RXF Catalogue IOM English

RXF
ROTARY SCREW COMPRESSOR UNITS

INSTALLATION - OPERATION -
Supersedes:Non FORM NO.:6RH-B02C-NA-ZH(JUL 2011)
MAINTENANCE
RXF
ROTARY SCREW COMPRESSOR UNITS
ALL REFRIGERANTS
MODELS
12 through 101
THIS MANUAL CONTAINS RIGGING, ASSEMBLY, START-UP, AND MAINTENANCE INSTRUCTIONS. READ THOROUGHLY
BEFORE BEGINNING INSTALLATION. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DAMAGE OR IMPROPER
OPERATION OF THE UNIT.
Please check www.johnsoncontrols.com for the latest version of this publication.

6RH-B02C-NA-EN RXF ROTARY SCREW COMPRESSOR UNITS
Page INSTALLATION - OPERATION - MAINTENANCE
Contents
PREFACE 4 CAPACITY CONTROL 23
DESIGN LIMITATIONS 4 VOLUMIZER VOLUME RATIO CONTROL 23
JOB INSPECTION 4 SINGLE-PORT LIQUID INJECTION 25
TRANSIT DAMAGE CLAIMS 4 DUAL-PORT LIQUID INJECTION 25
COMPRESSOR and UNIT IDENTIFICATION 4 QUANTUM™LX EZ-COOL™ LIQUID INJECTION
ADJUSTMENT PROCEDURE 25
INSTALLATION OPERATION OF DANFOSS LIQUID INJECTION
FOUNDATION 6 VALVE 28
RIGGING and HANDLING 7 THERMOSYPHON OIL COOLING 33
SKID REMOVAL 8 INITIAL START‑UP PROCEDURE 33
CHECKING MOTOR/COMPRESSOR ROTATION 8 NORMAL START‑UP PROCEDURE 33
COMPRESSOR/MOTOR COUPLING INSTALLATION 8 MAINTENANCE 34
OIL PUMP COUPLING 10 GENERAL INFORMATION 34
HOLDING CHARGE AND STORAGE 10 NORMAL MAINTENANCE OPERATIONS 34
COMPRESSOR UNIT OIL 10 GENERAL MAINTENANCE 34
OIL CHARGE 10 COMPRESSOR SHUTDOWN and START-UP 34
OIL HEATER(S) 11 GENERAL INSTRUCTIONS FOR REPLACING
OIL FILTER(S) 11 COMPRESSOR UNIT COMPONENTS 35
SUCTION ISOLATION VALVE MOUNTING 11 OIL FILTER, SPIN-ON (RXF 12-50) 36
THER MOSYPHON OIL COOLING 12 OIL FILTER, SINGLE ELEMENT (58-101) 36
LIQUID INJECTION OIL COOLING (Optional) 15 COALESCER OIL RETURN STRAINER 37
DUAL DIP TUBE METHOD 16 CHANGING OIL 38
ELECTRICAL 17 DEMAND PUMP ASSEMBLY 41
VOLTAGE PROTECTION 17 THRUST BEARING ADJUSTMENT 43
MOTOR STARTER PACKAGE 18 INSTALLATION OF CARBON GRAPHITE BUSHINGS 43
CURRENT TRANSFORMER (CT) RATIOS 19 TROUBLESHOOTING THE DEMAND PUMP 44
MINIMUM BURDEN RATINGS 19 PREVENTATIVE MAINTENANCE 44
CONTROL POWER REGULATOR 20 OIL QUALITY and ANALYSIS 46
MAINTENANCE SCHEDULE 47
OPERATION OPERATING LOG 48
OPERATION and START‑UP INSTRUCTIONS 20 MOTOR BEARINGS 48
SGC COMPRESSOR 20
COMPRESSOR LUBRICATION SYSTEM 21 GREASE COMPATIBILITY
NO PUMP OIL SYSTEM 21 TROUBLESHOOTING GUIDE 49
COMPRESSOR OIL SEPARATION SYSTEM 21 A B N O R M A L O P E R AT I O N A N A LY S I S a n d
COLD-START SYSTEM 21 CORRECTION 49
DEMAND PUMP OIL SYSTEM 22 SERVICING THE COLD-START VALVEPRESSURE
COMPRESSOR OIL COOLING SYSTEMS 22 TRANSDUCERS-TESTING 50
COMPRESSOR HYDRAULIC SYSTEM 23 PRESSURE TRANSDUCERS-REPLACEMENT 51
RXF ROTARY SCREW COMPRESSOR UNITS 6RH-B02C-NA-EN
INSTALLATION - OPERATION - MAINTENANCE Page
CAPACITY LINEAR TRANSMITTER SLIDE VALVE

REPLACEMENT 53
VOLUMIZER® TRANSMITTER-SLIDE STOP 53
TEMPERATURE SENSOR 55
ROUBLESHOOTING THE RWF II COMPRESSOR 55
TROUBLESHOOTING THE OIL SEPARATION SYSTEM 56
TROUBLESHOOTING THE HYDRAULIC SYSTEM 57
TROUBLESHOOTING THE DEMAND PUMP SYSTEM 57
MOTOR and BARE COMPRESSOR REPLACEMENT 58
SHUTDOWN DUE TO IMPROPER OIL PRESSURE
(HIGH STAGE and BOOSTER) 61
COMPRESSOR PORT LOCATIONS 66
P & I DIAGRAM 73
P R O P E R I N S TA L L AT I O N O F E L E C T R O N I C
EQUIPMENT IN AN INDUSTRIAL ENVIRONMENT 74
FORMS 76
SAFETY PRECAUTION DEFINITIONS
DANGER
Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
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.
NOTE: Indicates an operating procedure, practice, etc., or portion thereof which is essential to highlight.
PREFACE and provisions made for control; operating cycles and

defrosting periods are reasonable; and that high side
This manual has been prepared to acquaint the condensers are sized within system and compressor
owner and serviceman with the INSTALLATION, design limits.
OPERATION, and MAINTENANCE procedures as
recommended by JCI/YORK for RWF II Rotary Screw DESIGN LIMITATIONS
Compressor Units.
The compressor units are designed for operation
For information about the functions of the Quantum™ within the pressure and temperature limits as shown in
LX control panels, communications, specifications, and JCI/YORK Pub. E70‑610 SED (Check with JCI/YORK
wiring diagrams, see publication series S90-020 O, M, marketing department for availability).
CS, and E90-020 SPC.
JOB INSPECTION
It is most important that these units be properly
applied to an adequately controlled refrigeration Immediately upon delivery examine all crates, boxes
system. Your authorized JCI/YORK representative and exposed compressor and component surfaces for
should be consulted for their expert guidance in this damage. Unpack all items and check against shipping
determination. lists for any discrepancy. Examine all items for damage
in transit.
Proper performance and continued satisfaction with
these units is dependent upon: TRANSIT DAMAGE CLAIMS
CORRECT INSTALLATION All claims must be made by consignee. This is an

PROPER OPERATION ICC requirement. Request immediate inspection by
REGULAR, SYSTEMATIC MAINTENANCE the agent of the carrier and be sure the proper claim
forms are executed. Report damage or shortage claims
To ensure correct installation and application, the immediately to JCI/YORK.
equipment must be properly selected and connected
to a properly designed and installed system. The COMPRESSOR and UNIT IDENTIFICATION
Engineering plans, piping layouts, etc. must be detailed
in accordance with the best practices and local codes, Each compressor unit has 2 identification data plates.
such as those outlined in ASHRAE literature. The compressor data plate containing compressor
model and serial number is mounted on the
A refrigeration compressor is a VAPOR PUMP. To be compressor body. The unit data plate containing unit
certain that it is not being subjected to liquid refrigerant model, serial number is mounted on the support of oil
carryover. it is necessary that refrigerant controls are separator.
carefully selected and in good operating condition; the NOTE: When inquiring about the compressor or
piping is properly sized and traps, if necessary, are unit, or ordering repair parts, provide the MODEL,
correctly arranged; the suction line has an accumulator SERIAL NUMBERS from these data plates.
or slugging protection; that load surges are known
UNIT DATA PLATE COMPRESSOR DATA PLATE
GEOMETRICAL SWEPT VOLUME TABLE
Rotor Max Geometrical

Compressor Diameter Rotor Speed Swept Volume Drive CFM M3/H
M3/Rev
Model mm L/D RPM Shaft End Ft3/ Rev 3550 RPM 2950 RPM
XJS/XJF 95M 95 1.4 5772 0.02513 0.000711 89 126
XJS/XJF 95L 95 1.4 4661 0.03112 0.000881 110 156
XJS/XJF 95S 95 1.4 3600 0.04086 0.001156 145 205
XJS/XJF 120M 120 1.4 5772 0.05065 0.001433 180 254
XJS/XJF 120L 120 1.4 4661 0.06272 0.001775 223 314
XJS/XJF 120S 120 1.4 3600 0.08234 0.00233 292 412
XJF 151A 151 1.6 6297 0.09623 0.002723 342 482
XJF 151M 151 1.6 5332 0.11366 0.003217 403 569
XJF 151L 151 1.6 4306 0.14075 0.003983 500 705
XJF 151N 151 1.6 3600 0.16833 0.004764 598 843
INSTALLATION When installing on a steel base, the following

guidelines should be implemented to properly design
FOUNDATION the system base:
If RXF Rotary Screw Compressor Unit is shipped 1. Use I-beams in the skid where the screw compressor
mounted on a wood skid, it must be removed prior to will be attached to the system base. They should run
unit installation. parallel to the package feet and support the feet for
their full length.
Allow space for servicing the unit 2. The compressor unit feet should be continuously
WARNING
per factory drawings. welded to the system base at all points of contact.
3. The compressor unit should not be mounted on
The first requirement of the compressor foundation vibration isolators in order to hold down package
is that it must be able to support the weight of the vibration levels.
compressor package including coolers, oil, and 4. The customer’s foundation for the system base
refrigerant charge. Screw compressors are capable should fully support the system base under all areas,
of converting large quantities of shaft power into gas but most certainly under the I-beams that support the
compression in a relatively small space and a mass is compressor package.
required to effectively dampen these relatively high-
frequency vibrations. When installing on the upper floors of buildings,
extra precautions should be taken to prevent normal
Firmly anchoring the compressor package to a suitable package vibration from being transferred to the
foundation by proper application of grout and building structure. It may be necessary to use rubber
elimination of piping stress imposed on the compressor or spring isolators, or a combination of both, to prevent
is the best insurance for a trouble-free installation. Use the transmission of compressor vibration directly to
only the certified general arrangement drawings from the structure. However, this may increase package
JCI/YORK to determine the mounting foot locations vibration levels because the compressor is not in
and to allow for recommended clearances around the contact with any damping mass. The mounting and
unit for ease of operation and servicing. Foundations support of suction and discharge lines is also very
must be in compliance with local building codes and important. Rubber or spring pipe supports may be
materials should be of industrial quality. required to avoid exciting the building structure at any
pipe supports close to the compressor package. It is
The floor must be a minimum of 6 inches(150mm) best to employ a vibration expert in the design of a
of reinforced concrete and housekeeping pads are proper mounting arrangement.
recommended. Anchor bolts are required to firmly tie
the unit to the floor. Once the unit is rigged into place In any screw compressor installation, suction and
(See RIGGING and HANDLING), the feet must then be discharge lines should be supported in pipe hangers
shimmed in order to level the unit. The shims should (preferably within 2 ft(610mm). of vertical pipe run)
be placed to position the feet roughly one inch(25mm) so that the lines won’t move if disconnected from the
above the housekeeping pad to allow room for grouting. compressor. See table for Allowable Flange Loads.
An expansion-type epoxy grout must be worked under
all areas of the base with no voids and be allowed to
settle with a slight outward slope so oil and water can
run off of the base.
ALLOWABLE FLANGE LOADS

NOZ. MOMENTS (ft-lbf) LOAD (lbf)
SIZE AXIAL VERT. LAT. AXIAL AXIAL LAT.
NPS MR Mc ML P Vc VL
1 25 25 25 50 50 50
1.25 25 25 25 50 50 50
1.5 50 40 40 100 75 75
2 100 70 70 150 125 125
3 250 175 175 225 250 250
4 400 200 200 300 400 400
5 425 400 400 400 450 450
6 1000 750 750 650 650 650
8 1500 1000 1000 1500 900 900
10 1500 1200 1200 1500 1200 1200
12 1500 1500 1500 1500 1500 1500
14 2000 1800 1800 1700 2000 2000
JCI/YORK recommends consulting a licensed architect Figure1 below).

to determine the proper foundation requirements for
any large engine or turbine drive.
When applying screw compressors at high pressures,

the customer must be prepared for package vibration
and noise higher than the values predicted for normal
refrigeration duty. Proper foundations and proper
installation methods are vital; and even then, sound
attenuation or noise curtains may be required to reduce
noise to desired levels.
For more detailed information on Screw

Compressor Foundations, please request JCI/
YORK publication S70-210 IB.
RIGGING and HANDLING
This screw compressor package

WARNING may be top-heavy. Use caution in
rigging and handling.
RXF 12–50 units can be moved with a forklift or with Figure 1a

rigging and a crane. The recommended method is to
insert lengths of 2" pipe through the base tubing (see
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 the skid. Using a 10-ton jack under the
separator raise the unit at the compressor end until it
clears the two mounting bolts. Spread the skid to clear
the unit mounting support, then lower the unit to the
surface. Repeat procedure on opposite end.
CHECKING MOTOR/COMPRESSOR
ROTATION
Make sure coupling hubs are

WARNING
tightened to the shaft before
rotating the motor to prevent them from flying off
Figure 1b and possibly causing serious injury or death.
The unit can be moved with rigging, using a crane and

Injury may occur if loose clothing,
spreader bar, by hooking into the four lifting eyes on WARNING
etc, becomes entangled on the
the oil separator. If a motor is mounted, appropriate
spinning motor shaft.
adjustment in the lifting point should be made to
COMPRESS OR ROTATION IS CLOCKWISE WHEN
compensate for motor. weight. Adjustment of the
FACING THE END OF THE COMPRESS OR SHAFT.
lifting point must also be made for any additions to the
Under NO conditions should the motor rotation be
standard package such as an external oil cooler, etc.,
checked with the coupling center installed as damage
because the center of balance will be affected. Refer
to the compressor may result. Bump the motor to check
to supplied engineering drawings to determine the
for correct compressor rotation. After verification, install
package center of gravity.
disc drive spacer, as applicable.
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.
COMPRESSOR/MOTOR COUPLING
SKID REMOVAL INSTALLATION
The RWF II unit has compressor to motor alignment
This screw compressor package
through the use of a machined cast iron tunnel. This
CAUTION may be top-heavy. Usecaution to
tunnel is factory set through machining tolerances
prevent unit from turning over.
ensuring motor compressor alignment. No alignment is
required in the field. See Figure 2.
If the unit is rigged into place, the skid can be removed
BP COUPLING INSTALLATION PROCEDURE
threads are clean and lightly oiled. Do not torque any

locknuts at this time. Now pivot the unitized flex disc
until the other bushing holes in the flex disc are in line
with the bolt holes in the spacer. Install the rest of the
spacer bolts at this time. The remaining bolts for this
end of the coupling can be installed through the hub
bolt holes and flex disc bushing holes.
Install the unitized flex disc in the other end of the

Figure 2 BP Coupling coupling. The unitized flex disc, as installed, should
look flat and parallel with the mating hub and spacer
BP Coupling flanges.
1. Install the motor and compressor coupling hubs Torque the disc pack locknuts as recommended in the
and keys on their respective shafts. Ensure that they BP COUPLING DATA TABLE. The bolts should be held
can slide horizontally so that once the disc packs are in place while the locknuts are torqued.
installed, no axial stress is transferred to the disc packs
by a stuck coupling hub. Use no lubricants. 3. Center the coupling between the shafts. Ensure that
the keys are fully engaged in their keyways.
2. Rotate both hubs so that the keys are 180° opposed.
With the hubs mounted and the axial spacing set, 4. Tighten the motor and compressor shaft clamping
proceed to place the spacer between the two hub bolts evenly. Torque to the recommended specification
flanges. Care should be taken when handling the in the BP coupling data table .
spacer. Be sure the spacer is fully supported at this
time. Damage to the unitized flex discs may result 5. Torque the keyway setscrews as recommended in
after they have been installed if the spacer is not fully the BP COUPLING DATA TABLE.
supported. IMPORTANT: Only after the shaft clamping bolts
are tightened to their final torque can the keyway
Install the unitized flex disc at this time. Start a bolt set screws be tightened. If the keyway set screws
through a bolt hole in the spacer. Put the unitized flex are tightened before the shaft clamping bolts are
disc between the hub and spacer until a bushing hole tightened, then the hubs can be cocked on the
in the unitized flex disc lines up with the bolt. Slide the shaft.
bolt through the bushing hole in the unitized flex disc.
Install the locknut until it is snug. Make sure that all bolt
Page 10 INSTALLATION - OPERATION - MAINTENANCE
BP SERIES COUPLING DATA TABLE

BP
DISC PACK LOCKNUT HUB CLAMPING BOLTS KEYWAY SETSCREW
SERIES
TORQUE (Lube*) TORQUE TORQUE
SIZE FT-LB NM SIZE UNF FT-LB NM SIZE UNF FT-LB NM SIZE NC
BP43 40 54.2 7/16-20 49 66.4 3/8-24 10 13.6 3/8-16
BP48 40 54.2 7/16-20 49 66.4 3/8-24 20 27.1 1/2-13
BP53 60 81.4 1/2-20 78 105.8 7/16-20 20 27.1 1/2-13
BP58 120 162.7 5/8-18 120 162.7 1/2-20 20 27.1 1/2-13
BPU-38* 22 30 5/16-24 N/A N/A N/A 22 30 3/8-16
BPU-41* 55 75 7/16-20 N/A N/A N/A 22 30 3/8-16
BPU-47* 120 162.7 9/16-18 N/A N/A N/A 50 68 1/2-13
BPU-54* 120 162.7 9/16-18 N/A N/A N/A 50 68 1/2-13
CH Coupling Data Table
OIL PUMP COUPLING COMPRESSOR UNIT OIL
Compressor units with direct motor/pump coupled DO NOT MIX OILS of different
WARNING
pumps need no pump/motor coupling alignment since brands, manufactur-ers, or types.
this is maintained by the close-coupled arrangement. Mixing of oils may cause excessive oil foaming,
nuisance oil level cutouts, oil pressure loss, gas or
HOLDING CHARGE AND STORAGE oil leakage and catastrophic compressor failure.
NOTE: The JCI/YORK oil charge shipped with the
Each RXF compressor unit is pressure and leak tested unit is the best suited lubricant for the conditions
at the factory and then thoroughly evacuated and specified at the time of purchase. If there is any
charged with dry nitrogen to ensure the integrity of the doubt due to the refrigerant, operating pressures,
unit during shipping and short term storage prior to or temperatures, refer to JCI/YORK Oil publication
installation. E160-802 spc for guidance.
NOTE: Care must be taken when entering the
unit to ensure that the nitrogen charge is safely OIL CHARGE
released.
The normal charging level is midway in the top
All units must be kept in a clean, dry location to prevent sight glass located midway along the oil separator
corrosion damage. Reasonable consideration must be shell. Normal operating level is midway between the
given to proper care for the solid-state components of top sight glass and bottom sight glass. The table gives
the microprocessor. the approximate oil charge quantity.
Units which will be stored for more than two months
must have the nitrogen charge checked periodically. Add oil by attaching the end of a suitable pressure type
Please contact JCI/YORK service for long term storage hose to the oil charging valve, located on the bottom of
requirements. the oil separator. Using a pressure-type pump and the
recommended JCI/YORK® oil, open the charging valve
and pump oil into the separator.
NOTE: Fill slowly because oil will fill up in the
separator faster than it shows in the sight glass.
INSTALLATION - OPERATION - MAINTENANCE Page 11
RXF BASIC CHARGE* OIL COOLER SUCTION ISOLATION VALVE MOUNTING

MODEL (gallon) (gallon)
The suction isolation valve is shipped loose from
12－19 10 1 the factory, so it can be installed at various positions
24－50 11 1 within the suction line piping to the compressor. DO
58，68 25 3 1/2 NOT INSTALL the valve at the compressor suction
with flow against the cone/button (see Figure 3).
85，101 36 3 1/2
When the isolation valve is installed in this position,
uneven flow is generated across the suction check
Oil distillers and similar equipment which act to trap oil valve which is mounted at the inlet to the compressor.
must be filled prior to unit operation to normal design This uneven flow causes the disks in the check valve
outlet levels. The same pump used to charge the unit to strike against the stop pin, and eventually damage
may be used for filling these auxiliary oil reservoirs. the internals of the check valve. If the isolation valve
is mounted at the compressor suction, DO INSTALL
NOTE: The sight glass located in the coalescing with flow across the cone/button (see Figure 4). Please
end of the separator near the discharge connection design your system piping accordingly.
should remain empty.
OIL HEATER(S)
Standard units are equipped with one to three 1000

watt 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 JCI/YORK®. The heaters
are energized only when the unit is not in operation.
Figure 3
DO NOT ENERGIZE THE HEATERS
WARNING
when there is no oil in the unit, the
heaters will burn out. The oil heaters will be energized
whenever 220 volt 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 FILTER(S)
Use of filter elements other than

WARNING
JCI/YORK® 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 Figure 4
system.
THERMOSYPHON OIL COOLING INSTALLATION: The plate-type thermosyphon Oil

cooler with oil side piping and a thermostatically
Thermosyphon oil cooling is an economical, effective controlled mixing valve are factory mounted and piped.
method for cooling oil on screw compressor units. See Figure 5.
Thermosyphon cooling utilizes liquid refrigerant at 1. Thermosyphon oil cooler is supplied with oil side
condenser pressure and temperature that is partially piped to the compressor unit and socket weld ends
vaporized at the condenser temperature in a plate and supplied on the refrigerant side.
shell vessel, cooling the oil to within 35°F(19.4℃) of 2. A refrigerant-side safety valve is required when
that temperature. The vapor, at condensing pressure, refrigerant isolation valves are installed between the
is vented to the condenser inlet and reliquified. This cooler and thermosyphon receiver. If no valves are
method is the most cost effective of all currently applied used between the cooler and thermosyphon receiver,
cooling systems since no compressor capacity is lost or the safety valve on the thermosyphon receiver must be
compressor power penalties incurred. The vapor from sized to handle the volume of both vessels. Then, the
the cooler need only be condensed, not compressed. safety valve on the cooler vent (liquid refrigerant side)
Refrigerant flow to the cooler is automatic, driven by can be eliminated.
the thermosyphon principle and cooling flow increases 3. System receiver must be mounted below
as the oil inlet temperature rises. thermosyphon receiver level in this arrangement.
4. The refrigerant source, thermosyphon or system
EQUIPMENT - The basic equipment required for a receiver should be in close proximity to the unit to
thermosyphon system consists of: minimize piping pressure drop.
1. A source of liquid refrigerant at condensing pressure 5. The liquid level in the refrigerant source must not be
and temperature located in close proximity to the unit less than 6 feet above the center of the oil cooler.
to minimize piping pressure drop. The liquid level in the 6. JCI/YORK recommends the installation of an angle
refrigerant source must be 6 to 8 feet above the center valve in the piping before the thermosyphon oil cooler
of the oil cooler. to balance the thermosyphon system. JCI/YORK also
2. A shell and tube or plate-type oil cooler with a recommends the installation of sight glasses at the
minimum 300 psi design working pressure on both the TSOC inlet and outlet to aid in troubleshooting. The
oil and refrigerant sides. factory-mounted plate-type thermosyphon oil cooler
Due to the many variations in refrigeration system requires a refrigerant-side drain valve to be provided
design and physical layout, several systems for and installed by the customer.
assuring the above two criteria are possible. The component and piping arrangement shown in
Figure 5 is intended only to illustrate the operating
principles of thermosyphon oil cooling. Other
component layouts may be better suited to a specific
installation. Refer to publication E70-900E for additional
information on Thermosyphon Oil Cooling.
WATER-COOLED OIL COOLING
The plate-type water-cooled oil cooler is mounted on

theunit complete with all oil piping. The customer must
supply adequate water to the oil cooler.
JCI/YORK recommends a closed-loop system for the
Figure 5
waterside of the oil cooler. Careful attention to water connection. These are available from a number of
treatment is essential to ensure adequate life of the suppliers of welding materials.
cooler if cooling tower water is used. It is imperative
that the condition of cooling water and closed-loop Heat-sink paste must be applied
fluids be analyzed regularly and as necessary and CAUTION around the base of the connection
maintained at a pH of 7.4, but not less than 6.0 for prior to welding. See Figure 6.
proper heat exchanger life. After initial start-up of the
compressor package, the strainer at the inlet of the oil 2. Two-pass welding is required; stagger start/stop
cooler should be cleaned several times in the first 24 region; welding procedure in accordance with ASME
hours of operation. Section 9.
In some applications, the plate-type oil cooler may 3. If possible use gas protection, when welding, to
be subjected to severe water conditions, including avoid oxidation of the surface. As it is rarely possible to
high temperature and/or hard water conditions. This clean the root side of the weld by grinding or brushing
causes accelerated scaling rates which will penalize to remove the root oxide, it is optimal to use root gas.
the performance of the heat exchanger. A chemical 4. Welding should occur in two segments, from 6:00
cleaning process will extend the life of the heat to 12:00. The maximum intersegment temperature
exchanger. It is important to establish regular cleaning should be 350°F. Temperature should be verified with
schedules. temperature indicating crayon or equivalent.
Cleaning: A 3% solution of Phosphoric or Oxalic 5. The fitting may be cooled with forced air to reduce
Acid is recommended. Other cleaning solutions can the temperature of the fitting to 350°F or lower, prior to
be obtained from your local distributor, but they must welding the second segment.
be suitable for stainless steel. The oil cooler may be The maximum connection static forces and moments
cleaned in place by back flushing with recommended for Alfa Nova heat exchangers are listed in the following
solution for approximately 30 minutes. After back table. Keep these values in mind when designing your
flushing, rinse the heat exchanger with fresh water to system. It is also recommended to minimize connection
remove any remaining cleaning solution. loads when designing piping systems. Also see Figure
NOTE: The component and piping arrangement 6.
shown in Figure 5 is intended only to illustrate the
operating principles of thermosyphon oil cooling. Fx Fy Fz Mx My Mz
Other component layouts may be better suited to a
(Ibf) (Ibf) (Ibf) (Ibf) (Ibfft) (Ibfft)
specific installation. Refer to publication E70-900E
ANHP52 202 13 13 57 32 32
for additional information on Thermosyphon Oil
Cooling. ANHP76 292 22 22 103 58 58
FIELD WELDING INSTRUCTIONS FOR TSOC AND

WCOC:
The heat exchanger body is constructed in stainless
steel, while the stub connections are carbon steel.
The highly polished stub connections can give the
appearance of stainless steel. The following are
requirements for welding to the socket weld fittings on
Plate heat exchangers:
1.Use a heat sink paste around the base of the
LIQ. LINE FLOW

RXF SIZE*
REFRIG RATE LIQUID
MODEL PIPE
SCH TUBING (lb) 5 VOLUME
80 OD MIN CU.FT
12 1/2 - 10 0.3
15 1/2 - 12.5 0.4
19 1/2 - 15 0.4
24 1/2 - 20 0.6
R717 30 1/2 - 25 0.7
HIGH 39 1/2 - 30 0.8
50 3/4 - 40 1.1
STAGE
58 3/4 - 47 1.3
68 3/4 - 55 1.6
85 3/4 - 70 2.0
Figure 6 -Application of heat-sink paste before welding 101 3/4 - 80 2.3
12 3/4 5/8 30 0.4
15 3/4 5/8 37.5 0.5
19 3/4 5/8 45 0.6
24 3/4 7/8 60 0.8
R22 30 3/4 7/8 75 1.0
HIGH 39 3/4 7/8 95 1.3
STAGE 50 1 1-1/8 125 1.7
58 1 1-1/8 145 1.9
68 1 1-1/8 170 2.3
85 1 1-1/8 210 2.8
101 1 1-1/8 250 3.4
12 1/2 - 2.0 0.1
15 1/2 - 2.5 0.1
19 1/2 - 3.5 0.1
24 1/2 - 4.5 0.1
R717 30 1/2 - 5.5 0.2
BOOSTER 39 1/2 - 6.5 0.2
50 1/2 - 8.5 0.3
Figure 7 - Maximum static forces and moments 58 1/2 - 10 0.3
68 1/2 - 12 0.3
85 1/2 - 15 0.4
LIQUID INJECTION OIL COOLING (Optional) 101 1/2 - 18 0.5
12 3/4 5/8 6 0.1
The liquid injection system provided on the unit is 15 3/4 5/8 7 0.1
19 3/4 5/8 9 0.1
self‑contained but requires the connection of the liquid 5/8
24 3/4 12 0.2
line sized as shown in the table. R22 30 3/4 5/8 14.5 0.2
BOOSTER 39 3/4 5/8 18 0.3
Liquid line sizes and the additional receiver volume 50 3/4 5/8 24 0.3
58 3/4 5/8 28 0.4
(quantity of refrigerant required for 5 minutes of liquid 5/8
68 3/4 33 0.5
injection oil cooling) are given in the following table: 85 3/4 5/8 41 0.6
101 3/4 5/8 50 0.7
* 100 ft. liquid line. For longer runs, increase line
size accordingly
High-stage compressor units may be supplied with DUAL DIP TUBE METHOD
single-port (low Vi, side, or closed thread) or dual-
port (low Vi and high Vi), liquid injection oil cooling. The dual dip tube method uses two dip tubes in
Single port will be furnished for low compression ratio the receiver. The liquid injection tube is below the
operation and dual port for high compression ratio evaporator tube to assure continued oil cooling when
operation. Booster compressor units use single-port the receiver level is low. See Figure 8.
(High Vi), liquid injection oil cooling due to the typically
lower compression ratios.
The control system on high-stage units with dual-

port, liquid injection oil cooling switches the liquid
refrigerant supply to the high port when the compressor
is operating at higher compression ratios (3.5 Vi and
above) for best efficiency. Figure 8
Where low compression ratios (low condensing ECONOMIZER - HIGH STAGE (OPTIONAL)
pressures) are anticipated, thermosyphon or water-
cooled oil cooling should be used. The economizer option provides an increase in system
capacity and efficiency by subcooling liquid from the
It is imperative that an uninterrup- condenser through a heat exchanger or flash tank
CAUTION
ted high-pressure liquid refrigerant before it goes to the evaporator. The subcooling is
be provided to the injection provided by flashing liquid in the economizer cooler
system at all times. Two items of EXTREME to an intermediate pressure level. The intermediate
IMPORTANCE are the design of the receiver/liquid pressure is provided by a port located part way down
injection supply and the size of the liquid line. It the compression process on the screw compressor.
is recommended that the receiver be oversized
sufficiently to retain a 5-minute supply of As the screw compressor unloads, the economizer
refrigerant for oil cooling. The evaporator supply port will drop in pressure level, eventually being fully
must be secondary to this consideration. Failure to open to suction. Because of this, an output from the
follow these requirements causes wire draw which microprocessor is generally used to turn off the supply
can result in damage to the expansion valve, loss of flashing liquid on a shell and coil or DX economizer
of oil cooling, and intermittant oil cooling. One when the capacity falls below approximately 60%-70%
method of accomplishing this is described below. capacity (85%-90% slide valve position). This is
done because the compressor will be more efficient
operating at a higher slide valve position with the
economizer turned on, than it will at a low slide valve
position with the economizer turned off. 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
economizer liquid solenoid can be left open whenever
the compressor is running.
Figure 9 - Shell and Coil Economizer System

Due to the tendency of the port pressure to fall with
decreasing compressor capacity, a back-pressure
regulator valve (BPR) is generally required on a
flash economizer system (Figure 11) in order to
maintain some preset pressure difference between
the subcooled liquid in the flash vessel and the
evaporators. If the back-pressure regulator valve is
not used on a flash economizer, it is possible that no
Figure 10 - Direct Expansion Economizer System
pressure difference will exist to drive liquid from the
flash vessel to the evaporators, since the flash vessel
pressure will approach suction pressure at a decreased
slide valve position. In cases where wide swings in
pressure are anticipated in the flash economizer vessel,
it may be necessary to add an outlet pressure regulator
to the flash vessel outlet to avoid over pressurizing the
economizer port, which could result in motor overload.
Example: A system feeding liquid to the flash vessel in
Figure 11 - Flash Economizer System
batches.
The recommended economizer systems are shown in

Figures 8-11. Notice that in all systems there should
be a strainer (STR) and a check valve (VCK) between
the economizer vessel and the economizer port on the
compressor. The strainer prevents dirt from passing
into the compressor and the check valve prevents
oil from flowing from the compressor unit to the Figure 12- Multiple Compressor Economizer System
economizer vessel during shutdown.
Other than the isolation valve economizer vessel, it is necessary to install a back-
WARNING needed for strainer cleaning, it pressure regulator valve with an electric shutoff option
is essential that the strainer be in the vapor line piped to the compressor's economizer
the last device in the economizer line before the port.
compressor. Also, piston-type check valves are
required for installation in the economizer line, as ELECTRICAL
opposed to disc-type check valves. The latter are
more prone to gas-pulsation induced failure. The NOTE: Before beginning electrical installation, read
isolation and check valves and strainer should be the instructions in the section "Proper Installation
located as closely as possible to the compressor, of Electronic Equipment" at the back of this
preferably within a few feet(1-2m). manual.
RXF units are supplied with a Quantum™LX control
For refrigeration plants employing multiple compre- system. Care must be taken that the controls are not
ssors on a common economizing vessel, regardless exposed to physical damage during handling, storage,
of economizer type, each compressor must have a and installation. The single-box control door must be
back-pressure regulating valve in order to balance the kept tightly closed to prevent moisture and foreign
economizer load, or gas flow, between compressors. matter from entry.
The problem of balancing load becomes most
important when one or more compressors run at Customer connections are made
partial load, exposing the economizer port to suction WARNING in the Quantum™LXcontrol panel*
pressure. In the case of a flash vessel, there is no need mounted on the unit. The electrical
for the redundancy of a back-pressure regulating valve enclosures should be kept tightly closed whenever
on the vessel and each of the multiple compressors. work is not being done inside. * Or starter panel (if
Omit the BPR valve on the flash economizer vessel provided).
and use one on each compressor, as shown in Figure
11. It is also recommended that the back-pressure VOLTAGE PROTECTION
regulating valves, used on economizer lines, should
be specified with electric shutoff option. The electric JCI/YORK does not advise nor support the use of
shutoff feature is necessary to prevent flow from the UPS power systems in front of the Quantum™LX
common economizer vessel to the suction side of a panel. With a UPS power system providing shutdown
stopped compressor, through the suction check valve protection for the Quantum™LX, the panel may not see
bypass line, if the other compressors and the common the loss of the 3-phase voltage on the motor because
economizer vessel are still operating and the HV2 the UPS could prevent the motor starter contactor from
valve on the suction bypass is open. dropping out. With the starter contactor still energized,
the compressor auxiliary will continue to feed an
For refrigeration plants using a Packaged Refrigerant “Okay” signal to the panel. This will allow the motor to
Recirculation Unit and a direct expansion (DX) be subjected to a fault condition on the 3-phase bus.
economizer system it is necessary to operate the liquid Some fault scenarios are:
feed solenoid on the unit and the liquid feed solenoid
on the DX vessel off of a common signal to avoid liquid 1. The 3-phase bus has power “on” and “off” in a
overfeed on the DX economizer system. continuous cyclic manner which may cause the motor
to overheat due to repeated excessive in-rush currents.
If multiple compressors are operated with a common 2. Motor cycling may damage the coupling or cause
other mechanical damage due to the repeated high damaged at start-up. See Figure 13.
torque motor “bumps”.
3. Prolonged low voltage may cause the motor to stall Motor starter and interlock wiring requirements
and overheat before the motor contactor is manually are shown in the Starter Wiring Diagram. All of the
turned off. equipment shown is supplied by the installer unless
a starter package is purchased separately from JCI/
Under normal conditions, the loss of 3-phase power will YORK. Starter packages should consist of:
shut down the Quantum™LX panel and it will restart
upon power return. If the panel was in: 1. The compressor motor starter of the specified HP
and voltage for the starting method specified (across-
• Auto – Compressor motor will return to running as the-line, wye-delta, or solid-state).
programmed. NOTE: If starting methods other than across-
• Remote – The external controller would reinitialize the-line are desired, a motor/compressor torque
the panel and proceed to run as required. analysis must be done to ensure that sufficient
• Manual – The compressor will have to be restarted starting torque is available, particularly in booster
manually after the 3-phase bus fault has been cleared. applications. Contact JCI/YORK if assistance is
required.
If the local power distribution system is unstable or 2. If specified, the starter package can be supplied
prone to problems, there are other recommendations as a combination starter with circuit breaker
to satisfy these problems. If power spikes or low or disconnect. However, the motor overcurrent protection/
high line voltages are the problem, then JCI/YORK disconnection device can be applied by others, usually
recommends the use of a Sola® constant voltage (CV) as a part of an electrical power distribution board.
transformer with a line suppression feature. If a phase 3. A 3.0 KVA control power transformer (CPT) to
loss occurs, then you will typically get a high motor supply 120 volt control power to the control system
amp shutdown. If problems continue to exist, then an and separator oil heaters is included. If environmental
examination of the plant’s power factor may be in order. conditions require more than 2000 watts of heat, an
appropriately oversized control transformer will be
Unless careful design failure analysis is considered in required.
the implementation of power systems, the alternative 4. One normally open compressor motor starter
s o l u t i o n s p r o v i de a safer and less expensive auxiliary contact should be supplied and wired as
implementation. In either case, only one Sola® may shown on the starter package wiring diagram. In
be used per compressor. Each compressor needs addition, the compressor starter coil and the CPT
to be individually isolated from each other through secondaries should be wired as shown on the starter
a dedicated control transformer. Sharing a common package wiring diagram, Figure 14.
control power source is an invitation for ground loops 5. The compressor motor Current Transformer (CT)
and the subsequent unexplainable problems. can be installed on any one phase of the compressor
leads.
MOTOR STARTER PACKAGE
NOTE: the CT must see all the current on any one
When starting at full voltage or phase, therefore in wye-delta applications BOTH
CAUTION across-the-line, a shunting de-vice leads of any one phase must pass through the CT.
must be installed or the Analog I/O
board in the Quantum™LX panel may be severely
Figure 13 - STARTER WIRING DIAGRAM Figure 14 - Point-To-Point Wiring Diagram
CURRENT TRANSFORMER SIZE
Calculate (CT) size using the following formula where the CT is higher than calculated, enter it's value for [CT
SF is Service Factor and FLA is Full Load Amps of the Factor] on the panel. The unit can operate with a CT
Motor. one size larger than calculated, however, replace with
FLA x SF x 1.1 the proper size ASAP. DO NOT operate unit with a
(round up to the next hundred) CT more than one size larger than recommended.
Example: FLA = 379; Service Factor = 1.15
379 x 1.15 x 1.1 = 479 MINIMUM BURDEN RATINGS
Use a 500:5 CT
The following table gives the minimum CT burden
DO NOT use undersized current transformers since the ratings. This is a function of the distance between the
panel will not be capable of reading potential current. If motor starting package and the compressor unit.
BURDEN RATING MAXIMUM DISTANCE FROM JCI/YORK PANEL

ANSI VA USING #14 AWG USING 12#AWG USING 10#AWG
B-0.1 2.5 15 ft 25 ft 40 ft
B-0.2 5 35 ft 55 ft 88 ft
B-0.5 12.5 93 ft 148 ft 236 ft
NOTE: Do not install a compressor HAND/OFF/AUTO switch in the starter package as this would bypass the
compressor safety devices.
CONTROL POWER REGULATOR
Compressor units that will be used in areas that suffer

brownouts and other significant power fluctuations can
be supplied with a control power regulator. See Figure
15, Recommended Regulator Installation.
Figure 15 - Recommended Regulator Installation

OPERATION to carry axial loads are mounted at the discharge end

of compressor.
OPERATION and START‑UP INSTRUCTIONS 3. Movable slide valve to provide fully modulating
capacity control from 100% to approximately 10% of
The RXF Rotary Screw Compressor Unit is an full load capacity.
integrated system consisting of seven major 4. VOLUMIZER® volume ratio control to allow infinitely
subsystems: variable volume ratio from 2.2 to 5.0 during compressor
1. Quantum™LX Control Panel operation for all models.
(See publications S90-020 O, M, & CS) 5. A hydraulic unloader cylinder to operate the slide
2. Compressor stop and slide valve.
3. Compressor Lubrication System 6. Compressor housing suitable for 350 PSI pressure.
4. Compressor Oil Separation System 7. Most bearing and control oil is vented to closed
5. Compressor Hydraulic System threads in the compressor instead of suction port to
6. Compressor Oil Cooling System avoid performance penalties from superheating suction
gas.
The information in this section of the manual provides 8. The shaft seal is designed to maintain operating
the logical step‑by‑step instructions to properly start pressure on the seal well below discharge pressure for
up and operate the RWF II Rotary Screw Compressor increased seal life.
Unit. 9. Oil is injected into the rotors to maintain good
NOTE: For alarm descriptions and shutdown or volumetric and adiabatic efficiency, even at very high
cutoutparameters, see publication 090-020, -021, compression ratios.
-022 O.
It is mandatory that the coupling
WARNING
WARNING THE FOLLOWING SUBSECTIONS center be removed and the directi-
MUST BE READ AND UNDERST- on of motor rotation be confirmed before running
O O D B E F O R E AT T E M P T I N G TO S TA R T O R the compressor. Proper rotation of the compressor
OPERATE THE UNIT. shaft is clockwise looking at the end of the
compressor shaft. Failure to follow this step could
RXF COMPRESSOR result in backward compressor rotation which
can cause compressor failure or explosion of the
The JCI/YORK RXF rotary screw compressor utilizes suction housing.
mating asymmetrical profile helical rotors to provide a
continuous flow of refrigerant 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. Heavy‑duty, four-point angular-contact ball bearings
COMPRESSOR LUBRICATION SYSTEM the compressor outlet and back to the oil separator.
For normal high-stage operation an oil pump is not
The RXF compressor is designed specifically required.
for operation without an oil pump for high stage
service. Boosters and some low-differential pressure COLD-START SYSTEM
applications will require the demand pump option.
The RXF package is equipped with a special "cold-
The lubrication system on an RXF screw compressor start" discharge check valve on the gas outlet
unit performs several functions: connection of the oil separator. This valve causes
the oil separator to develop oil pressure rapidly
1. Lubricates the rotor contact area, allowing the male on initial start in order to lubricate the compressor
rotor to drive the female rotor on a cushioning film of without requiring an oil pump, even in cold ambient
oil. temperatures with all pressures equalized. See Figure
2. Provides lubrication of the bearings and shaft seal. 16.
3. Serves to remove the heat of compression from For high-stage packages, the cold-start valve is
the gas, keeping discharge temperatures low and equipped with a large spring that creates 30 psi of
minimizing refrigerant or oil breakdown. pressure in the oil separator (above suction pressure),
4. Fills gas leakage paths between or around the for lubrication of the compressor.
rotors with oil, thus greatly reducing gas leakage and
maintaining good compressor performance even at DO NOT ATTEMPT TO SERVICE
CAUTION
high compression ratios. THE COLD-START VALVE. PLEASE
5. Provides oil pressure for development of balance CONTACT THE JCI/YORK SERVICE DEPARTMENT.
load on the balance pistons to reduce bearing loading
and increase bearing life. Once the compressor is running it will begin to force
gas to the condenser at connection P2. See Figure
NO PUMP OIL SYSTEM 16. As the condenser heats up it will begin to rise in
pressure as the compressor suction pulls down in
The RXF screw compressor unit is designed to be pressure. As soon as differential pressure is developed
self‑lubricating. Oil being supplied to the compressor between the condenser and suction, these pressures
from the oil separator is at system head pressure. act across a piston inside the coldstart valve to partially
Within the compressor, oil porting to all parts of overcome the spring force. When the differential
the compressor is vented back to a point in the pressure reaches and exceeds 30 psi, the piston fully
compressor’s body that is at a pressure lower than overcomes the spring force and powers the valve fully
compressor discharge pressure. The compressor’s open for very low operating pressure drop.
normal operation makes the compressor unit operate For booster applications, the valve is equipped with
essentially as its own oil pump. All oil entering the a lighter spring which produces 1/2 bar (7 psig) oil
compressor is moved by the compressor rotors out pressure above suction pressure before it fully powers
open. The heavier spring is not required because main oil injection port. If this differential is less than
booster compressors are equipped with a demand oil 35 PSI(2.4bar), then the demand pump will turn on
pump. and will continue to run until 45 PSI (3.1bar)differential
is obtained. Then, the pump will shut down and start
The RXF package is also equipped with a suction only when the differential pressure falls below 35
check valve bypass. The oil separator will slowly bleed PSI(2.4bar).
down to system suction pressure when the unit is
stopped. This allows the compressor drive motor to NOTE: For alarm descriptions and shutdown or
have an easier start, and the discharge check valve will cutout parameters, see publication S90-020 O.
seat more tightly. See the "SUCTION CHECK VALVE
BYPASS" section for operation. COMPRESSOR OIL SEPARATION SYSTEM
The RXF is an oil-flooded screw compressor. Most

of the oil discharged by the compressor separates
from the gas flow in the oil charge reservoir. Some
oil, however, is discharged as a mist which does not
separate readily from the gas flow and is carried past
the oil charge reservoir. The coalesce filter element
then coalesces the oil mist into droplets, the droplets
of oil fall to the bottom of the coalescer section of the
oil separator. The return of this oil to the compressor
is controlled by a hand expansion valve (HV1). See
Figure 17.
NOTE: Open HV1 only enough to keep the coalesce
end of the separator free of oil.
Figure 16 - Cold-Start Valve
The sight glass located near the bottom of the coalesce
Section of the oil separator should remain empty during
DEMAND PUMP OIL SYSTEM normal operation. If an oil level develops and remains
in the sight glass, a problem in the oil return separation
This system is designed to provide adequate system or compressor operation has developed. Refer
compressor lubrication when there is low differential to Maintenance for information on how to correct the
oil pressure across the compressor suction and problem.
discharge for some high stage applications and booster
applications as required. NOTE: The normal operating level is midway
between the two sight glasses located midway
On start-up, Quantum™LX will calculate the pressure along the oil separator shell.
differential between the compressor discharge and the
Figure 18
COMPR ESSOR 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
Figure 17 - Oil Separation System
discharge pressure on the slide valve piston to unload
the slide valve as the piston moves outward.
COMPRESSOR HYDRAULIC SYSTEM
ADJUSTMENT (Capacity Control): A needle valve
The hydraulic system of the RXF compressor utilizes (HV2) is provided to adjust slide valve travel time,
oil pressure from internally drilled passages in the preventing excessive slide valve “hunting”. HV2 should
compressor casing to selectively load and unload the be adjusted to restrict oil flow to the compressor port so
compressor by applying this pressure to the actuating that slide valve travel time from full load to full unload,
hydraulic piston of the movable slide valve (MSV). It or vice versa, is a minimum of 30 seconds.
also uses oil pressure to actuate a hydraulic piston NOTE: A change in operating conditions, such
that moves the movable slide stop, Volumizer ® II. This as winter-to- summer operation, may require
allows adjustment of the compressor volume ratio, (Vi) readjustment of slide valve travel time.
while the compressor is running.
VOLUMIZER® II Vi CONTROL
CAPACITY CONTROL
The RXF compressor is equipped with a special internal
COMPR ESSOR LOADING: The compressor loads control that automatically adjusts the compressor
when MSV solenoid coil YY2 is energized and oil flows volume ratio to the most efficient of three available
from the solenoid valve through the needle valve (HV2) steps, (2.2, 3.5, or 5.0 volume ratio). This gives the
to compressor port 2, where it enters the load side of compressor the ability to operate at varying operating
the slide valve piston. This equalizes the force on the conditions while minimizing power consumption by
slide valve piston and discharge pressure on the slide avoiding over or undercompression.
valve area loads the compressor. See Figure 18.
Solenoid valves 3 and 4 (See Figures 18 - 20 and
location on P & I diagram represented by YY3 and
YY4) control the Volumizer® II volume ratio control. Oil
is internally ported to apply hydraulic pressure to two or excessive oil foaming. See Figures 19-21 for correct
stepping pistons in order to move the moveable slide installation of gaskets and location of solenoids.
stop to the optimum position. The following chart shows
the logic of solenoid operation to adjust the volume
ratio.
Vi YY3 YY4
2.2 Energized Energized
3.5 Deenergized Energized
5.0 Deenergized Deenergized
Proper operation of the Volumizer® II control can be

checked as follows.
Figure 19 - RXF 12–19 Vi Control
1. Confirm that the slide valve travel number in Factory
Setup is set at 190 degrees. If necessary, adjust the
setting to 190 degrees before proceeding further.
2. Set the compressor Vi to 2.2, then record the voltage
that is shown on the Slide Valve calibration screen for
the current Slide Valve and 0% Slide Valve positions.
The difference between these voltages must be in the
1.35 - 1.65 Vdc range.
0.95 - 1.15 Vdc range.
0.73 - 0.93 Vdc range.
5. If the above voltage measurements are all in range,
the Volumizer® II is working properly. If any of the
voltages are out of range, go to the troubleshooting
section.
Proper installation of the Vi control valves and gaskets

is essential to the operation of this equipment.
Incorrectly installed parts may cause the compressor
to operate at the wrong Vi, or to load or unload
improperly. Operation at the wrong compressor Vi can
cause excessive power consumption, noise, vibration,
SLIDE VALVE CALIBRATION cooling.
Slide valve calibration is performed on the Quantum™ The dual-port system contains all the components of
LX control panel in automatic mode. If further problems the single-port system with the addition of a double-
occur or persist, contact Johnson Controls-Frick acting solenoid valve and operates as outlined.
service.
The liquid injection solenoid valve is energized by the
COMPRESSOR OIL COOLING SYSTEMS microprocessor when the temperature sensor, installed
in the oil manifold, exceeds the setpoint. Liquid
The RXF unit can be equipped with one of several refrigerant is then passed through the temperature
systems for controlling the compressor oil temperature. control valve (TCV) to the double- acting solenoid
They are single or dual-port liquid injection, valve. Depending on the compressor’s operating
thermosyphon, or watercooled oil coolers. Each system volume ratio (Vi), the microprocessor will select the
is automatically controlled, independentof compressor flow of the liquid refrigerant to the optimum compressor
loading or unloading. port.
Oil cooling systems maintain oil temperature within the
following ranges for R-717 and R-22: QUANTUM™LX EZ-COOL™ LIQUID
Liquid Injection Oil Cooling - 130 ‑ 150°F INJECTION ADJUSTMENT PROCEDURE
External* Oil Cooling - 120 - 140°F
* Thermosyphon Oil Cooling (TSOC) or Water-Cooled Use the following directions to set up and tune the
Oil Cooling (WCOC). EZ-Cool LIOC with a Quantum™LX Control Panel.
Also refer to publication 090-022 O, Quantum™LX
SINGLE-PORT LIQUID INJECTION Operation, for an overview of PID control.
The single-port liquid injection system is designed First, complete calibration of the analog output used for
to permit liquid refrigerant injection into one port on EZCool ™ LIOC. Typically, this will be analog output #1
the compressor at any given moment and operates for PID #1.
as outlined. The liquid injection solenoid valve is Power down the panel and remove the two control
energized by the microprocessor when the temperature wires for the valve from terminals 1 & 2 of the P11A
sensor, installed in the compressor discharge, exceeds terminal strip of analog board #1.
the setpoint. High-pressure liquid refrigerant is then • Place the leads of a calibrated, quality meter to
supplied to the temperature control valve (TCV). terminal one (positive) and terminal two (negative). Set
Refer to P & I DIAGRAMS section for piping and the meter to read mA DC and power up the panel.
instrumentation drawings. • Set operating session to session [2] and go to
the screen shown in Figure 22 by pressing [Menu]
DUAL-PORT LIQUID INJECTION >[Calibration] > [Analog Outputs] > [Output Calibration].
• Press #1 on the keypad to drive the output to the
The dual-port liquid injection system is designed to low end. Using numbers 4, 7 and 0 on the keypad to
obtain the most efficient compressor performance at increase and decrease the output and change the “Delta
high and low compression ratios by permitting injection For Changing Output Percentage” setpoint, set the
of liquid refrigerant into one of two ports optimally output to 4mA.
located on the compressor. This minimizes the • If the read value is less than the objective of 4 or
performance penalty incurred with liquid injection oil 20mA use 7 on the keypad, increase the output by the
Delta. If the read value is more than the objective, use • Proportional Gain - This value is calculated from
4 to decrease the value by the Delta. the Proportional Band setpoint and is the same value
• Use the 0 key to change the Delta from 10 to 1, .10 or that was entered as a Proportional Gain setpoint in the
.01% to tune the output to the objective of 4 or 20mA. Quantum. The control setpoint will not be achieved with
• Press #3 on the keypad to set the output to the high proportional control only. Integral control is needed to
end and repeat the process in the preceding steps to further correct the control input to achieve the setpoint.
set the output to 20mA. • Integral Gain - This setpoint controls the influence
• Power down the panel, remove the meter and the Integral component exerts on the PID Output value.
reconnect the control wires for the EZ-Cool LIOC valve The Integral component works to push the Control
as they were removed to terminals 1 & 2 of the P11A Input toward the Control Setpoint by tracking the
terminal strip of analog board #1. difference between the Control Input and the Control
Setpoint over time.
Description of Proportional Band and Gain • Derivative Gain - This setpoint controls the influence
setpoints: the Derivative component exerts on the PID Output
• Proportional Band – This setpoint determines value. The Derivative component reacts to rapid
the size of a region either above or below the changes in the value of the Control Input by predicting
Control Setpoint. Within this region the Proportional the direction the Control Input is traveling and then
component of the PID Output value is the number turning it back toward the Control Setpoint.
between 0% and 100% that directly corresponds to
the difference between the Control Input (Actual) and Example of Proportional Only Control:
the Control Setpoint (Setpoint). Outside of this region Control Input: Discharge Temperature
the Proportional component is either 100% or 0%. Control Setpoint: 150°F
If the PID Action is Forward, the Proportional Band Dead Band: 0°F
extends above the Control Setpoint. If the PID Action Proportional Band: 25
is Reverse, the Proportional Band extends below the Action: Forward
Control Setpoint.
Figure 22
Figure 23
Notes: OPERATION OF DANFOSS LIQUID

1.Set the “Liquid Slugging” Alarm and Shutdown INJECTION VALVE
setpoints to 90 to prevent nuisance shutdowns during
the tuning process. Be sure to return these setpoints to
their original values when finished.
2.While the discharge temperature will be the Control
Point, it reacts quickly to adjustments. Be sure to allow
an adjustment to the proportional band or integral gain
setpoints the opportunity to counter and correct the
control input (discharge temperature) before making
additional adjustments.
3.Tune the output by making small adjustments of 1-5
to the Proportional Band and .1-.5 of the Integral Gain
setpoints. Adjust only one at a time, allowing each
adjustment time to settle out.
• Using the chart below, as long as the control input
is 155°F the output will be at 20% with proportional
control only. Integral control will increase the output in
increments, over time, to correct the control input to the Figure 24
setpoint.
The Danfoss ICAD (Industrial Control Actuator with
Display) is equipped with an LED Interface from which
Control Input Output %
it is possible to monitor and change the setting of
150oF 0%
parameters to adapt the ICAD and the corresponding
155oF 20%
ICM (Motorized Industrial Control Valve) to the actual
160oF 40%
refrigeration application.
165oF 60%
The setting of parameters is managed by means of the
170oF 80%
integrated ICAD MMI (Figures 24 and 25) and consists
175oF 100%
of:
• “Down” arrow push button (Figures 24 and 25)
Based on these descriptions set PID #1 for EZ-Cool™
- Decreases parameter number by 1 at each activation
LIOC per Figure 23 as a starting point. Tuning of the
• “Up” arrow push button (Figures 24 and 25)
output will be required. There should be no need to use
- Increases parameter number by 1 at each activation
a derivative gain.
Figure 25
Enter push button (Figures 24 and 25) valve like an ON/OFF solenoid valve with low speed
- Gives access to the Parameter list by keeping the according to a digital input signal.
push button activated for 2 seconds. A Parameter list - Med represents that ICAD is operating the ICM valve
example is shown below (parameter i08, Figure 26). like an ON/OFF solenoid valve with medium speed
- Gives access to change a value once the Parameter according to a digital Input signal.
list has been accessed. - High represents that ICAD is operating the ICM
valve like an ON/OFF solenoid valve with high speed
according to a digital input signal (Figure 28).
Figure 26
- Acknowledge and save change of value of a
parameter.
Figure 28
- To exit from the Parameter list and return to the
display of Opening Degree (OD), keep the push button Alarms
activated for 2 seconds. - If an alarm has been detected the ICAD display (Figure
• Display (Figure 27) 24) will alternate between showing Actual alarm and
- Normally the Opening Degree (OD) 0 - 100% of the present Opening Degree.
ICM valve is displayed. No activation of push buttons - If more than one alarm is active at the same time, the
for 20 seconds means that the display will always show alarm with the highest priority will take preference. A1
0(Figure 26). has the highest priority, A3 the lowest.
- All alarms will automatically reset themselves when
they physically disappear.
- Old alarms (alarms that have been active, but
have physically disappeared again) can be found in
parameter i11.
Ty p i c a l l y m o t o r i z e d v a l v e s a r e f a c t o r y s e t . I f
adjustments are needed, the following procedure can
be used.
Figure 27 1. Ensure that there is power to the valve (24 VDC) and
all wiring is complete prior to configuring the motorized
• Displays the parameter. valve. The ICAD 600 requires 1.2 amps for operation
• Displays the actual value of a parameter. and the ICAD 900 requires 2.0 amps.
• Displays the function status by means of text (Figure 2. Identify which actuator is being used (ICAD 600 or
24). 900) and which motorized valve is being used (ICM 20,
- Mod represents that ICAD is positioning the ICM 25, 32, 40, 50, or 65). Ensure that the correct actuator
valve according to an analog input signal (Current or is being used with the ICM valve as follows:
Voltage). ICM20 with ICAD 600
- Low represents that ICAD is operating the ICM ICM25 with ICAD 600
ICM32 with ICAD 600 6. The ICAD will store these parameters with the power
ICM40 with ICAD 900 removed.
ICM50 with ICAD 900 Alarms - ICAD can handle and display different alarms.
ICM65 with ICAD 900
3. When the valve is initially powered, A1 and CA will ICM
be flashing on the LED display. Hold the enter button Description Alarm Text Comments
down for two seconds until these values stop flashing. No valve A1 At start-up A1 and CA
4. Push the down arrow button and scroll until j10 is type will
displayed and push the enter button. Using the up selected be displayed
arrow, scroll until j11 is displayed and push the enter Controller A2 Internal fault inside
button. This step must be completed within 20 seconds fault electronics
or the valve will reset. All input A3 When input amps are
5. Push the down arrow button again and scroll until error >22mA
j26 is displayed and push the enter button. Identify the
ICM valve being used and push the up arrow until the
correct number is displayed for the ICM valve and then
push the enter button.
The values are as follows:
1 for ICM20
2 for ICM25
3 for ICM32
4 for ICM40
5 for ICM50
6 for ICM65
Reset to factory setting: 4.Release down arrow and up arrow push buttons.
1.Remove the power supply. 5.When the display on ICAD (Figure 24) is alternating
2.Activate down arrow and up arrow push buttons at between showing: CA and A1 the factory resetting is
the same time. complete.
3.Connect the power supply
Display Factory
Description Min. Max. Unit Comments (Standard Setting)
Name Setting
ICM OD - 0 100 - % ICM valve Opening Degree is displayed during
(Opening normal operation.
Degree) Running display value (see j01, j05).
Main Switch j01 1 2 1 - Internal main switch
1: Normal operation
2: Manual operation. Valve Opening Degree will be
flashing. With the down arrow and the up arrow push
buttons the OD can be entered manually.
Mode j02 1 2 1 - Operation mode
Analog Input 1: Modulating - ICM positioning according to
signal Analogue input (see j03)
2: ON/OFF - operating the ICM valve like an ON/
OFF solenoid valve controlled via Digital Input. See
also j09.
Speed at ON j03 1 4 2 - Type of Analog input signal from external controller
/OFF and 1: 0-20mA
Modulating 2: 4-20mA
3: 0-10V
4: 2-10V
Mode j04 1 100 100 % Speed can be decreased. Max. speed is 100 %
Not active when j01 = 2
If j02 = 2, the display will indicate speed in display.
Low, Med, and High also means ON/OFF operation.
If j04 < = 33, Low is displayed
33 < If j04 < = 66, Med is displayed
If j04 > = 67, High is displayed
Automatic j05 0 1 0 - Not active before j26 has been operated.
calibration Always auto reset to 0.
CA will flash in the display during calibration.
Analog j06 0 2 2 - Type of A0 signal for ICM valve position
Output 0: No signal
signal 1: 0 - 20mA
2: 4 - 20mA
Fail-safe j07 1 4 1 - Define condition at power cut when fail-safe is
installed.
1: Close valve
Display Factory
Description Min. Max. Unit Comments (Standard Setting)
Name Setting
2: Open valve
3: Maintain valve position
4: Go to OD given by j12
Digital Input j09 1 2 1 - Define function when Dl is ON (short circuited Dl
function terminals) when j02 = 2
1: Open ICM valve (Dl = OFF = > Close ICM
valve)
2: Close ICM valve (Dl = OFF = > Open ICM
valve)
Password j10 0 199 0 - Enter number to access password protected
parameters: j26
Old Alarms j11 A1 A99 - - Old alarms will be listed with the latest shown
first. Alarm list can be reset by means of
activating down arrow and up arrow at the same
time for 2 seconds.
OD at powercut j12 0 100 50 - Only active if j07 = 4
If fail-safe supply is connected and powercut
occurs, ICM will go to entered OD.
ICM j26 0 6 0 NB: Password protected. Password = 11
configuration 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
} You must get number
off of 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 j54 0 1 - - Digital Input signal
function
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
THERMOSYPHON OIL COOLING Current thermosyphon systems are using single-pass

oil coolers and flow rates based on 3:1 overfeed.
Thermosyphon oil cooling is an economical, effective The liquid/vapor returned from the cooler is separated
method for cooling oil on screw compressor units. in the receiver. The vapor is vented to the condenser
inlet and need only be reliquified since it is still at
Thermosyphon cooling utilizes liquid refrigerant at
condenser pressure (see Figure 29).
condenser pressure and temperature which is partially
vaporized at the condenser temperature in a shell and
INITIAL START‑UP PROCEDURE
tube or plate-type vessel, cooling the oil. The vapor,
at condensing pressure, is vented to the condenser Having performed the checkpoints on the Prestart
inlet and reliquified. This method is the most cost Checklist (see FORMS in Table of Contents), the
effective of all currently applied cooling systems since compressor unit is ready for start-up. It is important that
no compressor capacity loss or compressor power an adequate refrigerant load be available to load test
penalties are incurred. The vapor from the cooler need the unit at normal operating conditions. The following
only be condensed, not compressed. Refrigerant flow points should be kept in mind during initial start-up.
to the cooler is automatic, driven by the thermosyphon 1. On start-up the unit should be operated at as high
principle, and cooling flow increases as the oil inlet a load possible for 3 hours. During the period, adjust
liquid injection oil cooling, if applicable. If unit has
temperature rises.
water-cooled oil cooling, adjust water control valve to
cooler (if applicable).
2. The compressor slide valve should be calibrated.
3. Pull and clean suction strainer after 24 hours
operation. If it is excessively dirty, repeat every 24
hours until system is clean. Otherwise, follow the
Maintenance Schedule. See the Recommended
Maintenance Program section.
NORMAL START‑UP PROCEDURE
1. Confirm system conditions permit starting the

compressor.
Figure 29
2. Press the [RUN] key.
SYSTEM OPERATION: Liquid refrigerant fills the
cooler. Warm or hot oil (above the liquid return 3. Allow the compressor to start up and stabilize. At
temperature) flowing through the cooler will cause startup, the slide stop (volumizer) and the slide valve
some of the refrigerant to boil and vaporize. The vapor (capacity control) are in the AUTO mode.
rises in the return line.
4. RETIGHTEN MANWAY BOLTS at condenser design
The density of the refrigerant liquid/vapor mixture in pressure (while system is running).
the return line is considerably less than the density of
the liquid in the supply line. This imbalance provides a R E S TA R T I N G C O M P R E S S O R U N I T A F T E R
differential pressure which sustains a flow condition to CONTROL POWER INTERRUPTION (PLANT
the oil cooler. This relationship involves: POWER FAILURE)
1. Liquid height above the cooler.
2. Oil heat of rejection. 1. Check ADJUSTABLE setpoints.
3. Cooler size and piping pressure drops. 2. Follow normal start‑up procedure.
MAINTENANCE before returning to service. Water vapor condensing in

the compressor while running, or more likely while shut
GENERAL INFORMATION down, can cause rusting of critical components and
reduce life.
This section provides instructions for normal
maintenance, a recommended maintenance program, 2. Keep suction strainer clean. Check periodically,
troubleshooting and correction guides, and typical particularly on new systems where welding slag or pipe
P and I diagrams. For typical wiring diagrams and scale could find its way to the compressor suction.
information about the Quantum™LX control panel, Excessive dirt in the suction strainer could cause it to
consult publication S90-020 M. collapse, dumping particles into the compressor.
WARNING THIS SECTION MUST BE READ
A N D U N D E R S TO O D B E F O R E 3. Keep oil filters clean. If filters show increasing
ATTEMPTING TO PERFORM ANY pressure drop, indicating dirt or water, stop the
MAINTENANCE OR SERVICE TO compressor and change filters. Running a compressor
THE UNIT. for long periods with high filter pressure drop can
starve the compressor for oil and lead to premature
NORMAL MAINTENANCE OPERATIONS bearing failure.
When performing maintenance you must take several 4. Avoid slugging compressor with liquid refrigerant.
precautions to ensure your safety: While screw compressors are probably the most
tolerant to ingestion of some refrigerant liquid of any
1. IF UNIT IS RUNNING, PRESS compressor type available today, they are not liquid
CAUTION
[STOP] KEY. pumps. Make certain to maintain adequate superheat
2. DISCONNECT POWER FROM and properly size suction accumulators to avoid
UNIT BEFORE PERFORMING ANY MAINTENANCE. dumping liquid refrigerant into compressor suction.
3. WEAR PROPER SAFETY EQUIPMENT WHEN
COMPRESSOR UNIT IS OPENED TO ATMOSPHERE. Keep liquid injection valves properly adjusted and in
4. ENSURE ADEQUATE VENTILATION. good condition to avoid flooding compressor with liquid.
5. TAKE NECESSARY SAFETY PRECAUTIONS Liquid can cause a reduction in compressor life and in
REQUIRED FOR THE REFRIGERANT BEING USED. extreme cases can cause complete failure.
CLOSE ALL COMPRESOR 5. Protect the compressor during long periods of shut
WARNING
PACKAGE ISOLATION VALVES down. If the compressor will be sitting for long periods
PRIOR TO SERVICING THE UNIT. without running it is advisable to evacuate to low
FAILURE TO DO SO MAY RESULT pressure and charge with dry nitrogen or oil. This is
IN SERIOUS INJURY. particularly true on systems known to contain water
vapor.
GENERAL MAINTENANCE
6. Preventive maintenance inspection is recommended
Proper maintenance is important in order to assure long any time a compressor exhibits a noticeable change in
and trouble-free service from your screw compressor vibration level, noise or performance.
unit. Some areas critical to good compressor operation
are: COMPRESSOR SHUTDOWN and START-UP
1. Keep refrigerant and oil clean and dry, avoid For seasonal or prolonged shutdowns the following
moisture contamination. After servicing any portion of procedure should be followed:
the refrigeration system, evacuate to remove moisture
1. Push [STOP] key to shut down unit. is critical that proper support be provided for the
2. Open disconnect switch for compressor motor compressor to prevent damage to the oil separator.
starter. Insert blocks or a jack between the separator shell
3. Turn off power. and compressor casting. Make sure the weight is held
4. Isolate the package by closing all package valves to safely by the separator shell. Loosen the compressor
the system. Tag all closed valves. discharge flange bolts to relax any flange and pipe
stress, then carefully remove the motor. Similarly,
CAUTION Open any solenoid valves orother before removing the compressor for servicing, the
valves that may t rap l iquid back end of the motor must be supported to prevent
between the isolation valves and damage. Again, insert either blocks or a jack between
other package valves to prevent the rear of the motor and the separator shell.
injury or damage to components.
GENERAL INSTRUCTIONS FOR REPLACING
5. With liquid injection, close the manual hand valve COMPRESSOR UNIT COMPONENTS
upstream of the solenoid and manually open the
solenoid by turning “in” the manual opening stem When replacing or repairing components which are
(clockwise viewed from below valve). exposed to refrigerant pressure (including suction
6. Shut off the cooling water supply valve to the oil strainer) proceed as follows:
cooler. Drain water, if applicable. Attach CLOSED tags.
7. Protect oil cooler from ambient temperatures below 1. Push [STOP] key on control panel to shut down unit.
freezing.
2. Open disconnect switches for compressor motor
NOTE: The unit should be inspected monthly starter and oil pump motor starter (if applicable).
during shutdown. Check for leaks or abnormal
pressure. Use the maintenance log to record 3. Isolate the package by closing all package valves to
readings to verify the pressure stability of the unit. the system. Tag all closed valves.
To prevent the seals and bearing from drying out,
run oil pump (if available) and manually rotate the Open any solenoid valves or
CAUTION
compressor shaft. Consult motor manufacturer for other valves that may t rap liquid
motor recommendations. between the isolation valves and
other package valves to prevent
To start up after a seasonal or prolonged shutdown injury or damage to components.
the following procedure should be followed:
4. SLOWLY vent separator to low-side system pressure
1. Perform routine maintenance. Change oil and using the suction check valve bypass. NOTE: Recover
replace filters. Check strainers. or transfer all refrigerant vapor, in accordance with
2. Any water necessary for the operation of the system local ordinances, before opening to atmosphere.
that may have been drained or shut off should be The separator MUST be equalized to atmospheric
restored or turned on. pressure.
3. Reset solenoid valves to automatic position, then
open all valves previously closed. Remove tags. 5. Make replacement or repair.
4. Compressor unit is ready for prestart checks. Refer 6. Isolate the low pressure transducer, PE-1, to prevent
to PRESTART CHECKLIST. damage during pressurization and leak test.
7. Pressurize unit and leak test.
COMPRESSOR/MOTOR SERVICING 8. Evacuate unit to 29.88" Hg (1000 microns).
9. Open all valves previously closed and reset solenoid
Before removing the motor from an RXF unit, it valves to automatic position. Remove tags.
10. Close disconnect switches for compressor motor Use of filter elements other than Frick may cause
starter and oil pump motor starter, if applicable. warranty claim to be denied.
11. Unit is ready to put into operation.
To change the filter cartridge proceed as follows:
OIL FILTER, SPIN-ON (RXF 12 – 50) 1. If a single oil filter is installed, push [STOP] key to
shut down the unit. Open disconnect switches for the
Use of oil filters other than JCI/ compressor and (if applicable) oil pump motor starters.
CAUTION YORK may cause warranty claim 2. Close discharge service valve. SLOWLY vent the
to be denied. separator to low‑side system pressure using the suction
check valve bypass. Close suction valve and suction
To change the filter proceed as follows: check valve bypass. NOTE: Recover or transfer
1. Push [STOP] key to shut down the unit. Open all refrigerant vapor, in accordance with local
disconnect switches for the compressor. ordinances, before opening to atmosphere. The oil
2. Isolate the package by closing all package valves to filter cartridge MUST be equalized to atmospheric
the system. Tag all closed valves. pressure before opening.
Open any solenoid valves or Oil-entrained refrigerant may

CAUTION CAUTION
other valves that may trap liquid vaporize, causing a pressure
between the isolation valves and increase. Repeat venting and
other package valves to prevent recovery procedure, if necessary.
injury or damage to components.
3. Close oil filter isolation valves. Open drain valve on
SLOWLY vent separator to low-side system pressure oil filter head and drain the oil. Remove the canister
using the suction check valve bypass. NOTE: Recover cover. Discard the cartridge and gasket.
or transfer all refrigerant vapor, in accordance with 4. Flush the filter body with clean Frick refrigeration oil;
local ordinances, before opening to atmosphere. wipe dry with a clean, lint‑free cloth; and close drain
The separator MUST be equalized to atmospheric valve.
pressure. 5. Place a new cartridge in the filter canister. Replace
the gasket and spring and reinstall the canister cover.
CAUTION Oil entrained refrigerant may Torque cover bolts in sequence to:
vaporize, causing a separator a. Finger tight
pressure increase. Repeat transfer b. 17 ft-lb
and recovery procedure, if c. 35 ft-lb
necessary. 6. Isolate the low pressure transducer, PE-1, to prevent
damage during pressurization and leak test.
3. Remove spin-on oil filter element and discard. 7. Pressurize and leak test. Evacuate the unit to 29.88"
4. Replace with new oil filter element. Make finger tight hg (1000 microns).
plus an additional half turn. 8. Add 2 gallons of oil by attaching a suitable pressure-
5. Isolate the low pressure transducer, PE-1, to prevent type hose to the oil-charging valve located on top
damage during pressurization and leak test. of the separator. Use a pressure-type oil pump and
6. Pressurize and leak test. Evacuate unit to 29.88" Hg recommended Frick oil.
(1000 microns). 9. Open the suction and discharge service valves, oil
7. Open the suction and discharge service valves, and filter isolation valves, and the low pressure transducer.
the low pressure transducer. Close disconnect switches Readjust suction check valve bypass. Close disconnect
for the compressor. Start the unit. switches for the compressor and (if applicable) the oil
pump motor starters. Start the unit.
OIL FILTER, SINGLE ELEMENT (58-101)
COALESCER OIL RETURN STRAINER between the solenoid and the service valve.
4. Close the service valve located between the
1. Push [STOP] key to shut down the unit. Open compressor and the liquid injection thermal expansion
disconnect switches for the compressor. valve.
2. Isolate the package by closing all package valves to 5. Carefully loosen capscrews securing the strainer
the system. Tag all closed valves. cover to the strainer. Allow pressure to relieve slowly.
6. When all entrapped refrigerant has been relieved,
Open any solenoid valves or other valves that may trap carefully remove loosened capscrews (as liquid
liquid between the isolation valves and other package refrigerant is sometimes caught in the strainer), strainer
valves to prevent injury or damage to components. cover, and strainer basket.
SLOWLY vent separator to low-side system pressure 7. Wash the strainer basket and cover in solvent and
using the suction check valve bypass. NOTE: Recover blow clean with air.
or transfer all refrigerant vapor, in accordance with 8. Reassemble the strainer.
local ordinances, before opening to atmosphere. 9. Open the service valve between the compressor
The separator MUST be Equalized to atmospheric and the liquid injection thermal expansion valve, purge
pressure. entrained air, and check for leakage.
10. Screw out the manual solenoid valve stem.
Oil entrained refrigerant may 11. Carefully open the liquid supply service valve.
CAUTION
vaporize, causing a separator 12. Leak test.
pressure increase. Repeat transfer 13. Close disconnect switches for compressor starter.
and recovery procedure, if 14. Start the unit.
necessary.
OIL PUMP STRAINER (Optional)
3. Close strainer isolation valves. Remove the large
plug from the bottom of the strainer and remove the To clean the full-lube oil pump strainer, the unit must be
element from the strainer. shut down. The procedure is as follows:
4. Wash the element in solvent and blow clean with air. 1. Push [STOP] key to shut down the unit, then open
5. Replace the cleaned element and removed plug. the Disconnect switches for the compressor and (if
Open strainer isolation valves. applicable) the oil pump motor starters.
6. Isolate the low pressure transducer, PE-1, to prevent 2. Close strainer service valves.
damage during pressurization and leak test. 3. Open the drain valve located in the strainer cover
7. Pressurize and leak test. Evacuate unit to 29.88" Hg and drain the oil into a container.
(1000 microns). 4. Remove the capscrews securing the strainer cover,
8. Open the suction and discharge service valves, and strainer cover gasket, and element. Retain the gasket.
the low pressure transducer. Close disconnect switches 5. Wash the element in solvent and blow it clean with
for the compressor. Start the unit. air.
6. Wipe the strainer body cavity clean with a lint‑free
LIQUID INJECTION STRAINER clean cloth.
7. Replace the cleaned element and gasket, then
To clean the liquid injection strainer the unit must be reattach the cover using the retained capscrews.
shut down. The procedure is as follows: 8. Reinstall the drain plug and open the strainer service
1. Push [STOP] key to shut down the unit, then open valves.
disconnect switches for the compressor. 9. Check for leakage.
2. Close the liquid supply service valve located before 10. Close the disconnect switches for the compressor
the liquid solenoid. and (if applicable) the oil pump motor starters.
3. Immediately screw in the manual solenoid valve 11. Start the unit.
stem to relieve liquid refrigerant pressure trapped
SUCTION CHECK VALVE BYPASS Excessive torque can damage the element and
result in oil carryover. Install jam nut and tighten.
A 1/4" angle valve is installed between the compressor 7. Install a new head gasket and replace the coalescer
and suction flange that can be used as a suction head.
valve bypass. This feature has several uses including 8. Tighten the head bolts, first to finger tight, then 65 ft-
reducing starting torque, improving oil quality, and lb, then 130 ft-lb. NOTE: WHEN THE COMPR ESSOR
relieving the refrigerant to low side for servicing. UNIT IS REPR ESSURIZED, RETIGHTEN SINCE
HEAD BOLTS WILL LOOSEN.
In mo st ca se s, the valve should be left open 9. Refer to CHANGING OIL, Steps 9 thru 14.
approximately 1 to 2 turns at all times. If the
compressor back-spins or too much oil foaming is CHANGING OIL
experienced while venting, partially close valve to slow
speed of equalization. If system is on AUTO CYCLE DO NOT MIX OILS of different
WARNING
and short cycling occurs, the valve must be closed. brands, manufacturers, or
types. Mixing of oils may cause
To relieve refrigerant to low side, close separator excessive oil foaming, nuisance
discharge service valve. Slowly open bypass valve (if oil level cutouts, oil pressure loss,
closed) and wait for pressure to equalize. Close bypass gas or oil leakage and catastrophic
and suction service valves before evacuating the unit. compressor failure.
COALESCER FILTER ELEMENT(S) Shut down the unit when changing oil. At the same
time all oil filter cartridges must be changed and all oil
Use of coalescer filter elements strainer elements removed and cleaned. The procedure
CAUTION other than Frick may cause is as follows:
warranty claim to be denied..
1. Press the [STOP] key on the microprocessor panel
When changing the coalescer filter element, it is to stop the compressor unit.
recommended that the oil and oil filter be changed.
Applicable strainer elements should be removed and 2. Open the disconnect switch for the compressor
cleaned. motor starter.
1. Refer to CHANGING OIL, Steps 1 thru 8.
2. Remove coalescer head and gasket. Discard the 3. Close the suction and discharge service valves;
gasket. also close the liquid-injection and economizer service
3. Remove and retain nut securing coalescer filter valves, if applicable.
retainer.
4. Remove retainer, coalescer filter element(s), and two 4. Close discharge service valve. SLOWLY vent
O‑rings. Discard the filter element(s). separator to low-side system pressure using the
5. Install new coalescer filter element(s). NOTE: Frick bypass line on the suction trap. NOTE: Recover or
Super-Coalescer™ element (with drain feature), on transfer all refrigerant vapor, in accordance with
Models 24–101, must be installed with the "DRAIN local ordinances, before opening to atmosphere.
DOWN" tag on the bottom at the 6 o'clock position. The separator MUST be equalized to atmospheric
pressure.
Seat element in center of locating
CAUTION
tabs on separator bulkhead. Oil-entrained refrigerant may vapo-
WARNING
rize, causing a separator pressure
6. Replace coalescer filter retainer and nut. Tighten the increase. Repeat venting and
nut to 21 ft/lb torque. DO NOT OVERTIGHTEN NUT. recovery procedure, if necessary.
5. Open the drain valve(s) located on the underside of CAUTION Open any solenoid valves or
the separator and drain the oil. other valves that may t rap l iquid
between the isolation valves and
6. Drain the oil filter(s) OF‑1 and, if applicable, the oil other package valves to prevent
coolers and filter OF‑2. injury or damage to components.
7. Remove the old filter cartridges, then install new 3. With liquid injection, close the manual hand valve
ones (as previously described in the section OIL upstream of YY7 and manually open YY7 by turning
FILTER (OF-1) MAIN SINGLE/DUAL). in the manual opening stem (clockwise viewed from
below valve).
8. Remove, clean, and reinstall strainer elements in the
strainers. Failure to follow this procedure
CAUTION
will damage valve YY7.
9. Evacuate unit to 29.88" Hg (1000 microns) vacuum.
(139Pa) 4. SLOWLY vent the separator to low-side system
pressure using the suction check valve bypass.
10. Open the suction service valve and pressurize NOTE: Recover or transfer all refrigerant vapor, in
the unit to system suction pressure. Close the suction accordance with local ordinances, before opening
valve and leak test. to atmosphere. The separator MUST be equalized to
atmospheric pressure.
11. Add oil by attaching a suitable pressure-type
hose to the oil-charging valve located on top of Oil entrained refrigerant may
CAUTION
the separator. Using a pressure-type oil pump and vaporize, causing a separator
recommended JCI/YORK oil, open the charging valve pressure increase. Repeat transfer
and fill the separator until the oil level is midway in the and recovery procedure, if neces-
top sight glass. NOTE: Fill slowly because oil will fill sary.
up in the separator faster than it shows in the sight
glass. Refer to the table in the oil charge section for 5. Remove cover plate.
approximate oil charge quantities. 6. Remove strainer.
7. Clean strainer.
12. Open the suction and discharge service valves, and 8. Reinstall the strainer in the proper direction (outboard
also the liquid injection and economizer service valves, end is marked) and replace the gasket.
if applicable.
If the strainer is installed backw-
CAUTION
13. Close the disconnect switch for the compressor ards, it will be damaged.
motor starter.
9. Pressurize and leak test. Evacuate unit to 29.88" Hg
14. Start the unit. (1000 microns).
10. First, reset solenoid valves to automatic position
SUCTION STRAINER CLEANING then open all valves previously closed. Remove tags.
PROCEDURE Close disconnect switches for compressor. Start unit.
1. Open disconnect switch. DEMAND PUMP DISASSEMBLY

2. Isolate the package by closing all package valves to
the system. Tag all closed valves. BEFORE OPENING ANY VIKING
DANGER
PUMP LIQUID CHAMBER (PUMP-
I N G C H A M B E R , R E S E RV O I R ,
JACKET, ETC.) ENSURE: on end of shaft with a lead hammer or, if using a
regular hammer, use a piece of hardwood between
1. That any pressure in the chamber has been shaft and hammer.
completely vented through suction or discharge
lines or other appropriate openings or connections. The rotary member of the seal will come out with rotor
and shaft.
2. That the driving means (motor, turbine, engine,
etc.) Has been “locked out” or made nonoperational 10. AS , AK, AL : Remove bearing retainer washer. The
so that it cannot be started while work is being washer may have stayed with rotor and shaft when
done on the pump. removed or is against ball bearing. See Figure 31.
FAILURE TO FOLLOW ABOVE LISTED PRECAUTI- 11. Remove the mechanical seal rotary member and
ONARY MEASURES MAY RESULT IN SERIOUS spring from rotor and shaft assembly.
INJURY OR DEATH.
12. GG, HJ, HL: Remove inner snap ring and single-
1. Mark head and casing before disassembly to ensure row ball bearing from casing.
proper reassembly. The idler pin, which is offset in the
pump head, must be positioned up and equal distance AS, AK, AL: Remove single-row ball bearing from
between port connections to allow for proper flow of casing.
liquid through the pump.
13. Remove seal seat or stationary part of seal from
2. Remove the head capscrews. casing.
3. Tilt top of head back when removing to prevent idler 14. Disassemble thrust-bearing assembly.
from falling off idler pin.
GG, HJ, HL: Remove outer snap ring from bearing
4. Remove idler and bushing assembly. If idler bushing housing and remove ball bearing. See Figure 30.
needs replacing, see INSTALLATION OF CARBON
GRAPHITE BUSHINGS. AS, AK, AL: Loosen two set screws in flange outside
diameter. Rotate end cap and lip seal counterclockwise
5. Insert a brass bar or piece of hardwood in the port and remove. Remove ball bearing. See Figure 31.
opening and between rotor teeth to keep shaft from
turning. Turn the locknut counterclockwise and remove The casing should be examined for wear, particularly in
locknut. See. Figure 30 or 31. the area between ports. All parts should be checked for
wear before pump is put together.
6. Loosen two setscrews in face of bearing housing
and turn thrust bearing assembly counterclockwise and When making major repairs, such as replacing a
remove from casing. See Figure 30 or 31. rotor and shaft, it is advisable to also install a new
mechanical seal, head and idler pin, idler, and bushing.
7. GG, HJ, HL: Remove snap ring from shaft. See S e e I N S TA L L AT I O N O F C A R B O N G R A P H I T E
Figure 30. AS, AK, AL: Remove bearing spacer from BUSHINGS.
shaft. See Figure 31.
Clean all parts thoroughly and examine for wear or
8. Remove brass bar or piece of hardwood from port damage. Check lip seals, ball bearings, bushing, and
opening. idler pin and replace if necessary. Check all other
parts for nicks, burrs, excessive wear and replace if
9. The rotor and shaft can now be removed by tapping necessary.
Wash bearings in clean solvent. Blow out bearings with DEMAND PUMP ASSEMBLY
compressed air. Do not allow bearings to spin; turn
them slowly by hand. Spinning bearings will damage Assembly Notes On Standard Mechanical Seal
race and balls. Make sure bearings are clean, then (Synthetic Rubber Bellows Type)
lubricate with refrigeration oil and check for roughness.
Roughness can be determined by turning outer race by
NOTE: Read carefully before reassembling pump
hand. Replace bearings if bearings have roughness.
The seal used in this pump is simple to install and

Be sure shaft is free from nicks, burrs and foreign
good performance will result if care is taken during
particles that might damage mechanical seal.
installation.
Scratches on shaft in seal area will provide leakage
paths under mechanical seal. Use fine emery cloth to
remove scratches or sharp edges. The principle of mechanical seal is contact between the
rotary and stationary members. These parts are lapped
to a high finish and their sealing effectiveness depends
on complete contact.
Prior to installing rotary portion of mechanical seal,

prepare and organize rotor shaft, head and idler
assemblies and appropriate gaskets for quick assembly
Once rotary portion of mechanical seal is installed on

rotor shaft, it is necessary to assemble parts as quickly
as possible to ensure that the seal does not stick to
shaft in wrong axial position. The seal will stick to the
shaft after several minutes setting time.
Figure 30 - Thrust-Bearing assembly (GG, HJ, HL)
Never touch sealing faces with anything except clean
hands or clean cloth. Minute particles can scratch the
seal faces and cause leakage.
1. Coat idler pin with refrigeration oil and place idler

and bushing on idler pin in head. If replacing a carbon-
graphite bushing, refer to "Installation of Carbon
Graphite Bushings".
2. Clean rotor hub and casing seal housing bore.

Make sure both are free from dirt and grit. Coat outer
diameter of seal seat and inner diameter of seal
housing bore with refrigeration oil.
Figure 31 - Thrust-Bearing assembly (AS, AK, AL)
3. Start seal seat in seal housing bore. If force is
necessary, protect seal face with a clean cardboard
disc and gently tap it in place with a piece of wood. Be
sure seal seat is completely seated in the bore. can be installed either side first or do not need to be
packed with grease. For older models with single seal
4. Place tapered installation sleeve on shaft. Refer bearings, pack the inner ball bearing with multi-purpose
to Figure32. Sleeve is furnished with GG, AS, AK, grease, NLGI #2.
and AL replacement mechanical seals. Coat rotor
shaft, tapered installation sleeve, and inner diameter GG, HJ, HL: Drive the bearing into the bore. Tap
of mechanical seal rotary member with a generous the inner race with a brass bar and lead hammer to
amount of refrigeration oil. Petrolatum may be used but position bearing. Install the inner snap ring.
grease is not recommended.
AS, AK, AL: Install the bearing retainer washer over the
5. Place seal spring on shaft against rotor hub. Refer to shaft before installing the ball bearing. Install the ball
Figure 33. bearing in the casing with sealed side towards head
end of the pump. Drive the bearing into the bore. Tap
6. Slide rotary member, with lapped contact surface the inner race with a brass bar and lead hammer to
facing away from spring, over installation sleeve on position the bearing.
shaft until just contacting the spring. Do not compress
spring. Remove installation sleeve. 13. GG, HJ, HL: Install the shaft snap ring in groove in
the shaft. See Figure 30.
7. Coat rotor shaft with refrigeration oil. Install shaft AS, AK, AL: Install the bearing spacer over the shaft
slowly pushing until the ends of rotor teeth are just and against the single row ball bearing. See Figure 31.
below the face of the casing.
14. Pack the lubrication chamber between the inner
8. Leave the rotor in this position. Withdrawal of rotor ball bearing and double row ball bearing in the thrust
and shaft may displace the carbon seal rotating face bearing assembly approximately one-half full of multi-
and result in damage to the seal. purpose grease, NLGI #2. The thrust bearing assembly
will take the remaining space. See Figures 30 and 31.
9. Place O‑ring gasket on head and install head and
idler assembly on pump. Pump head and casing 15. Pack the double row ball bearing with multi-purpose
were marked before disassembly to ensure proper grease, NLGI #2.
reassembly. If not, be sure idler pin, which is offset
in pump head, is positioned up and equal distance GG, HJ, HL: Install the ball bearing into the bearing
between port connections to allow for proper flow of housing with shield side toward the coupling end of
liquid through pump. the shaft. See Figure 30. Install the snap ring into
bearing housing to retain ball bearing. This snap ring
10. Tighten head capscrews evenly has a tapered edge to fit tapered groove in bearing
housing. The tapered edge is located away from the
11. If the pump was equipped with a relief valve and ball bearing.
was removed during disassembly, install on the head
with new O-Rings or gaskets. The relief valve adjusting AS, AK, AL: Install the ball bearing into the bearing
screw cap must always point towards the suction port. housing. Install the lip seal in the bearing housing end
cap. The lip should face towards the end of the shaft.
12. In 2005, the use of single seal bearings were Put the bearing spacer collar in the lip seal and install
phased out. Pumps now use “Sealed for Life” bearings in the bearing housing and tighten the set screws
that have seals on both sides. The new bearings securely. See Figure 31.
16. Insert a brass bar or piece of hardwood through the THRUST BEARING ADJUSTMENT
port opening between the rotor teeth to keep the shaft
from turning. Loosen two screws in face of thrust-bearing assembly.
See Figures 30 and 31.
17. Start the thrust bearing assembly into casing. Turn If shaft cannot be rotated freely, turn thrust-bearing
by hand until tight. This forces the rotor against the assembly counterclockwise until shaft can be turned
head. Replace and tighten the locknut or shaft. easily.
1. While turning rotor shaft, rotate thrust-bearing
18. Remove the brass bar or hardwood from port assembly clockwise until noticeable drag occurs. This
opening. is zero end clearance.
2. Mark position of bearing housing with respect to the
19. Adjust pump end clearance, refer to “Thrust Bearing casing.
Adjustment”. 3. Rotate thrust-bearing assembly counterclockwise
the distance listed below as measured on outside of
B E F O R E S T A R T I N G P U M P, bearing housing.
DANGER
E N S U R E T H AT A L L D R I V E 4. Tighten two setscrews in face of bearing housing
EQUIPMEN TGUARDS ARE IN PLACE. FAILURE after adjustment is made to secure thrust-bearing
TO PROPERLY MOUNT GUARDS MAY RESULT IN assembly position.
SERIOUS INJURY OR DEATH. For viscosities above 2500 SSU, add additional end
clearance (0.004" for GG, HJ and HL size pumps and
0.005" for AS, AK and AL size pumps).
Distance (in.) on
End Clearance
Pump Size O.D.of Bearing
(in.)
Housing
GG 7/16 .003
HJ, HL 9/16 .003
AS, AK, AL 1/2 .003
INSTALLATION OF CARBON GRAPHITE

Figure 32 BUSHINGS
When installing carbon graphite bushings, extreme care

must be taken to prevent breaking. Carbon graphite
is a brittle material and easily cracked. If cracked, the
bushing will quickly disintegrate. Using a lubricant and
adding a chamfer on the bushing and the mating part
will help in installation. The additional precautions listed
below must be followed for proper installation:
1. A press must be used for installation.
Figure 33
2. Be certain bushing is started straight.
3. Do not stop pressing operation until bushing is in b. Liquid too viscous to flow through the piping.
proper position. Starting and stopping will result in a c. Lift too high.
cracked bushing. d. Line too small.
4. Check bushing for cracks after installation. 2. Low reading would indicate:
a. Air leak in suction line.
TROUBLESHOOTING THE DEMAND PUMP b. End of pipe not in liquid.
c. Pump is worn.
BEFORE OPEN ING AN Y PUMP d. Pump is dry - should be primed.
DANGER
LIQUID CHAMBER (PUMPING
CHAMBER, RESER VOIR, JACKET 3. Fluttering, jumping, or erratic reading:
ETC.) ENSURE: a. Liquid vaporizing.
b. Liquid coming to pump in slugs - possibly an air leak
1. THAT AN Y PRESS URE IN CHAMBER HAS BEEN or insufficient liquid above the end of the suction pipe.
COMPLE TEL Y VEN TED THROUGH SUCTION OR c. Vibrating from cavitation, misalignment, or damaged
DISCHARGE LINES OR OTHER APPROPRIATE parts.
OPENINGS OR CONNECTIONS.
Pressure Gauge - Discharge Port
2. THAT THE DRIVING MEANS (MOTOR, TURBINE,
ENGINE, ETC.) HAS BEEN “LOCKED OUT” OR 1. High reading would indicate:
MADE NONOPERATIONAL SO THAT IT CANNOT a. High viscosity and small and/or long discharge line.
BE STARTED WHILE WORK IS BEING DONE ON b. Gate valve partially closed.
PUMP. c. Filter plugged.
d. Vertical head did not consider a high specific gravity
FA I L U R E TO F O L L O W A B O V E L I S T E D liquid.
PRECAUTIONARY MEASURES MAY RESULT IN e. Line partially plugged from buildup on inside of pipe.
SERIOUS INJURY OR DEATH. f. Liquid in pipe not up to temperature.
g. Liquid in pipe has undergone a chemical reaction
Mark valve and head before disassembly to ensure and has solidified.
proper reassembly. h. Relief valve set too high.
If trouble does develop, one of the first steps 2. Low reading would indicate:
toward finding the difficulty is to install a vacuum a. Relief valve set too low
gauge in the suction port and a pressure gauge b. Relief valve poppet not seating properly.
in the discharge port. Readings on these gauges c. Too much extra clearance.
often will give a clue as to where to start looking d. Pump worn.
for the trouble.
3. Fluttering, jumping, or erratic reading:
Vacuum Gauge—Suction Port a. Cavitation.
b. Liquid coming to pump in slugs.
1. High reading would indicate: c. Air leak in suction line.
a. Suction line blocked - foot valve stuck, gate valve d. Vibrating from misalignment or mechanical problems.
closed, strainer plugged. Some of the following may also help pinpoint the
problem: c. Air leak in suction piping or along pump shaft.

d. Running too slowly - is motor the correct speed and
1. Pump does not pump. is it wired up correctly.
a. Lost its prime - air leak, low level in tank. e. Relief valve set too low or stuck open.
b. Rotating in wrong direction. f. Pump worn out.
c. Motor does not come up to speed. g. Tighten end clearance.
d. Suction and discharge valves not open. h. Head position incorrect.
e. Strainer clogged.
f. Relief valve set too low, relief valve poppet stuck 5. Pump takes too much power.
open. a. Running too fast - is correct motor speed, reducer
g. Pump worn out. ratio, sheave size, etc. being used.
h. Any changes in the liquid system, or operation that b. Liquid more viscous than unit sized to handle – heat
would help explain the trouble, e.g. new source of the liquid, increase the pipe size, slow the pump down,
supply, added more lines, inexperienced operators, etc. or get a bigger motor.
i. Tighten end clearance. c. Discharge pressure higher than calculated – check
j. Head position incorrect. with pressure gauge. Increase size or reduce length of
pipe, reduce speed (capacity), or get bigger motor.
2. Pump starts, then loses its prime. d. Pump misaligned.
a. Low level in tank. e. Extra clearance on pumping elements may not be
b. Liquid vaporizing in the suction line. sufficient for operating conditions. Check parts for
c. Air leaks or air pockets in the suction line; leaking air evidence of drag or contact in pump and increase
through packing or mechanical seal. clearance where necessary.
d. Worn out. 6. Rapid Wear.
Examination of a pump that has gradually lost its ability
3. Pump is noisy to deliver capacity or pressure would show a smooth
a. Pump is being starved (heavy liquid cannot get wear pattern on all parts. Rapid wear shows up as
to pump fast enough). Increase suction pipe size or heavy grooving, galling, twisting, breaking, or similar
reduce length. severe signs of trouble.
b. Pump is cavitating (liquid vaporizing in the suction
line). Increase suction pipe size or reduce length; if RECOMMENDED MAINTENANCE PROGRAM
pump is above the liquid, raise the liquid level closer to
the pump; if the liquid is above the pump, increase the In order to obtain maximum compressor unit
head of liquid. performance and ensure reliable operation, a regular
c. Check alignment. maintenance program should be followed (see
d. May have a bent shaft or rotor tooth. Straighten or Maintenance Schedule): The compressor unit should
replace. be checked daily for leaks, abnormal vibration, noise,
e. May be a foreign object trying to get into the pump and proper operation. A daily log should also be
through the suction port. maintained. There should be a continued monitoring
of oil quality and oil analysis testing. In addition,
4. Pump not up to capacity an analysis of the unit’s vibration should be made
a. Starving or cavitating - increase suction pipe size or periodically.
reduce length.
b. Strainer partially clogged - clean.
VIBRATION ANALYSIS WARNING DO NOT MIX OILS of different

brands, manufacturers, or
Periodic vibration analysis can be useful in detecting types. Mixing of oils may cause
bearing wear and other mechanical failures. If excessive oil foaming, nuisance
vibration analysis is used as a part of your preventive oil level cutouts, oil pressure loss,
maintenance program, take the following guidelines gas or oil leakage and catastrophic
into consideration. compressor failure.
1. Always take vibration readings from exactly the NOTE: The oil charge shipped with the unit is the
same places and at exactly the same percentage of best suited lubricant for the conditions specified
load. at the time of purchase. If there is any doubt
due to the refrigerant, operating pressures, or
2. Use vibration readings taken from the new unit at temperatures, refer to JCI/YORK Oil publication
start-up as the base line reference. E160-802 spc for guidance.
3. Evaluate vibration readings carefully as the 1. Only use JCI/YORK oil filter elements or warranty
instrument range and function used can vary. Findings claim may be denied.
can be easily misinterpreted.
2. Participate in a regular, periodic oil analysis program
4. Vibration readings can be influenced by other to maintain oil and system integrity.
equipment operating in the vicinity or connected to the
same piping as the unit. For additional information, 3. Oil samples for analysis should be taken after the
request JCI/YORK publication E70-902 IB. oil filter. A 1/4" purge valve is provided in the oil filter
canister head.
OIL QUALITY and ANALYSIS
High quality refrigeration oil is necessary to ensure

compressor longevity and reliability. Oil quality will
rapidly deteriorate in refrigeration systems containing
moisture and air or other contaminants. In order
to ensure the quality of the refrigeration oil in the
compressor unit.
MAINTENANCE SCHEDULE
This schedule should be followed to ensure trouble-free operation of the compressor unit.
FREQUENCY OR Hours of Operation (Maximum)
10.000
15,000
20,000
25,000
30.000
35,000
40,000
45,000
50,000
55,000
60,000
65,000
70,000
75,000
80,000
85,000
90,000
95,000
Maintenance
1.000
5,000
8,000
200
Change Oil As Directed By Oil Analysis

Oil Analysis ■ Every 6 Months
Replace Filters ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
Clean Oil Strainers
Clean Liquid Strainers ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
Replace Coalescers ■ ■ ■
Check and Clean Suction Strainer ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
Check Coupling (a) ■ Annually Regardless of Operating Hours
Suction & Disch Flange Bolts (d) ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
VFD Units Check Skip Freq. (f)
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
Check Electrical Connections (b)
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
Check Sensor Calibration (c)
■ Every 6 Months, More Frequently If Levels Increase
Vibration Analysis (e)
Replace Shaft Seal When Leak Rate Exceeds 7 - 8 Drops Per 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.
d. Verify tightness of bolts on suction and discharge flanges. See table below for torque requirements.
e. 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 variable speed drives - check for excess vibration and skip frequencies anytime unit operating conditions
change.
Motor Flange to Compressor Compressor Flange to

Compressor
RXF Model Tunnel (1) Separator Flange (2)
Model
Bolt Size (in.) Torque* (ft-lb) Bolt Size (in.) Torque* (ft-lb)
12,15,19 XJF 95S,M,L 1/2 or 5/8 58 M20 X 2.5 107
24,30,39,50 XJF 120S,M,L,S 1/2 or 5/8 58 M20 X 2.5 150
58,68,85,101 XJF 151A,M,L,N 5/8 or 3/4 144 M22 X 2.5 167
1. Based on metal to metal contact.

2. Based on: Gaskets: Garlock® Blue-Gard® 3300; Bolts: class 8.8 or stronger hex head bolts, lightly oiled and clean
OPERATING LOG any deviations from normal operating conditions. It is

recommended that readings be taken at least every
The use of an operating log as included in this four hours.
manual (see Table of Contents) permits thorough
analysis of the operation of a refrigeration system by MOTOR BEARINGS
those responsible for its maintenance and servicing.
Continual recording of gauge pressures, temperatures, Lubricate motor bearings properly before start-up.
and other pertinent information, enables the observer Maintain subsequent lubrication as recommended by
and serviceman to be constantly familiar with the the motor manufacturer. See Figure 34.
operation of the system and to recognize immediately
LUBRICATION SCHEDULE / INSTRUCTIONS
SYNC. FRAME SERVICE CYCLE* - BALL BEARING**

RPM SERIES 8 HR/DAY OPERATION 24 HR/DAY OPERATION
3600 360-5800 150 DAYS (1200 HRS) 50 50 DAYS (1200 HRS)
360 390 DAYS (3120 HRS) 130 DAYS (3120 HRS)
400-440 270 DAYS (2160 HRS) 90 DAYS (2160 HRS)
1800 5000-5800 210 DAYS (1680 HRS) 70 DAYS (1680 HRS)
360-440 390 DAYS (3120 HRS) 130 DAYS (3120 HRS)
1200 5000-5800 270 DAYS (2160 HRS) 90 DAYS (2160 HRS)
* LUBRICATION SCHEDULE FOR SEVERE SERVICE (VIBRATION, SHOCK AND/OR ENVIRONMENTAL
EXTREME) = 1/3 OF THE ABOVE INTERVALS.
** LUBRICATION SCHEDULE FOR ROLLER BEARINGS = 1/3 OF THE ABOVE INTERVALS.
• LUBRICATE BEARINGSWITH POWER IN THE • WITH THE VENT PORTS OPEN, OPERATE THE
OFF CONDITION. MOTOR FOR A MINIMUM OF 15 MINUTES AND
• CLEAR AND CLEAN THE GREASE FITTINGS UNTIL ANY GREASE FLOW HAS CEASED AT THE
AND SURROUNDING AREA. VENTING PORTS.
• REMOVE THE PIPE PLUG FROM THE VENTING • REMOVE POWER.
PORT OPPOSITE THE GREASE FITTING. • REPLACE THE VENT PIPE PLUGS.
• USING A LOW PRESSURE GREASE GUN • REPLACE ANY AND ALL GUARDS AND COVERS
APPLY 1 OZS. (30 GRAMS) OF GREASE AT EACH THAT MAY HAVE BEEN REMOVED TO ACCESS
FITTING,DO NOT OVER GREASE. THE MOTOR.
THE FACTORY INSTALLED, RECOMMENDED LUBRICANT IS LISTED ON THE MOTOR DATA PLATE. THIS
IS POLYUREA GREASE, AS ARE THE PRODUCTS LISTED BELOW. THE INTRODUCTION OF LUBRICANTS
OF ALTERNATE CHEMICAL MAKEUP IS NOT RECOMMANDED AND WILL CAUSE MACHANICAL FAILURE
WITHOUT THE COMPLETE PURGE OF THE FACTORY PRODUCT FROM THE BEARING AND RESERVIOR.
WHEREEVER POSSIBLY, APPLY THE POLYUREA PRODUCT.
CHEVRON OIL CO. - SRI#2 MOBIL POLYREX EM
Figure 34
TROUBLESHOOTING GUIDE solving the wrong problem a new problem was created.
Successful problem solving requires an organized The following list of abnormal system conditions
approach to define the problem, identify the cause, and can cause abnormal operation of the RXF compressor
make the proper correction. Sometimes it is possible unit:
that two relatively obvious problems combine to provide 1. Insufficient or excessive refrigeration load.
a set of symptoms that can mislead the troubleshooter. 2. Excessively high suction pressure.
Be aware of this possibility and avoid solving the “wrong 3. Excessively high suction superheat.
problem”. 4. Excessively high discharge pressure.
5. Inadequate refrigerant charge or low receiver level.
ABNORMAL OPERATION ANALYSIS and 6. Excessively high or low temperature coolant to the
CORRECTION oil cooler.
7. Liquid return from system (carryover).
Four logical steps are required to analyze an 8. Refrigerant underfeed or overfeed to evaporators.
operational problem effectively and make the 9. Blocked tubes or plates in water-cooled oil cooler
necessary corrections: from high mineral content of water.
10. Insufficient evaporator or condenser sizing.
1. Define the problem and its limits. 11. Incorrect refrigerant line sizing.
2. Identify all possible causes. 12. Improper system piping.
3. Test each cause until the source of the problem is 13. Problems in electrical service to compressor unit.
found. 14. Air and moisture present in the system.
4. Make the necessary corrections. Make a list of all deviations from normal plant operat-
ion and normal compressor unit operation. Delete
The first step in effective problem solving is to any items which do not relate to the symptom and
define the limits of the problem. If, for example, separately list those items that might relate to the
the compressor periodically experiences high oil symptom. Use the list as a guide to further investigate
temperatures, do not rely on this observation alone the problem.
to help identify the problem. On the basis of this
information the apparent corrective measure would The second step in problem solving is to decide which
appear to be a readjustment of the liquid injection items on the list are possible causes and which items
system. Lowering the equalizing pressure on the are additional symptoms. High discharge temperature
thermal expansion valve would increase the refrigerant and high oil temperature readings may both be
feed and the oil temperature should drop. symptoms of a problem and not casually related. High
suction superheat or a low receiver level, however,
If the high oil temperature was the result of high could cause both symptoms.
suction superheat, however, and not just a matter of
improper liquid injection adjustment, increasing the The third step is to identify the most likely cause and
liquid feed could lead to other problems. Under low take action to correct the problem. If the symptoms
load conditions the liquid injection system may have are not relieved, move to the next item on the list and
a tendency to overfeed. The high suction superheat repeat the procedure until you have identified the cause
condition, moreover, may only be temporary. When of the problem. Once the cause has been identified
system conditions return to normal the unit’s liquid and confirmed, make the necessary corrections.
injection will overfeed and oil temperature will drop. In
PRESSURE TRANSDUCERS - TESTING 8. Isolate the oil pressure transducers (PE‑3) from
the package and depressurize. NOTE: Recover or
Test Procedure: transfer all refrigerant vapor, in accordance with
1. Shut compressor down and allow pressures to local ordinances, before opening to atmosphere.
equalize.
9. Measure the voltage of (PE‑3) on connector (P5A)
2. Isolate suction transducer (PE-1) from unit and (terminals 5 and 6) on the analog board.
depressurize.
10. The voltage reading should be between 1.1 VDC
NOTE: Recover or transfer all refrigerant vapor, in and 1.29 VDC at standard atmospheric pressure. (PE-2)
accordance with local ordinances, before opening and (PE-3) have a span of 500 PSI as compared to
to (PE-4) with a span of 200 PSI. Therefore, atmospheric
atmosphere. pressure changes have a lesser effect which is 0.0067
VDC per 1000 feet of elevation and 0.00067 VDC per
3. Measure the DC voltage of (PE-1) on connector 0.1 inch Hg barometric deviation.
(P6A) (terminals 2 and 3) on the analog board with a
digital voltmeter. 11. Subtract 1.2 from the voltage.
4. The voltage reading should be between 1.48 VDC 12. Multiply by 75, the result will be PSIG.
and 1.72 VDC at standard atmospheric pressure (14.7
PSIA or 0 PSIG). When checking transducers at higher 13. Since the discharge pressure (PE-2) cannot be
elevations, an allowance in the readings must be made closed off from its sensing point (code requirements),
by subtracting approximately 0.02 VDC per 1000 feet remove all transducers from atmosphere and open
of elevation above sea level. Barometric pressure can them to their sensing points so all transducers can
generally be ignored but in extreme cases may be equalize to separator pressure.
compensated for by adding/ subtracting 0.002 VDC
for each 0.1 inch of barometric pressure (adjusted to 14. Measure the voltage of (PE-2) on connector (P5B)
sea level) above/below 0 PSIG. Therefore, if (PE-1) (terminals 5 and 6) on the analog board.
is measured at 5000 feet elevation under relatively 15. Test complete.
normal weather conditions, the output voltage should
differ by 0.10 VDC to read between 1.38 VDC and 1.62 PRESSURE TRANSDUCERS -
VDC. REPLACEMENT
5. Subtract 1 from the voltage. 1. Shut off control power.
6. Multiply by 25. 2. Close the applicable transducer isolation valve.

N O T E : To c h a n g e t h e d i s c h a r g e p r e s s u r e
7. This result is the absolute suction pressure (PSIA). transducer (PE-2), it will be necessary to
Subtract
depressurize the entire compressor package. 6. Recalibrate. NOTE: If replacing older hard-wired
Follow "General Instructions For Replacing transducer, cut cable at back of old transducer and
Compressor Unit Components" section before rewire to the Danfoss unit.
going to step 3.
7. Reopen the transducer isolation valve or compressor
3. Remove DIN connector screw, then remove DIN package isolation valves.
connector from the transducer.
8. Turn on control power.
TRANSDUCER CONNECTION
Suction Pressure PE-1
Discharge Pressure PE-2
Oil Pressure PE-3
4. Unscrew the transducer using a wrench on the metal

hex at the base of the transducer. DO NOT ATTEMPT
TO LOOSEN OR TIGHTEN TRANSDUCERS BY
THEIR TOP CASING.
5. Install new transducer, reconnect DIN connector,

and retighten DIN connector screw.
PRESSURE TRANSDUCER CONVERSION DATA

Sensor 200 psi 500 psi
Voltage Range - PSIG* Range - PSIG*
low high low high
1.0 29.92” 9.57” 29.92” 4.1
1.1 29.92” 0.3 29.92” 16.6
1.2 29.92” 5.3 17.10” 29.1
1.3 19.74” 10.3 4.1 41.6
1.4 9.57” 15.3 16.6 54.1
1.5 0.3 20.3 29.1 66.6
1.6 5.3 25.3 41.6 79.1
1.7 10.3 30.3 54.1 91.6
1.8 15.3 35.3 66.6 104.1
1.9 20.3 40.3 79.1 116.6
2.0 25.3 45.3 91.6 129.1
2.1 30.3 50.3 104.1 141.6
2.2 35.3 55.3 116.6 154.1
2.3 40.3 60.3 129.1 166.6
2.4 45.3 65.3 141.6 179.1
2.5 50.3 70.3 154.1 191.6
2.6 55.3 75.3 166.6 204.1
2.7 60.3 80.3 179.1 216.6
2.8 65.3 85.3 191.6 229.1
2.9 70.3 90.3 204.1 241.6
3.0 75.3 95.3 216.6 254.1
3.1 80.3 100.3 229.1 266.6
3.2 85.3 105.3 241.6 279.1
3.3 90.3 110.3 254.1 291.6
3.4 95.3 115.3 266.6 304.1
3.5 100.3 120.3 279.1 316.6
3.6 105.3 125.3 291.6 329.1
3.7 110.3 130.3 304.1 341.6
3.8 115.3 135.3 316.6 354.1
3.9 120.3 140.3 329.1 366.6
4.0 125.3 145.3 341.6 379.1
4.1 130.3 150.3 354.1 391.6
4.2 135.3 155.3 366.6 404.1
4.3 140.3 160.3 379.1 416.6
4.4 145.3 165.3 391.6 429.1
4.5 150.3 170.3 404.1 441.6
4.6 155.3 175.3 416.6 454.1
4.7 160.3 180.3 429.1 466.6
4.8 165.3 185.3 441.6 479.1
4.9 170.3 190.3 454.1 491.6
5.0 175.3 195.3 466.6 504.1
At 0 PSIg 1.094 V 1.494 V 0.968 V 1.268 V
* Below 0 PSIG measured in inches of mercury.
SLIDE VALVE TRANSMITTE REPLACEMENT 3. Unscrew knurled ring and remove transmitter unit.
- SLIDE STOP 4. Apply thermal compound to new sensor assembly,
The Slide Valve Transmitter (Figure 35) is located on insert into thermal well, and tighten knurled ring.
the right side of the compressor (facing shaft) at the 5. Apply DIN connector plug to transmitter.
inlet end. 6. Turn on control power.
The linear transmitter with hermetic enclosure is NOTE: For calibration instructions, refer to
based on the inductive measuring principle. It features Quantum™ LX Operator's Manual 090-020 O, -021 O,
removable electronics (from the sensor well) eliminating -022 O.
the need to evacuate the compressor for replacement.
This type of transmitter is dedicated to volume ratio
control and has no user adjustments.
1. Shut off control power.
2. Remove DIN connector plug from transmitter.
3. Loosen set screws.
4. Remove transmitter unit.
5. Install new transmitter unit.
6. Tighten set screws.
7. Apply DIN connector plug to transmitter.
8. Turn on control power. Figure 36 - Temperature Transmitter
NOTE: For calibration of the Slide Valve unit, refer
to the Analog Calibration instructions in publication OIL LEVEL TRANSMITTER REPLACEMENT
090-020 O.
The Oil Level Transmitter is located on the front of
the separator near the bottom/center. See Figure 37.
Figure 35 - Slide Valve Transmitter
TEMPERATURE SENSOR REPLACEMENT
This device is static sensitive.

CAUTION Please follow proper ESD Figure 37 - Oil Level Transmitter
procedures when handling.
The linear transmitter with hermetic enclosure is based
1. Shut off control power. on the capacitive measuring principle. It features
2. Remove DIN connector plug from transmitter. See removable electronics (from the sensor well) eliminating
Figure 36. the need to evacuate the compressor for replacement.
This transmitter is dedicated to oil level control and has TEMPERATURE and/or PRESSURE
no user adjustments. ADJUSTMENT
If it is necessary to replace the All temperature and pressure sensors are factory set.
CAUTION
well, the separator must be purged If calibration is required, refer to Analog Calibration for
and the oil drained. Refer to the temperature or pressure in QUANTUM™LX publication
section "CHANGING OIL." 090-021 O or 090-022 O.
1. Shut off control power. BARE COMPRESSOR MOUNTING

2. Remove DIN connector plug from transmitter.
3. Loosen set screws. Refer to publication 070-660 SM.
4. Remove transmitter unit.
5. Install new transmitter unit.
6. Tighten set screws.
7. Apply DIN connector plug to transmitter.
8. Turn on control power.
TROUBLESHOOTING THE RXF COMPRESSOR
SYMPTOM PROBABLE CAUSES and CORRECTIONS
EXCESSIVE NOISE and Main oil injection valve may be closed. Open valve.
VIBRATION Main oil injection valve may be open too far. Adjust.
Bearing damage or excessive wear. CONTACT JCI/YORK Factor or JCI/
YORK 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 S70-660 SM
Refrigerant flood back. Correct system problem.
NOTE: 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 COMPRESSOR.
TROUBLESHOOTING THE OIL SEPARATION SYSTEM

GRADUAL OIL LOSS WITH AN Maintaining too high an oil level, lower level.
OIL LEVEL IN THE COALESCER Refrigerant carryover or liquid injection overfeeding, correct operation.
SECTION SIGHT GLASS 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 On shutdown, compressor unit suction check valve did not close. Repair
LEVEL IN THE COALESCER valve.
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 Solenoid coils may be burned out. Test and replace if necessary.
OR 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" 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 A side solenoid coil may be burned out. Test and replace if necessary.
BUT 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 Solenoid coils may be burned out. Test and replace if necessary.
FUNCTION EITHER DIRECTION Solenoid service valves may be closed. Open.
Manually actuate solenoid. If slide stop will not move mechanical problems
are indicated. Consult JCI/YORK factor or JCI/YORK service.
MOTOR and BARE COMPRESSOR The compressor must not operate with incorrect oil
REPLACEMENT pressure.
1. Refer to CONTROL SETUP - "OIL SETPOINTS
SHUTDOWN DUE TO IMPROPER OIL DISPLAY" in publication S90-022 O.
PRESSURE (HIGH STAGE and BOOSTER)
COMPRESSOR PORT LOCATIONS - RXF 12~19



P & I DIAGRAM, LIQUID INJECTION – SINGLE PORT
P & I DIAGRAM, LIQUID INJECTION – DUAL PORT

RXF COOLING OPTIONS (See P & I Diagrams)

PLATE OIL COOLER
RXF MODELS 12 throughy 50 without OIL PUMP
LEGEND*
AS AIR SUPPLY P PUMP TAH HIGH TEMPERATURE ALARM
C COMPRESSOR PAH HIGH PRESSURE ALARM TAHH HIGH TEMP. SHUTDOWN
CV CHECK VALVE PAHH HIGH PRESSURE SHUTDOWN TAL LOW TEMPERATURE ALARM
DP DISCHARGE PRESSURE PAL PAL LOW PRESSURE ALARM TALL LOW TEMPERATURE SHUTDOWN
F FILTER OR FILTER DRIER PALL LOW PRESSURE SHUTDOWN TCV TEMPERATURE CONTROL VALVE
FG FLOW GLASS PCV PRESSURE CONTROL VALVE TE TEMPERATURE ELEMENT
HTR HEATER PDSLL LOW DIFFERENTIAL PRESS SHUTDOWN TI TEMPERATURE INDICATOR
HV HAND ACTUATED VALVE PE PRESSURE ELEMENT TS TEMPERATURE SWITCH
LG SIGHT OR LEVEL GLASS PI PRESSURE INDICATOR TSH TEMP. SWITCH HIGH ALARM
LSL OIL LEVEL SWITCH LOW PIC/TIC PRESS./TEMP. INDICATING CONTROLLER TSLL LIQUID INJECTION SHUTOFF
LSLL LOW OIL LEVEL SHUTDOWN PM PUMP MOTOR TW THERMOWELL
M MOTOR PS AUTO CYCLE/PRESSURE SWITCH VI VI CONTROL
1MC MOTOR CONTROL CENTER PSV PRESSURE SAFETY VALVE WS WATER SUPPLY
2MC MOTOR CONTROL CENTER SP SUCTION PRESSURE YY SOLENOID VALVE/EVENT VALVE
OP OIL PRESSURE STR STRAINER
RXF MODELS 12 through 50 with OIL PUMP
LEGEND (Cont.)
CONNECTIONS
1. PRESSURE TRANSDUCERS INDICATE:
1 MAIN OIL SUPPLY 12 COALESCER BLEED LINE
PE-1 SUCTION PRESSURE
2 SLIDE VALVE PISTON 15 VENT - UNLOADING PE-2 DISCHARGE PRESSURE
3 LOW VI LIQUID INJECTION 16 THERMOWELL PE-3 OIL PRESSURE
4 HIGH VI LIQUID INJECTION 19 SUCTION PRESSURE 2. TEMPRERATURE PROBES INDICATE:
5 ECONOMIZER TE-1 SUCTION GAS TEMPERATURE
6 OIL DRAIN TE-2 DISCHARGE GAS TEMPERATURE
7 SUCTION PRESSURE TE-3 LUBE OIL TEMPERATURE
8 CLOSED THREAD TE-4 SEPARATOR OIL TEMPERATURE
10 DISCHARGE PRESSURE 3. TERMINATIONS "A" THROUGH "C" REFER
11 LIQ. INJ. BLEED LINE TO CONNECTION POINTS FOR VARIOUS OPTIONS.

RXF MODELS 58, 68, 85, & 101 without OIL PUMP
LEGEND*
AS AIR SUPPLY P PUMP TAH HIGH TEMPERATURE ALARM
C COMPRESSOR PAH HIGH PRESSURE ALARM TAHH HIGH TEMP. SHUTDOWN
CV CHECK VALVE PAHH HIGH PRESSURE SHUTDOWN TAL LOW TEMPERATURE ALARM
DP DISCHARGE PRESSURE PAL LOW PRESSURE ALARM TALL LOW TEMPERATURE SHUTDOWN
F FILTER OR FILTER DRIER PALL LOW PRESSURE SHUTDOWN TCV TEMPERATURE CONTROL VALVE
FG FLOW GLASS PCV PRESSURE CONTROL VALVE TE TEMPERATURE ELEMENT
HTR HEATER PDSLL LOW DIFFERENTIAL PRESS SHUTDOWN TI TEMPERATURE INDICATOR
HV HAND ACTUATED VALVE PE PRESSURE ELEMENT TS TEMPERATURE SWITCH
LG SIGHT OR LEVEL GLASS PI PRESSURE INDICATOR TSH TEMP. SWITCH HIGH ALARM
LSL OIL LEVEL SWITCH LOW PIC/TIC PRESS./TEMP. INDICATING CONTROLLER TSLL LIQUID INJECTION SHUTOFF
LSLL LOW OIL LEVEL SHUTDOWN PM PUMP MOTOR TW THERMOWELL
M MOTOR PS AUTO CYCLE/PRESSURE SWITCH VI VI CONTROL
1MC MOTOR CONTROL CENTER PSV PRESSURE SAFETY VALVE WS WATER SUPPLY
2MC MOTOR CONTROL CENTER SP SUCTION PRESSURE YY SOLENOID VALVE/EVENT VALVE
OP OIL PRESSURE STR STRAINER
RXF Models 58, 68, 85, & 101 with OIL PUMP
LEGEND (Cont.)
CONNECTIONS
1. PRESSURE TRANSDUCERS INDICATE:
1 MAIN OIL SUPPLY 11 THERMOWELL (SUCT. TEMP.)
PE-1 SUCTION PRESSURE
2 SLIDE VALVE PISTON 12 MAIN OIL INJECTION PE-2 DISCHARGE PRESSURE
3 LOW VI LIQUID INJECTION 13 SUCTION PRESSURE PE-3 OIL PRESSURE
4 HIGH VI LIQUID INJECTION 14 SEAL WEEPAGE 2. TEMPRERATURE PROBES INDICATE:
5 ECONOMIZER 15 ELECTRICAL CONNECTION TE-1 SUCTION GAS TEMPERATURE
6 SUCTION PRESSURE 16 OIL PRESSURE TE-2 DISCHARGE GAS TEMPERATURE
7 CLOSED THREAD TE-3 LUBE OIL TEMPERATURE
8 DISCHARGE PRESSURE TE-4 SEPARATOR OIL TEMPERATURE
9 LIQ. INJ. BLEED LINE 3. TERMINATIONS "A" THROUGH "C" REFER
10 COALESCER BLEED LINE TO CONNECTION POINTS FOR VARIOUS OPTIONS.

PROPER INSTALLATION OF ELECTRONIC EQUIPMENT IN AN INDUSTRIAL ENVIRONMENT

In today’s refrigeration plants, electronic controls have are to be used in conjunction with the NEC code and
found their way into almost every aspect of refrigeration any other applicable codes.
control. Electronic controls have brought to the industry
more precise control, improved energy savings, and With exclusion of the three phase wire sizing, JCI/
operator conveniences. Electronic control devices have YORK drawing 649D4743 should be used as a
revolutionized the way refrigeration plants operate reference for properly sizing control wires and other
today. wiring specifications.
The earlier relay systems were virtually immune to Throughout this document the term Electronic Control
radio frequency interference (RFI), electromagnetic Panel is used to refer to the microprocessor mounted
interference (EMI), and ground loop currents. Therefore on the compressor package or a Central Control
installation and wiring were of little consequence System panel.
and the wiring job consisted of hooking up the point-
to-point wiring and sizing the wire properly. In an NOTE: It is very important to read the installation
electronic system, improper installation will cause instructions thoroughly before beginning the
problems that may outweigh the benefits of electronic project. Make sure you have drawings and
control. Electronic equipment is susceptible to RFI, instructions with your equipment. If not, call the
EMI, and ground loop currents which can cause manufacturer and request the proper instructions
equipment shutdowns, processor memory and program and drawings. Every manufacturer of electronic
loss, as well as erratic behavior and false readings. equipment should have a knowledgeable staff,
Manufacturers of industrial electronic equipment willing to answer your questions or provide
take into consideration the effects of RFI, EMI, and additional information. Following correct wiring
ground loop currents and incorporate protection of the procedures will ensure proper installation and
electronics in their designs. However, these design consequently, proper operation of your electronic
considerations do not make the equipment immune, equipment.
so manufacturers require that certain installation
precautions be taken to protect the electronics from WIRE SIZING
these effects. All electronic equipment must be
viewed as sensitive instrumentation and therefore Control power supply wires should be sized one size
requires careful attention to installation procedures. larger than required for amperage draw to reduce
These procedures are well known to instrumentation, instantaneous voltage dips caused by large loads
networking, and other professions but may not be such as heaters, contactors, and solenoids. These
followed by general electricians. sudden dips in voltage can cause the electronic control
panel, whether it is a microprocessor, a computer, or a
There are a few basic practices that if followed, will PLC, to malfunction momentarily or cause a complete
minimize the potential for problems resulting from RFI, reset of the control system. If the wire is loaded to its
EMI and/or ground loop currents. The National Electric maximum capacity, the voltage dips are much larger,
Code (NEC) is a guideline for safe wiring practices, and the potential of a malfunction is very high. If the
but it does not necessarily deal with procedures used wire is sized one size larger than required, the voltage
for electronic control installation. Use the following dips are smaller than in a fully loaded supply wire
procedures for electronic equipment installation. These and the potential for malfunction is much lower. The
procedures do not override any rules by the NEC, but NEC code book calls for specific wire sizes to be used
based on current draw. An example of this would be to

use #14 gauge wire for circuits up to 15 amps or #12
gauge wire for circuits of up to 20 amps. Therefore,
when connecting the power feed circuit to an electronic
control panel, use #12 gauge wire for a maximum
current draw of 15 amp and #10 wire for a maximum
current draw of 20 amp. Use this rule of thumb to
minimize voltage dips at the electronic control panel.
VOLTAGE SOURCE
Selecting the voltage source is extremely important for

proper operation of electronic equipment in an industrial
environment. Standard procedure for electronic
instrumentation is to provide a clean, isolated,
separate-source voltage in order to prevent EMI (from
other equipment in the plant) from interfering with the
operation of the electronic equipment. Connecting
electronic equipment to a breaker panel (also known as
lighting panels or utility panels) subjects the electronic
equipment to noise generated by other devices Figure 38
connected to the breaker panel. This noise is known
as electromagnetic interference (EMI). EMI flows on GROUNDING
the wires that are common to a circuit. EMI cannot
travel easily through transformers and therefore can Grounding is the most important factor for successful
be isolated from selected circuits. Use a control power operation and is typically the most overlooked. The
transformer of the proper VA rating, usually provided NEC states that control equipment may be grounded by
in the compressor drive motor starter, to isolate the using the rigid conduit as a conductor. This worked for
electronic control panel from other equipment in the the earlier relay systems, but it is in no way acceptable
for electronic control equipment. Conduit is made of
plant that generate EMI. See Figure 38.
steel and is a poor conductor relative to an insulated
stranded copper wire. Electronic equipment reacts to
very small currents and must have a proper ground in
order to operate properly; therefore, stranded copper
grounds are required for proper operation.
For proper operation, the control power ground circuit

must be a single continuous circuit of the proper sized
insulated stranded conductor, from the electronic
control panel to the plant supply transformer (Figure
39). Driving a ground stake at the electronic control
may also cause additional problems since other
equipment in the plant on the same circuits may
ground themselves to the ground stake causing large
ground flow at the electronic control panel. Also, to earth ground to avoid possible interference with
running multiple ground conductors into the electronic sensitive equipment. Therefore sizing this conductor
control panel from various locations can create multiple 1 – 2 sizes larger than required by code will provide
potentials resulting in ground loop currents. A single better transfer of this noise.
ground wire (10 AWG or 8 AWG) from the electronic
control panel, that is bonded to the control power JCI/YORK requires that the ground conductor meet the
neutral at the secondary side of the control power following requirements be:
transformer in the starter and then to the 3-phase • Stranded Copper
ground point, will yield the best results. • Insulated
• One size larger than NEC requirements for
conventional starters
• Two sizes larger than NEC requirements for VFD
starters
• Conduit must be grounded at each end
• This circuit must be complete from the motor to the
starter continuing in a seamless manner back to the
plant supply transformer (power source).
For Direct Coupled, Package Mounted Starters, the

ground between the motor and the starter may need
to be made externally (Figure 40). The connection
on the starter end must be on the starter side of the
Figure 39 vibration isolators. Be certain the connection is metal
Note: Structural grounding can also result to metal. Paint may need to be removed to ensure a
in multiple ground potentials and is also a proper conductive circuit. The use of counter-sunk star
relatively poor conductor. Therefore, this is not washers at the point of connection at each end will
an acceptable method for proper operation of maximize metal to metal contact.
electronic equipment.
There must be a ground for the three-phase power

wiring. This must be sized in accordance to the NEC
and any local codes relative to the highest rated
circuit overload protection provided in the circuit. The
manufacturer may require a larger ground conductor
than what is required by the NEC for proper steering of
EMI from sensitive circuits. This conductor must also
be insulated to avoid inadvertent contact at multiple
points to ground, which could create Ground Loops.
In many installations that are having electronic control
problems, this essential wire is usually missing, is not
insulated, or improperly sized. Figure 40
NEC size ratings are for safety purposes and not VFD APPLICATION
necessarily for adequate relaying of noise (EMI)
The primary ground conductor that accompanies the
three phase supply must be stranded copper, insulated • For variable frequency drives (VFDs) of any type,
and two sizes larger than the minimum required by the threaded metallic or threaded PVC-coated metallic is
NEC or any other applicable codes. This is necessary required for both the power feed (line side) from the
due to the increased generation of EMI which is a source and between the VFD output and the motor (load
characteristic of a VFD output to the motor when side).
compared to a conventional starter. • PVC conduit is acceptable only when VFD rated cable
of the proper conductor size and ground is used. This
For VFD applications, isolation of the control power, applies to both the line side and load side of the drive.
analog devices, and communications ground from the When VFD rated cable is not used, threaded metallic
3-phase ground within the starter and the electronic or threaded PVC-coated metallic must be used.
control panel may be necessary. This is due to the • When threaded metallic or threaded PVC-coated
higher noise (RFI/EMI) levels generated between the metallic is used, it must be grounded at both ends.
VFD output and the motor, relative to a conventional • When not required to be in metal or other material
starter. If these grounds are left coupled by a common by national or local codes, conduits for the power feed
back-plate in the starter/drive, this noise can be direct (3-phase) of constant speed starters may be PVC.
coupled to the control power, analog device, and • When not required to be in metal or other material by
communications grounding and may cause unexplained national or local codes, conduits between a constant
behavior and possible damage to components. speed starter and the motor (3-phase) may be PVC.
• Any unshielded control voltage, signal, analog, or
To install correctly, run a separate, properly sized communication wiring that does not maintain 12 inches
(10 or 8 AWG typically) insulated ground along with of separation from any 3-phase conductors for every 33
and taken to ground with, the 3-phase ground at the feet (10 meters) of parallel run must be in metal conduit
3-phase supply transformer (plant). This will require which will be grounded.
that the 3-phase ground and the control power ground Separation: (0-33 feet, 0-10 meters – 12 inches, .3
be electrically isolated except for the connection at the meters), (33-66 feet, 10-20 meters – 24 inches, .6
plant supply transformer. meters)
This style of grounding should steer the noise (EMI/ • Since PVC conduit does absolutely nothing to protect
RFI) to earth ground, reducing the potential for it to lower voltage lines from the magnetic field effects of
affect the sensitive equipment, which could occur if higher voltage conductors, running either the lower or
the grounds were left coupled. NOTE: If all other the higher voltage lines in PVC, does not reduce these
recommendations for grounding are followed, this requirements on separation. Only running in metal
process should not be necessary. conduit can relieve these requirements.
• Due to the level of EMI that can be induced onto lower
CONDUIT voltage lines when running multiple feeders in a trench,
control power, communications, analog, or signal wiring
All national and local codes must be followed cannot be run in trenches that house multiple conduits/
for conduit with regard to materials, spacing and electrical ducts carrying 3-phase power to starters/vfd
grounding. In addition, JCI/YORK-JCI/YORK or motors.
requirements must be followed where they exceed or • Control power, communications, analog, or signal
match national or local codes. Conversely, there is no wiring should be run overhead (preferred) or in a
allowance for any practices that are substandard to separate trench. If these lines are not in threaded
what is required by national or local codes. metallic or threaded PVCcoated metallic, abiding by
the separation requirements noted above is necessary.
JCI/YORK conduit requirements: • Though not recommended, if cable trays are used,
metallic dividers must be used for separation of be to run 480 volts from the starter through the
conductors of unlike voltages and types (AC or DC). electronic control panel to an oil pump motor.
Note: When in doubt contact the factory or use When running conduit to the electronic control panel,
threaded metallic or threaded PVC coated metallic use the access holes (knockouts) provided by the
conduit. manufacturer. These holes are strategically placed
so that the field wiring does not interfere with the
WIRING PRACTICES electronics in the panel. Never allow field wiring to
come in close proximity with the controller boards since
Do not mix wires of different voltages in the same this will almost always cause problems.
conduit. An example of this would be the installation
of a screw compressor package where the motor Do not drill into an electronic control panel to locate
voltage is 480 volts and the electronic control panel conduit connections. You are probably not entering
power is 220 volts. The 480 volt circuit must be run the panel where the manufacturer would like you to
from the motor starter to the motor in its own conduit. since most manufacturers recommend or provide
The 220 volt circuit must be run from the motor starter prepunched conduit connections. You may also be
control transformer to the electronic control panel in negating the NEMA rating of the enclosure. Drilling
its own separate conduit. If the two circuits are run in can cause metal filings to land on the electronics and
the same conduit, transients on the 480 volt circuit will create a short circuit when powered is applied. If you
be induced onto the 220 volt circuit causing functional must drill the panel, take the following precautions:
problems with the electronic control panel. Metallic • First, call the panel manufacturer before drilling into
dividers must be used in wire way systems (conduit the panel to be sure you are entering the panel at the
trays) to separate unlike voltages. The same rule right place.
applies for 220 volt wires and 220 volt wires. Also, • Ta k e m e a s u r e s t o a v o i d E S D ( e l e c t r o s t a t i c
never run low voltage wires for DC analog devices or discharge) to the electronics as you prep the inside
serial communications in the same conduit with any AC of the Electronic control panel. This can be done by
wiring including 220 volt wires. See Figure 41. employing an antistatic wrist band and mat connected
to ground.
• Cover the electronics with plastic and secure it with
masking or electrical tape.
• Place masking tape or duct tape on the inside of the
panel where you are going to drill. The tape will catch
most of the filings.
• Clean all of the remaining filings from the panel before
removing the protective plastic.
When routing conduit to the top of an electronic control

panel, condensation must be taken into consideration.
Figure 41 Water can condense in the conduit and run into the
Never run any wires through an electronic control panel causing catastrophic failure. Route the conduit
panel that do not relate to the function of the panel. to the sides or bottom of the panel and use a conduit
Electronic control panels should never be used as drain. If the conduit must be routed to the top of the
a junction box. These wires may be carrying large panel, use a sealable conduit fitting which is poured
transients that will interfere with the operation of the with a sealer after the wires have been pulled,
control panel. An extreme example of this would
terminated, and the control functions have been Daisy-chaining ground wires, taking them to ground
checked. A conduit entering the top of the enclosure at each device, allows ground loop currents to flow
must have a NEMA-4 hub type fitting between the between electronic control panels which also causes
conduit and the enclosure so that if water gets on top of malfunctions. See Figure 42.
the enclosure it cannot run in between the conduit and
the enclosure. This is extremely important in outdoor
applications.
Note: It is simply NE VER a good practice to enter

through the top of an electronic control panel or
starter panel that does not already have knockouts
provided. If knockouts are not provided for this
purpose it is obvious this is not recommended and
could VOID WARRANTY.
Never add relays, starters, timers, transformers,

etc. inside an electronic control panel without first
contacting the manufacturer. Contact arcing and EMI
emitted from these devices can interfere with the
electronics. Relays and timers are routinely added
to electronic control panels by the manufacturer, but
the manufacturer knows the acceptable device types
and proper placement in the panel that will keep
interference to a minimum. If you need to add these
devices, contact the manufacturer for the proper device
types and placement.
Figure 42
Never run refrigerant tubing inside an electronic control
panel. If the refrigerant is ammonia, a leak will totally COMMUNICATIONS
destroy the electronics.
The use of communications such as serial and Ethernet
If the electronic control panel has a starter built into the in industrial environments are commonplace. The
same panel, be sure to run the higher voltage wires proper installation of these networks is as important to
where indicated by the manufacturer. EMI from the the proper operation of the communications as all of
wires can interfere with the electronics if run too close the preceding practices are to the equipment.
to the circuitry.
Serial communications cable needs to be of the proper
Never daisy-chain or parallel-connect power or ground gauge based on the total cable distance of the run.
wires to electronic control panels. Each electronic Daisy-chaining is the only acceptable style of running
control panel must have its own control power supply the communications cable. While Star Networks
and ground wires back to the power source (Plant may use less cable, they more often than not cause
Transformer). Multiple electronic control panels on problems and interruptions in communications, due to
the same power wires create current surges in the varying impedances over the varying lengths of cable.
supply wires, which may cause controller malfunctions. Ground or drain wires of the communications cable
are to be tied together at each daisy-chain connection
and only taken to ground in the central control system motor because the UPS may prevent the motor starter
panel. contactor from dropping out. With the starter contactor
still energized, the compressor auxiliary will continue
It is important to carefully consider the type of cable to to feed an “okay” signal to the Quantum™LX panel.
be used. Just because a cable has the proper number This may allow the motor to be subjected to the fault
of conductors and is shielded does not mean it is an condition on the 3-phase bus.
acceptable cable. JCI/YORK recommends the use of
Belden #9829 for RS-422 communications and Belden A couple of fault scenarios are: 1. The 3-phase bus
# 9841 for RS-485 up to 2000 feet (600 Meters) total has power “on” and “off” in a continuous cycle manner
cable length. Refer to JCI/YORK drawing 649D4743 for which may cause the motor to overheat due to
more detail. repeated excessive in-rush current experiences. 2. The
motor cycling may damage the coupling or cause other
Comm Port Protection: Surge suppression for the mechanical damage due to the repeated high torque
comm. ports may not be the best method, since from rapid sequential motor “bumps.” 3. Prolonged
suppression is required to divert excess voltage/current low voltage may cause the motor to stall and possibly
to ground. Therefore, the success of these devices is overheat before the motor contactor is manually turned
dependent on a good ground (covered earlier in this off.
section). This excess energy can be quite high and
without a proper ground, it will access the port and Under normal conditions, the loss of 3-phase power will
damage it. shut down the Quantum™LX panel and it will reboot
upon proper power return. If the panel was in “Auto,” it
Isolation or Optical Isolation is the preferred comm port will come back and return to running as programmed.
protection method. With optical isolation, there is no If the unit was in “Remote,” the external controller will
continuity between the communications cable and the re-initialize the panel and proceed to run as required.
comm port. There is no dependence on the quality of If the panel was in “Manual” mode, the compressor will
the ground. Be sure to know what the voltage isolation have to be restarted manually after the 3-phase bus
value of the optical isolator is before selecting it. These fault/interruption has been cleared / restored.
may range from 500 to 4000 Volts.
If the local power distribution system is unstable or
JCI/YORK Optical Isolation Kits are offered under part prone to problems there are other recommendations to
number 639C0133G01. One kit is required per comm satisfy these problems. If power spikes or low or high
port. line voltages are the problem, then a constant voltage
(CV) transformer with a noise suppression feature is
UPS POWER and QUANTUM™LX PANELS recommended. JCI/YORK, Inc. can provide these types
of transformers for this purpose. Contact JCI/YORK for
JCI/YORK, Inc. does not advise nor support the use of proper sizing (VA Rating) based on the requirement of
uninterrupted power supply systems for use with the the job. If a phase loss occurs, then you will typically get
Quantum™LX panel. With a UPS system providing a high motor amp shutdown. If the problem continues,
shutdown protection for a Quantum panel, the panel an analysis of the facility’s power supply quality may be
may not see the loss of the 3-phase voltage on the necessary.
NOTE: It is very important to read the installation instructions thoroughly before beginning the project.
Make sure you have drawings and instructions for the equipment being installed. If not, call the
manufacturer to receive the proper instructions and drawings. Every manufacturer of electronic equipment
should have a knowledgeable staff, willing to answer your questions or provide additional information.
Following correct wiring procedures will ensure proper installation and consequently, proper operation of
your electronic equipment.
SCREW COMPRESSOR Order No .
Compr.Ser.No .
Operating Log Sheet Unit Location
Date
Time
Hour Meter Reading
Equipment Room Temp./Outdoor Temp.
Suction Pressure
Suction Temperature
Suction Superheat
Discharge Pressure
Corresponding Temperature
Actual Discharge Temperature
Compressor Oil Pressure
Oil Temperature
Oil Filter Press. Drop-DP
Slide Valve Position %
Volume Ratio(V.I.)
FLA%
Seal Leakage(drops/min)
Capacity Contro; Setpoint
Separator Temperature
OIL Sep. Oil Level(example)
Oil Added(gallons)
Inlet Temperature
Evap. Brine Outlet Temperature
Pressure Drop-DP
Flow Rate-GPM
OPERATION LOG SHEET
Air Air On Temperature

Air Off Temperature
Condenser Inlet Temperature
RXF ROTARY SCREW COMPRESSOR UNITS
Outlet Temperature
INSTALLATION - OPERATION - MAINTENANCE
Water
Pressure Drop-DP
Flow Rate-GPM
Leaving Liguid Refrigerant Temperature
Rcvr/Econ Level
Pressure
Remarks:
NOTE:Temperature and Pressure Units in F and PSIG respectively, unless otherwise indicated
6RH-B02C-NA-EN
Page 75
RWF II COMPRESSOR PRESTART CHECKLIST
The following items MUST be checked and completed by the installer prior to the arrival of the JCI/YORK
Field Service Supervisor. Details on the checklist can be found in this manual. Certain items on this checklist
will be reverified by the JCI/YORK Field Service Supervisor prior to the actual start-up.
Mechanical Checks Electrical Checks

-Confirm that motor disconnect is open - Confirm that main disconnect to motor starter and
- Isolate suction pressure transducer micro is open
- Pressure test and leak check unit - Confirm that electrical contractor has seen this sheet,
- Evacuate unit ALL PERTINENTWIRING information, and drawings
- Remove compressor drive coupling guard - Confirm proper power supply to the starter package
- Remove coupling center and DO NOT reinstall (motor - Confirm proper motor protection (breaker sizing)
rotation must be checked without center) - Confirm that all wiring used is stranded copper and is
- Check for correct position of all hand, stop, and 14 AWG or larger (sized properly)
check valves prior to charging unit with OIL or - Confirm all 220 volt control wiring is run in a separate
REFRIGERANT conduit from all high voltage wiring
- Charge unit with correct type and quantity of oil - Confirm all 220 volt control wiring is run in a separate
- Lubricate electric drive motor bearings PRIOR to conduit from oil pump and compressor motor wiring
checking motor rotation - Confirm no high voltage wiring enters the micro panel
- Check oil pump alignment (if applicable) at any point
- Check for correct economizer piping (if applicable) - Check current transformer for correct sizing and
-Check separate source of liquid refrigerant supply (if installation
applicable, liquid injection oil cooling) - Check all point-to-point wiring between the micro and
- Check water supply for water-cooled oil cooler (if motor starter
applicable, water cooled oil cooling) - Confirm all interconnections between micro, motor
- Check thermosyphon receiver refrigerant level (if starter, and the system are made and are correct
applicable, thermosyphon oil cooling) - Ensure all electrical panels are free from installation
- Check for PROPER PIPE SUPPORTS and correct debris, METAL PARTICLES, and moisture
foundation
- Check to ensure ALL piping INCLUDING RELIEF
VALVES is 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
- Manually energize compressor drive motor and check motor rotation
Start-up Report JCI/YORK Order No:_________________________
Sold To: ____________________________Contact Name:________________ Date:______________________

End User:__________________________ Contact Name:________________ Phone:_____________________
End User Address:_______________________________________________ Fax No:_____________________
City, State, Zip:_____________________________Start-up Representative_____________________________
- Leave micro energized to ensure oil heaters are on and oil temperature is correct for start-up
Summary: The JCI/YORK 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 : 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 JCI/YORK as confirmation of completion.
Sales Order Number:____________________________ Print Name:___________________________________

Compressor Model Number:______________________ Company:____________________________________
Unit Serial Number:_ ___________________________ Job Site Contact:_______________________________
End User Name:_ ______________________________ Contact Phone Number:_________________________
Address of Facility:_____________________________ Signed:_______________________________________
City, State, Zip: ________________________________
START-UP REPORT JCI/YORK Order No:_________________

Sold To: ______________________________Contact Name:_________________________ Date:______________________
End User:_____________________________ Contact Name:_________________________ Phone:____________________
End User Address:__________________________________________________________ _ Fax No:____________________
City, State, Zip:________________________________ Start-up Representative_____________________________________
Unit General Information

Unit Model #_________________________________ Customer Package Identification #____________________________
Compressor Serial #____________________________ Separator National Board #___________________________________
Unit Serial #__________________________________ Oil Cooler National Board #__________________________________
Evaporator National Board #_________ Serial #__________ Condenser National Board #__________ Serial #____________
Oil Pot National Board #_____________________________ H.P. Receiver National Board #__________________________
Economizer National Board #_________________________ Suction Accumulator National Board #____________________
Refrigerant______________ Oil Filters______________ Lube Oil Type______________ Oil Cooling __________________
Design Operating Conditions ______________________ 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 ________________________
JCI/YORK Interface Serial #__________ Prog. Ver.______________ Date ____________ P/N ________________________
CT Location Checked CT Phase______________ CT Ratio____________ Transition Time__________ DBS Ver.#_________
Oil Pump Information

Pump Mfg.___________ Model #____________ Serial #_________________ Motor Mfg.______________ H.P.__________
Motor RPM______ Service Factor_____ Volt_____ HZ______ FLA_______ Design ____ Code_______ Starter Size_______
Cooling Fan Information

Motor HP_______ RPM_______ Service Factor_______ Volt_______ Hz________ FLA________ Cooling Fans__________
Special Options
_____________________ ______________________ _________________________________________________
Prestart Checks
Installation, Foundation Compressor PHD Setup Coolant Installed
Position of all valves Motor PHD Setup 4-20 Coolant Loop Pump Setup
Proper oil charge Motor Winding RTDs Setup Coolant Loop Temp Setup
All wiring connections Motor Bearing RTDs Setup Cooling Fan Motor I/O Setup
Starter Cleanliness Motor Temperature Thermistor Setup Cooling Fan Rotation Checked
All micro settings 4-20 Motor Drive Signal Calibrated Oil pump motor rotation
4-20 CT Channel 16 Setup Cold alignment Motor rotation
4-20 Output Calibration-Liquid Makeup Valve, Coolant Temp Valve, Economizer Makeup Valve
Configuration
Capacity Channel 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 _____________
Unit Serial #________________________ JCI/YORK Order No:_________________________

Mode___________________ Capacity Control Setpoints Mode___________
Setpoint_________ RegulationSafeties Setpoint _________ Regulation Safeties
High Low Load Inhibit ________ High Low Load Inhibit ________
____ ____ Force Unload ________ Prop. Band. ____ ____ Force Unload _______
Prop. Band.
Dead Band ____ ____ Warning ________ Dead Band ____ ____ Warning __________
____Sec ____Sec Warning Delay___ Sec ____Sec ____Sec Warning Delay___ Sec
Cycle Time Cycle Time
VFD Prop Band ____ ____ Shutdown__________ VFD Prop Band ____ ____ Shutdown__________
VFD Integ. Time ____Sec ____Sec Shutdown Delay__ S ec VFD Integ. Time ____Sec ____Sec Shutdown Delay__ S ec
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 _______ S ec Shutdown Delay _______ S ec
Compressor Safeties
High Discharge Temperature High Suction Pressure
Load Inhibit ________ Load Inhibit ________ PSIG
Force Unload ________ Force Unload ________ PSIG
Warning ________ Warning ________ PSIG
Warning Delay ________ Sec Start Differential Warning Delay ________ Sec
Shutdown ________ Pressure Below Shutdown ________ PSIG
Shutdown Delay ________ S ec _________ PSI Shutdown Delay ________ Sec
High Discharge Pressure Dual Mode ________________ Economizer ________________
Regulation Modes 1 & 3 Modes 2 & 4
Load Inhibit ____ PSIG _____ PSIG On When Above _______%
Force Unload ____ PSIG _____ PSIG Off When Below _______%
Warning ____ PSIG _____ PSIG Override Discharge Pressure ________
Warning Delay ____ Sec _____ Sec Port Value ________
Shutdown ____ PSIG _____ PSIG Pressure Input __________________
Shutdown Delay ____ Sec _____ S ec Fixed Pressure Setpoint ____________
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 _______ S ec
Compression Ratio _ ______________ Main Oil Injection On When Discharge Temperature
Liquid Slug Warning _ ______________ Is Above___________ F ° for_ _____ S ec
Liquid Slug Shutdown _ ______________
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________
Shutdown ____________ Delay________ Sec Min
Low Compressor Oil Pressure DX Circuit
Warning __________ PSI Delay_______ Sec #1 Action________________________
Shutdown __________ PSI Delay______ Sec Off When Below _ ______________ %
High Filter Pressure On When Above _ ______________ %
Warning __________ PSI Delay________ Min #2 Action _________________________
Shutdown __________ PSI Delay_______ Min Off When Below________________ %
Main Oil Injection___________________ On When Above________________ %
Shutdown __________ PSI Delay_______ Sec Liquid Injection __________________
Oil Heater Off Above__________ On When Above _ ____________ Delay_________ Sec
High Level Shutdown Delay___________ Sec Dual Port Transition ________
Low Oil Level Delay_________________ Sec
Oil Pump Lube Time Before Starting____ Sec Hot Gas Bypass __________ %
Dual Pump Transition Time____________ Sec Power Assist __________ s ec
Unit Serial #___________________________ JCI/YORK Order No:_____________________

Compressor Motor Setpoints and Information
Motor Name Plate
VFD Manufacturer_______
Motor Amps ____________
Maximum Drive Output____ %
Volts ____________ Minimum Drive Output ____ %
Service Factor ____________
Remote Control Frame Size_________
Horsepower ____________
Rate Of Increase______ % Delay____ Sec H.P_______________
CT Factor ____________
Rate Of Decrease_____ % Delay____ Sec RPM ______________
Recycle Delay___________ Min
Capacity Control Serial #____________
High Motor Amps
When Slide Valve Reaches_ ___ % Service Factor_______
Load Inhibit______________
Drive Speed Reaches _________ % Voltage____________
Force Unload__________ Variable Speed Min. Slide Valve Position ___ % Hz_ ______________
Warning________ Delay____ Sec
Skip Frequency Bands Design ____________
Shutdown________ Delay____ Sec
Bottom Top Code______________
_______ _______ Bearing
Low Motor Amps
_______ _______ Type________
Shut Down_________ Delay______ Sec
_______ _______ Motor Coupling
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

Suction End Delay Discharge End Delay
High Warning ______ gF____ Sec High Warning_ _____gF______ Sec Digital Controls Step Order
High Shutdown _____ gF____ Sec High Shutdown_____ gF______ Sec Module A ________
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 ____________
Stator 3 Delay Proportional Band _________ PSI
High Warning _______ F_____ Sec Integration Time ________ Sec
High Shutdown _____ F_____ Sec High Limit _________ PSI
Low Limit ________ Sec
Miscellaneou
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°
Unit Serial #__________________ JCI/YORK Order No:______________________
P&ID Setpoints
Name _________________ _________________ _________________ _________________
Control _________________ _________________ _________________ _________________
Action _________________ _________________ _________________ _________________
Control Point _________________ _________________ _________________ _________________
Device Source _________________ _________________ _________________ _________________
Device Channel _________________ _________________ _________________ _________________
Setpoint _________________ _________________ _________________ _________________
Dead Band _________________ _________________ _________________ _________________
Prop. Band _________________ _________________ _________________ _________________
Integral Gain _________________ _________________ _________________ _________________
Communicatio ns
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
Address Type __________ Naming Data Protocols
IP Address __________
Gateway Address __________ Host Name __________ ModBus TCP ____________
Subnet Mask __________ Work Group__________ Ethernet I/P ____________
Web Server Port __________ Comments ___________ Profinet _____________
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 SCRs’ 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
Vibration Data Sheet

Date: _______________________________________ Sales Order Number:_________________________
End User: ___________________________________ Installing Contractor:_________________________
Address: ____________________________________ Service Technician: _________________________
____________________________________________
____________________________________________
Equipment ID (As in Microlog): ___________________________
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 # Temp °F V.I. Ratio
Temp °F Temp °F Temp °F F.L.A. %
FORM NO.:6RH-B02C-NA-ZH(JUL 2011)
Supersedes:Non

RXF Catalogue IOM English

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RXF

ROTARY SCREW COMPRESSOR UNITS

Please check www.johnsoncontrols.com for the latest version of this publication.

CAPACITY LINEAR TRANSMITTER SLIDE VALVE

SAFETY PRECAUTION DEFINITIONS

PREFACE and provisions made for control; operating cycles and

CORRECT INSTALLATION All claims must be made by consignee. This is an

UNIT DATA PLATE COMPRESSOR DATA PLATE

GEOMETRICAL SWEPT VOLUME TABLE

Rotor Max Geometrical

INSTALLATION When installing on a steel base, the following

ALLOWABLE FLANGE LOADS

JCI/YORK recommends consulting a licensed architect Figure1 below).

When applying screw compressors at high pressures,

For more detailed information on Screw

RIGGING and HANDLING

This screw compressor package

RXF 12–50 units can be moved with a forklift or with Figure 1a

Make sure coupling hubs are

The unit can be moved with rigging, using a crane and

The unit can be moved with a forklift by forking under

threads are clean and lightly oiled. Do not torque any

Install the unitized flex disc in the other end of the

BP SERIES COUPLING DATA TABLE

CH Coupling Data Table

OIL PUMP COUPLING COMPRESSOR UNIT OIL

RXF BASIC CHARGE* OIL COOLER SUCTION ISOLATION VALVE MOUNTING

Standard units are equipped with one to three 1000

Use of filter elements other than

THERMOSYPHON OIL COOLING INSTALLATION: The plate-type thermosyphon Oil

WATER-COOLED OIL COOLING

The plate-type water-cooled oil cooler is mounted on

FIELD WELDING INSTRUCTIONS FOR TSOC AND

LIQ. LINE FLOW

The control system on high-stage units with dual-

position with the economizer turned off. Please note

Figure 9 - Shell and Coil Economizer System

The recommended economizer systems are shown in

Figure 13 - STARTER WIRING DIAGRAM Figure 14 - Point-To-Point Wiring Diagram

CURRENT TRANSFORMER SIZE

BURDEN RATING MAXIMUM DISTANCE FROM JCI/YORK PANEL

CONTROL POWER REGULATOR

Compressor units that will be used in areas that suffer

Figure 15 - Recommended Regulator Installation

OPERATION to carry axial loads are mounted at the discharge end

The RXF is an oil-flooded screw compressor. Most

COMPR ESSOR UNLOADING: The compressor

Proper operation of the Volumizer® II control can be

Proper installation of the Vi control valves and gaskets

SLIDE VALVE CALIBRATION cooling.

Notes: OPERATION OF DANFOSS LIQUID

6: ICM65 with ICAD 900

THERMOSYPHON OIL COOLING Current thermosyphon systems are using single-pass

NORMAL START‑UP PROCEDURE

1. Confirm system conditions permit starting the

MAINTENANCE before returning to service. Water vapor condensing in

Open any solenoid valves or Oil-entrained refrigerant may

1. Open disconnect switch. DEMAND PUMP DISASSEMBLY

The seal used in this pump is simple to install and

Prior to installing rotary portion of mechanical seal,

Once rotary portion of mechanical seal is installed on

1. Coat idler pin with refrigeration oil and place idler

2. Clean rotor hub and casing seal housing bore.

INSTALLATION OF CARBON GRAPHITE

Sold To: ______Contact Name: Date:

Sales Order Number: Print Name:_______

Unit Serial # JCI/YORK Order No:_

Unit Serial #_______ JCI/YORK Order No:_

Unit Serial # JCI/YORK Order No:____