit.
1. Place a new gasket on the oil separator flange. (Contact
the Baltimore Parts Center for replacement gaskets, Ph:
800-336-7264). Assemble the new compressor to the tunnel
and hand tighten the bolts in a star pattern. Then torque to
1/3 of table value in star pattern increasing by 1/3s to full
torque. Refer to Table 3 for torque specifications.
2. Set the compressor and motor assembly on the separator
flange and align the oil separator flange bolt holes to the
compressor discharge flange bolt holes while supporting
the assembly with a hydraulic piston underneath the motor.
The hydraulic piston must support the motor weight, motor
support / tunnel weight, plus 1/2 the compressor weight.
Reference Table 2 for compressor weights.
TABLE 2 - COMPRESSOR WEIGHT
Compressor Weight - Approximate
XJS/XJF
lb
kg
95
600
272
120
845
383
151
1,210
549
3. Insert the bolts through the oil separator flange and into
the compressor discharge flange. Tighten bolts using a star
pattern. Lube bolts then finger tight on all bolts, then torque
to 1/3 of table value in star pattern increasing by 1/3s to full
torque. Reference Table 3.
4. The motor feet should rise above the support base. If
not, remove the compressor, add another gasket on top of
the oil separator flange and repeat steps 4 & 5.
5. While the assembly is still supported, measure the
clearance between the motor feet and base plate with a
feeler gage. Shim the motor feet to gage reading plus .002
gap between each motor foot and the support base. Then,
bolt the motor to the mounting base and torque the motor
mounting bolts to 250 ft-lb.
6. Connect all tubing and pipe connections to the
compressor and all wiring to the motor.
7. Remove the lifting assembly.
TABLE 3 - BOLT TORQUE VALUE
Compressor
Model
XJF 95
XJF 120
XJF 151
Screw Size
1/2 or 5/8
1/2 or 5/8
5/8 or 3/4
Torque
ft-lb
NM
58
79
58
79
144
195
OIL HEATER(S)
Your package must be equipped with oil heaters that
provide sufficient heat to prevent condensation from
occurring during shutdown cycles.
OIL FILTER(S)
Your package must be equipped with full-flow oil filtration.
Typical oil filter specification 5 = 75 according to ISO 4572
is required to obtain the recommended oil cleanliness class
16/14/11 according to ISO 4406. Frick SuperFilters can be
ordered separately.
CAUTION
Other than the isolation valve needed for strainer cleaning, it
is essential that the strainer be the last device in the
economizer line before the compressor. The strainer must
be strong enough to handle the gas pulsations from the
compressor. Johnson Controls-Frick recommends an R/S
or Hansen strainer. Also, piston-type check valves are
recommended for installation in the economizer line, as
opposed to disc-type check valves. The latter are more
prone to gas-pulsation-induced failure. The isolation and
check valves and strainer should be located as closely as
possible to the compressor, preferably within a few feet.
5 MIN
LIQUID
TUBING SUPPLY VOLUME
POUNDS CU. FT
OD
REFRIG
XJF
MODEL
R-717
HIGH
STAGE
95
3/8
12
0.3
120
1/2
33
0.9
151
3/4
65
1.8
95
3/8
1/2
24
0.4
120
3/8
1/2
60
1.0
151
1/2
5/8
99
1.6
95
3/8
0.1
120
3/8
0.2
151
3/8
14
0.4
R-507
HIGH
STAGE
R-717
BOOSTER
R-507
BOOSTER
95
120
151
PIPE
SCH 80
* 100 ft. liquid line. For longer runs, increase line size accordingly.
CAUTION
It is imperative that an uninterrupted high-pressure
liquid refrigerant be provided to the injection system
at all times. Two items of EXTREME IMPORTANCE are
the design of the receiver/liquid injection supply and
the size of the liquid line. It is recommended that the
receiver be oversized sufficiently to retain a 5-minute
supply of refrigerant for oil cooling. The evaporator
supply must be secondary to this consideration. Failure
to follow these requirements causes wire draw which
can result in damage to the expansion valve, loss of oil
cooling, and intermittant oil cooling. One method of
accomplishing this is described below.
Figure 8
ELECTRICAL INSTALLATION
CAPACITY SLIDE VALVE TRANSMITTER
The slide valve transmitter (Figure 9) measures the position
of the slide valve (SV) and sends a 4 to 20mA signal to your
control system. See Figure 10. The controller will adjust the
position of the SV according to the motor load set point.
The correct position is important to properly load the
compressor and motor. It is important not to overload the
compressor and motor. Observe the maximum power input
and ensure design limitations are not exceeded. Connect to
+/- and signal as shown in the wiring diagram, Figure 10.
Refer to Frick compressor panel instructions for calibration
procedure 090.040-O.
Figure 11 - Hydraulic Schematic
COMPRESSOR UNLOADING: The compressor unloads when
MSV solenoid YY1 is energized and oil is allowed to flow
from compressor port 2 thru the needle valve to the MSV
solenoid. This allows discharge pressure on the slide valve
piston to unload the slide valve as the piston moves outward.
NOTICE
A change in operating conditions, such as winter-tosummer operation, may require readjustment of slide
valve travel time.
VOLUMIZER II Vi CONTROL
The XJF compressor is equipped with a special internal
control that automatically adjusts the compressor volume
ratio to the most efficient of three available steps, (2.2, 3.5,
or 5.0 volume ratio). This gives the compressor the ability
to operate at varying operating conditions while minimizing
power consumption by avoiding over or undercompression.
CAPACITY CONTROL
COMPRESSOR LOADING: The compressor loads when MSV
solenoid coil YY2 is energized and oil flows from the solenoid
valve through the needle valve (HV2) to compressor port 2,
where it enters the load side of the slide valve piston. This
equalizes the force on the slide valve piston and discharge
pressure on the slide valve area loads the compressor. See
Figure 11.
SOLENOID 3 / YY3
Energized
Deenergized
Deenergized
SOLENOID 4 / YY4
Energized
Energized
Deenergized
YY3
COMMON
COMMON
PRESSURE
YY4
GASKET INSTALLATION
OUT
OUT
VENT
SIDE VIEW
OPERATION
MAINTENANCE
GENERAL INFORMATION
CAUTION
NOTICE
THE FOLLOWING SUBSECTIONS MUST BE READ AND
UNDERSTOOD BEFORE ATTEMPTING TO START OR
OPERATE THE UNIT.
permit
INITIAL START-UP
1. Confirm system
compressor.
WARNING
THIS SECTION MUST BE READ AND UNDERSTOOD BEFORE ATTEMPTING TO PERFORM ANY MAINTENANCE
OR SERVICE TO THE UNIT.
starting
the
2. Start.
3. Observe the compressor unit for mechanical tightness of
the external piping, bolts and valves. Ensure that the
machine has no oil and vapor leaks. If any of these occur,
shut down the compressor and correct the problem as
necessary using good safety precautions.
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.
Shut down the unit when changing oil. At the same time all
oil filter cartridges must be changed and all oil strainer elements removed and cleaned. The procedure is as follows:
MAINTENANCE SCHEDULE
This schedule should be followed to ensure trouble-free operation of the compressor unit.
Change Oil
Oil Analysis
Replace Filters
Clean Oil Strainers
Clean Liquid Strainers
Replace Coalescers
Check and Clean Suction Strainer
Check Coupling (a)
Suction & Disch Flange Bolts (d)
VFD Units Check Skip Freq. (f)
Check Electrical Connections (b)
Check Sensor Calibration (c)
Vibration Analysis (e)
Replace Shaft Seal
95,000
90,000
85,000
80,000
75,000
70,000
65,000
60,000
55,000
50,000
45,000
40,000
35,000
30,000
25,000
20,000
15,000
10,000
8000
5000
1000
Maintenance
200
n
n
n
n
n
n
n
n
n
n
n
n
n
n
Every 6 Months
n
n
n
n
n
n
n
n
n
n
n
n
n
n
n
n
n
n
n
n
n
n
Annually Regardless of Operating Hours
n n n n n n n n n n n n n n n n n n
n n n n n n n n n n n n n n n n n n
n
n
n n n n n n n n n n n n n n
n n n
n n n n n n n n n n n n n n
n
Every 6 Months, More Frequently If Levels Increase
When Leak Rate Exceeds 7 - 8 Drops Per Minute
a.
b.
c.
d.
e.
n
n
n
n
n
n
n
n
n
n
n
n
n
n
n
n
n
n
n
n
n
n
n
n
n
Check bolts, shim packs, center inserts, keys, and all bolt torques.
Check and torque all terminals in the processor and starter panel per the specification posted in the enclosure.
Check calibration of Slide Valve, Slide Stop, pressures and temperatures. Calibration should be conducted with NIST certified devices.
Verify tightness of bolts on suction and discharge flanges. See table below for torque requirements.
Vibration measurement must be carried out continuously to obtain optimum preventative control on bearings. If not continuously controlled,
then every 6 months, more frequently if levels increase.
f. Units with varible speed drives - check for excess vibration and skip frequencies any time unit operating conditions change.
Compressor
Model
XJF 95S,M,L
XJF 120S,M,L
XJF 151A,M,L,N
Motor Flange to
Compressor Tunnel (1)
Bolt Size (in.)
Torque (ft-lb)
1/2 or 5/8
58
1/2 or 5/8
58
5/8 or 3/4
144
Compressor Flange to
Separator Flange (2)
Bolt Size
Torque (ft-lb)
M20 X 2.5
107
M20 X 2.5
150
M22 X 2.5
167
VIBRATION ANALYSIS
Periodic vibration analysis can be useful in detecting bearing
wear and other mechanical failures. If vibration analysis is
used as a part of your preventive maintenance program,
take the following guidelines into consideration.
1. Always take vibration readings from exactly the same
places and at exactly the same percentage of load.
2. Use vibration readings taken from the new unit at startup as the baseline reference.
3. Evaluate vibration readings carefully as the instrument
range and function used can vary. Findings can be easily
misinterpreted.
4. Vibration readings can be influenced by other equipment
operating in the vicinity or connected to the same piping as
the unit.
TROUBLESHOOTING GUIDE
Successful problem solving requires an organized approach
to define the problem, identify the cause, and make the
proper correction. Sometimes it is possible that two
relatively obvious problems combine to provide a set of
symptoms that can mislead the troubleshooter. Be aware of
this possibility and avoid solving the wrong problem.
NOTICE
For calibration of the Slide Valve unit, refer to the Analog Calibration instructions in publication 090.040-O.
NOTICE
Unless the Service Technician has been certified by Johnson Controls Frick to rebuild our compressors, troubleshooting
the compressor is limited to identifying the probable cause. If a mechanical problem is suspected contact Johnson
Controls Frick Service. DO NOT ATTEMPT TO DISASSEMBLE COMPRESSOR.
P and I Drawings
XJF MODELS 95 and 120 without OIL PUMP (See OIL COOLING ADDITIONS)
LEGEND*
AS
C
CV
DP
F
FG
HTR
HV
LG
LSL
LSLL
M
1MC
2MC
OP
AIR SUPPLY
COMPRESSOR
CHECK VALVE
DISCHARGE PRESSURE
FILTER OR FILTER DRIER
FLOW GLASS
HEATER
HAND ACTUATED VALVE
SIGHT OR LEVEL GLASS
OIL LEVEL SWITCH LOW
LOW OIL LEVEL SHUTDOWN
MOTOR
MOTOR CONTROL CENTER
MOTOR CONTROL CENTER
OIL PRESSURE
P
PAH
PAHH
PAL
PALL
PCV
PDSLL
PE
PI
PIC/TIC
PM
PS
PSV
SP
STR
PUMP
HIGH PRESSURE ALARM
HIGH PRESSURE SHUTDOWN
LOW PRESSURE ALARM
LOW PRESSURE SHUTDOWN
PRESSURE CONTROL VALVE
LOW DIFFERENTIAL PRESS. SHUTDOWN
PRESSURE ELEMENT
PRESSURE INDICATOR
PRESS./TEMP. INDICATING CONTROLLER
PUMP MOTOR
AUTO CYCLE/PRESSURE SWITCH
PRESSURE SAFETY VALVE
SUCTION PRESSURE
STRAINER
TAH
TAHH
TAL
TALL
TCV
TE
TI
TS
TSH
TSLL
TW
VI
WS
YY
XJF MODELS 95 and 120 with OIL PUMP (See OIL COOLING ADDITIONS)
LEGEND (Cont.)
CONNECTIONS
1
2
3
4
5
6
7
8
10
11
12
15
16
19
VENT - UNLOADING
THERMOWELL
SUCTION PRESSURE
NOTES:
1. PRESSURE TRANSDUCERS INDICATE:
PE-1 OIL PRESSURE
PE-3 DISCHARGE PRESSURE
PE-4 SUCTION PRESSURE
2. TEMPRERATURE PROBES INDICATE:
TE-1 SUCTION GAS TEMPERATURE
TE-2 DISCHARGE GAS TEMPERATURE
TE-3 LUBE OIL TEMPERATURE
TE-4 SEPARATOR OIL TEMPERATURE
3. TERMINATIONS "A" THROUGH "C" REFER
TO CONNECTION POINTS FOR VARIOUS OPTIONS.
XJF MODEL 151 without OIL PUMP (See OIL COOLING ADDITIONS)
LEGEND*
AS
C
CV
DP
F
FG
HTR
HV
LG
LSL
LSLL
M
1MC
2MC
OP
AIR SUPPLY
COMPRESSOR
CHECK VALVE
DISCHARGE PRESSURE
FILTER OR FILTER DRIER
FLOW GLASS
HEATER
HAND ACTUATED VALVE
SIGHT OR LEVEL GLASS
OIL LEVEL SWITCH LOW
LOW OIL LEVEL SHUTDOWN
MOTOR
MOTOR CONTROL CENTER
MOTOR CONTROL CENTER
OIL PRESSURE
P
PAH
PAHH
PAL
PALL
PCV
PDSLL
PE
PI
PIC/TIC
PM
PS
PSV
SP
STR
PUMP
HIGH PRESSURE ALARM
HIGH PRESSURE SHUTDOWN
LOW PRESSURE ALARM
LOW PRESSURE SHUTDOWN
PRESSURE CONTROL VALVE
LOW DIFFERENTIAL PRESS. SHUTDOWN
PRESSURE ELEMENT
PRESSURE INDICATOR
PRESS./TEMP. INDICATING CONTROLLER
PUMP MOTOR
AUTO CYCLE/PRESSURE SWITCH
PRESSURE SAFETY VALVE
SUCTION PRESSURE
STRAINER
TAH
TAHH
TAL
TALL
TCV
TE
TI
TS
TSH
TSLL
TW
VI
WS
YY
XJF MODEL 151 with OIL PUMP and DUAL OIL FILTERS (See OIL COOLING ADDITIONS)
LEGEND (Cont.)
NOTES:
CONNECTIONS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
FORMS
Mechanical Checks
Electrical Checks
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.
Note: Customer connections are to be made per the electrical diagram for the motor starter listed under
the installation section and per the wiring diagram listed under the maintenance section of the IOM.
Please complete and sign this form & fax to 717-762-8624 as confirmation of completion.
Frick Sales Order Number:_______________________
Compressor Model Number:______________________
Unit Serial Number:_____________________________
End User Name:_ _______________________________
Address of Facility:______________________________
City, State, Zip: _________________________________
Print Name:____________________________________
Company:______________________________________
Job Site Contact:________________________________
Contact Phone Number:_________________________
Signed: _ ______________________________________
Rim
Rim
Rim
SUCTION
DISCHARGE
OIL
SEPARATOR
Press
Press
Press
Temp
Temp
Temp
Compressor Outboard
(Noncoupled End)
Axial Direction
____.____ IPS Overall
Compressor
Outboard
Vertical Direction
____.____ IPS (Male)
____.____ IPS (Female)
Compressor Inboard
(Coupling End Center)
Vertical Direction
____.____ IPS Overall
Compressor Inboard
(Jackshaft)
Horizontal Direction
____.____ IPS Overall
Temp
Vi Ratio
F.L.A.
End)
IPS Overall
IPS Overall
IPS Overall
Index
A
accumulator, 3
Allowable Flange Loads, 15
Antifriction bearings, 6
ASHRAE, 3
Assembly Torque Table, 14
Capacity control, 6
Compressor Oil, 15
Compressor Port Locations, 8
Compressor Prestart Checklist, 30
compressor shaft, 5
compressor shaft seal, 6
compressor volume ratio, 19
condensation, 3, 16
Coolware, 3
corrosion, 4, 14
Customer Connections, 15
D
dimensions, 7
Direct Expansion Economizer System, 17
discharge pressure, 23
discharge temperature, 3
Drive Train Alignment, 31
dry nitrogen, 14
dual dip tube method, 18
DX economizer, 17
E
economizer, 17
Economizer
back-pressure regulator valve, 17
balancing load, 17
check valve, 17
DX economizer, 17
economizer port, 17
flashing liquid, 17
flash vessel, 17
isolation valve, 17
microprocessor, 17
outlet pressure regulator, 17
strainer, 17
subcooling liquid, 17
Evacuation lines, 5
F
female rotor, 6
flashing liquid, 17
Foundation, 15
G
gas load, 23
L
lifting rings, 15
liquid injection, 18
dual dip tube method, 18
high-stage units, 18
low condensing pressures, 18
load surges, 3
Long term storage, 4
low compression ratios, 18
lubrication system, 5
M
maintenance, 21
Maintenance
DIN connector plug, 23
linear transmitter, 23
Maintenance Schedule, 22
sensor well, 23
volume ratio control, 23
Maintenance
Bare Compressor Mounting, 24
Operating Log Sheet, 29
male rotor, 6
male rotor shaft, 5
microprocessor, 17
Motor, 31
motor mount, 6
motor rotation, 5
movable slide valve, 19
Multiple Compressor Economizer System, 18
O
Oil analysis, 22
oil cooler, 23
oil cooling system, 21
oil filter cartridges, 22
oil filters, 21
Oil Filter(S), 17
Oil Heater(S), 16
Oil Pump, 15
Oil quality, 23
oil strainer elements, 22
operating log, 23
Operating Log Sheet, 31
P
pipe hangers, 15
piping layouts, 3
piping stress, 15
Prestart Checklist, 30
R
Rigging And Handling, 15
rotor housing, 6
RXF rotary screw compressor
shaft seal, 5
RXF/XJF
Compressor Replacement
Discharge flange, 16
Separator flange, 16
Shim motor feet, 16
S
SAE straight thread, 14
selflubricating, 5
serial number, 3
Shaft rotation, 5
Shell And Coil Economizer System, 17
shipping gauges, 14
shutdown, 22
slide stop, 6
slide valve, 5, 6, 19, 23
slide valve piston, 19
slide valve transmitter, 19
start-up, 20
Start-up, 30
storage, 14
subcooled, 17
subcooling, 17
suction accumulator, 21
suction housing, 5
suction line, 3
suction pressure, 23
suction strainer, 21
system piping, 23
T
thermal stability, 6
traps, 3
troubleshooting, 21
Troubleshooting, 24
Excessive Noise And Vibration, 24
Slide Valve, 24
U
under-compression, 6
unloading, 6
UN/UNF straight threads, 14
V
vacuum, 5
Vacuum, 18
vacuum pump, 18
Vapor Pump, 3
vibration analysis, 21, 23
Vibration Data Sheet, 32
vibration level, 22
Volumizer volume ratio control, 5
W
Warranty, 4
water vapor, 22
Water vapor, 21
Johnson Controls
100 CV Avenue
Waynesboro, PA 17268-1206 USA
Phone: 717-762-2121 FAX: 717-762-8624
www.jci.com/frick