Frick XJS 95M Owner's manual

Form 070.450-IOM (NOV 2013)
INSTALLATION - OPERATION - MAINTENANCE
File: EQUIPMENT MANUAL - Section 070
Replaces: NOTHING
Dist: 3, 3a, 3b, 3c
XJF
ROTARY SCREW COMPRESSOR
MODELS XJF 95, 120, 151
THIS MANUAL CONTAINS RIGGING, ASSEMBLY, START-UP,
AND MAINTENANCE INSTRUCTIONS. READ THOROUGHLY
BEFORE BEGINNING INSTALLATION. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR DEATH,
DAMAGE TO THE UNIT, OR IMPROPER OPERATION.
Please check www.jci.com/frick for the latest version of this publication.

070-450 IOM (NOV 13)
Page 2
XJF ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
Contents
GENERAL INFORMATION
PREFACE .......................................................................... 3
DESIGN LIMITATIONS ........................................................ 3
JOB INSPECTION .............................................................. 3
STANDARD BARE COMPRESSOR ...................................... 3
TRANSIT DAMAGE CLAIMS .............................................. 3
COMPRESSOR IDENTIFICATION ........................................ 3
LONG TERM STORAGE ...................................................... 4
PREPARING COMPRESSOR FOR STORAGE ........................ 5
MAINTAINING COMPRESSOR ............................................. 5
DESCRIPTION .................................................................... 5
XJF COMPRESSOR ....................................................... 5
COMPRESSOR LUBRICATION SYSTEM ......................... 5
OIL PUMP ...................................................................... 5
CONSTRUCTION DETAILS .................................................. 6
INSTALLATION
DESIGN LIMITS .................................................................. 7
OUTLINE DIMENSIONS ...................................................... 7
XJF 95 DIMENSIONS .......................................................... 8
XJF 120 DIMENSIONS ........................................................ 9
XJF 151 DIMENSIONS ...................................................... 10
XJF 95 COMPRESSOR PORT LOCATIONS..........................11
XJF 120 COMPRESSOR PORT LOCATIONS........................12
XJF 151 COMPRESSOR PORT LOCATIONS ........................13
SAE STRAIGHT THREAD O-RING FITTINGS - ASSEMBLY
PROCEDURE FOR RXF 58 - 101 ................................... 14
HOLDING CHARGE AND STORAGE................................... 14
RIGGING AND HANDLING ..................................................15
FOUNDATION ..................................................................15
CUSTOMER CONNECTIONS ..............................................15
COMPRESSOR OIL ............................................................15
OIL PUMP .........................................................................15
COMPRESSOR ..................................................................16
MOUNTING...................................................................16
COMPRESSOR/MOTOR COUPLING REQUIREMENTS. ....16
COUPLING ALIGNMENT REQUIREMENTS
(FOOT MOUNTED ONLY) ..........................................16
OIL HEATER(S) .................................................................16
OIL FILTER(S) ...................................................................17
OIL COOLING REQUIREMENTS..........................................17
ECONOMIZER - HIGH STAGE ............................................17
DEHYDRATION / EVACUATION TEST .................................18
ELECTRICAL INSTALLATION ..............................................19
CAPACITY SLIDE VALVE TRANSMITTER .......................19
LOW AMBIENT OPERATION ............................................ 20
OPERATION
OPERATION AND START-UP INSTRUCTIONS ...................21
INITIAL START-UP ...........................................................21
INITIAL START-UP PROCEDURE ..................................21
NORMAL START-UP PROCEDURE ...............................21
MAINTENANCE
GENERAL INFORMATION .................................................21
NORMAL MAINTENANCE OPERATIONS .........................21
GENERAL MAINTENANCE ............................................21
CHANGING OIL .............................................................22
RECOMMENDED MAINTENANCE PROGRAM ................22
VIBRATION ANALYSIS ......................................................23
OIL QUALITY AND ANALYSIS ..........................................23
OPERATING LOG .........................................................23
MAINTENANCE SCHEDULE ..........................................23
TROUBLESHOOTING GUIDE .............................................23
ABNORMAL OPERATION ANALYSIS AND CORRECTION ...23
SLIDE VALVE TRANSMITTER REPLACEMENT ....................23
P AND I DRAWINGS ..........................................................25
FORMS .............................................................................29
VIBRATION DATA SHEET ..............................................32
Indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
Indicates a potentially hazardous situation or practice which, if not avoided, will result in death or
serious injury.
SAFETY PRECAUTION DEFINITIONS
Indicates a potentially hazardous situation or practice which, if not avoided, will result in damage
to equipment and/or minor injury.
Indicates an operating procedure, practice, etc., or portion thereof which is essential to highlight.
DANGER
WARNING
CAUTION
NOTICE

070-450 IOM (NOV 13)
Page 3
XJF ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
THE INFORMATION CONTAINED IN THIS
DOCUMENT IS SUBJECT TO CHANGE
WITHOUT NOTICE
GENERAL INFORMATION
PREFACE
This manual has been prepared to acquaint the owner and
serviceman with the INSTALLATION, OPERATION, and
MAINTENANCE procedures as recommended by Johnson
Controls-Frick for XJF Rotary Screw Compressors.
It is most important that these compressors be properly ap-
plied to an adequately controlled refrigerant or gas system.
Your authorized Johnson Controls-Frick representative should
be consulted for his expert guidance in this determination.
Proper performance and continued satisfaction with these
units is dependent upon:
CORRECT INSTALLATION
PROPER OPERATION
REGULAR, SYSTEMATIC MAINTENANCE
To ensure correct installation and application, the equipment
must be properly selected and connected to a properly
designed and installed system. The Engineering plans,
piping layouts, etc. must be detailed in accordance with the
best practices and local codes, such as those outlined in
ASHRAE literature.
A screw compressor is a VAPOR PUMP. To be certain that it
is not being subjected to pumping liquid, it is necessary that
controls are carefully selected and in good operating
condition; the piping is properly sized and traps, if necessary,
are correctly arranged; the suction line has an accumulator
or slugging protection; that load surges are known and
provisions are made for control; operating cycles and stand
still periods are reasonable; and that high side components
are sized within system and compressor design limits.
NOTICE
It is required that the discharge temperature be kept
high enough to prevent condensation of any moisture
in the compressor and oil separator.
DESIGN LIMITATIONS
XJF compressors are designed for operation within the
pressure and temperature limits which are specied by
Johnson Controls-Frick and the Johnson Controls-Frick
selection software COOLWARE
™
. They are primarily used for
compressing refrigerant gas and most hydrocarbon gasses.
If your application is for sour gas, there are special requirements
to protect the compressor. Contact Johnson Controls - Frick
Compressor Engineering for application details.
JOB INSPECTION
Immediately upon delivery examine all crates, boxes and
exposed compressor and component surfaces for damage.
Unpack all items and check against shipping lists for any
discrepancy. Examine all items for damage in transit.
STANDARD BARE COMPRESSOR
Items not included with bare compressor that are available
as sales order options: Motor Mount, Solenoid Valve
Capacity, Tank Drain Tubing (T connection), Oil Feed Line
(P connection), Connection Fittings, Coupling.
TRANSIT DAMAGE CLAIMS
All claims must be made by consignee. This is an ICC re-
quirement. Request immediate inspection by the agent of
the carrier and be sure the proper claim forms are execut-
ed. Report damage or shortage claims immediately to
Johnson Controls-Frick Sales Administration Department,
in Waynesboro, PA.
COMPRESSOR IDENTIFICATION
Each compressor has an identication data plate, containing
compressor model and serial number mounted on the
compressor body.
NOTICE
When inquiring about the compressor or unit, or
ordering repair parts, provide the MODEL, SERIAL, and
JOHNSON CONTROLS - FRICK SALES ORDER NUMBERS
from the data plate. See Figure 1.
Figure 1 - Identication Data Plate
Rotary screw compressor serial numbers are dened by the
following information:
EXAMPLE: 10240A90000015Z
GLOBAL ADDITIONAL
PLANT DECADE MONTH YEAR SEQ NO. REMARKS
1024 0 A 9 0000015 Z
Month: A = JAN, B = FEB, C = MAR, D = APR, E = MAY, F =
JUN, G = JUL, H = AUG, K = SEP, L = OCT, M = NOV, N = DEC.
Additional Remarks: R = Remanufactured; Z = Deviation
from Standard Conguration.
Geometrical swept volume table ...

070-450 IOM (NOV 13)
Page 4
XJF ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
The name plates in Figure 2 show which refrigerants are
compatible with the compressor as manufactured.
Figure 2 - Refrigerant Name Plates
LONG TERM STORAGE
Long term storage (6 months to 5 years) provisions are
required, regardless of storage environment, if start-up
and/or useful operation does not occur within six (6) months
of equipment shipment. Special provisions may be required
for storage of less than six (6) months if the storage area is
subject to unusual environment such as high humidity, large
changes in temperature, dusty atmosphere, etc.
The standard Johnson Controls-Frick Warranty for an XJF
screw compressor covers twelve (12) months from start-up
or 18 months from shipment, whichever comes rst. It is
recommended that arrangements be made with the local
Johnson Controls-Frick service organization (arranged
through factory service) regarding surveillance and
maintenance during the storage period. It will be the
customer’s responsibility to submit a monthly report
showing the condition of the unit and noting any
discrepancies to the guidelines listed herein. Failure to
comply with this Long Term Storage Recommendation may
void the warranty.
Long term storage of equipment may lead to the deteriora-
tion of components over the period of time. Synthetic com-
ponents in the compressor may deteriorate over time even
if they are kept ooded with oil. A warm and dry environ-
ment is essential to minimize environmental and corrosion
damage. Long term storage of the affected equipment at a
customer’s site may involve additional requirements and
interested parties should refer to the Johnson Controls web
site, www.jci.com/frick, for specic instructions (Location:
Compressor And Packaged Equipment Storage Log
Model Serial No.
Compressor, Motor
Oil Pump and
Refrigerant Pump
Shaft Rotation
1½ Turn
Rotor
Housing
Charge
Charge
Added
Visual
Inspection
Per Qai-3 Charge Checked By Date
Geometrical
Rotor Max Swept Volume
Compressor Diameter Rotor Speed Drive Shaft End Cfm M³/H
Model mm L/D Rpm Ft³/ Rev M³/Rev 3550 Rpm 2950 Rpm
XJS/XJF 95M 95 1.4 5,772 0.02513 0.000711 89 126
XJS/XJF 95L 95 1.4 4,661 0.03112 0.000881 110 156
XJS/XJF 95S 95 1.4 3,600 0.04086 0.001156 145 205
XJS/XJF 120M 120 1.4 5,772 0.05065 0.001433 180 254
XJS/XJF 120L 120 1.4 4,661 0.06272 0.001775 223 314
XJS/XJF 120S 120 1.4 3,600 0.08234 0.002330 292 412
XJF 151A 151 1.6 6,297 0.09623 0.002723 342 482
XJF 151M 151 1.6 5,332 0.11366 0.003217 403 569
XJF 151L 151 1.6 4,306 0.14075 0.003983 500 705
XJF 151N 151 1.6 3,600 0.16833 0.004764 598 843
GEOMETRICAL SWEPT VOLUME TABLE

070-450 IOM (NOV 13)
Page 5
XJF ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
Bare Compressors\General\Warranties\Screw Compressor
Purchased for Long Term Storage).
The following guidelines must be followed to maintain the
SCREW COMPRESSOR WARRANTY.
PREPARING COMPRESSOR FOR STORAGE
Evacuate compressor to remove moisture. Evacuation lines
are to be connected to port SM1. Evacuation lines are to be
connected to the three Schrader valves provided with the
compressor. One valve is connected to compressor suction.
The other two valves are located at the block on the cylinder.
Break vacuum with dry nitrogen and bring pressure to 0 psig.
Pump oil into the same ports mentioned in step 1. Johnson
Controls-Frick recommends break-in oil P/N 111Q0831809
for storage purposes. The amounts of oil needed per
compressor are:
95mm - 2Gal
120mm - 3Gal
151mm - 8Gal
After compressor is oil charged, pressurize compressor to
15 psig with nitrogen.
MAINTAINING COMPRESSOR
Ensure that the 5-15 psig nitrogen charge is maintained
with 15 psig preferred.
Rotate the male rotor shaft every two weeks. Mark the
shaft to ensure the rotor does not return to the original
position.
The compressor must be stored inside a dry building
environment.
Grease the male rotor shaft to prevent rust.
Record all information in a “Compressor Long Term Storage
Log.” See bottom of page 4.
Contact Johnson Controls-Frick Service with any
questions regarding long term storage.
DESCRIPTION
XJF COMPRESSOR
The Frick XJF rotary screw compressor utilizes mating
asymmetrical prole helical rotors to provide a continuous
ow of vapor and is designed for both high-pressure and
low-pressure applications. The compressor incorporates
the following features:
1. High-capacity roller bearings to carry radial loads at both
the inlet and outlet ends of the compressor.
2. Heavy-duty angular contact ball bearings to carry axial
loads are mounted at the discharge end of compressor.
3. Moveable slide valve to provide fully modulating capacity
control from 100% to 25% of full load capacity.
4. VOLUMIZER II volume ratio control adjusts the compres-
sor volume ratio during operation to the most efcient of
three possible volume ratios, 2.2, 3.5, 5.0, depending upon
system requirements.
5. A hydraulic cylinder to operate the slide stop and slide
valve.
6. Compressor housing suitable for 400 PSIG pressure.
7. Most bearing and control oil is vented to closed threads in
the compressor instead of suction port to avoid performance
penalties from superheating suction gas.
8. The shaft seal is designed to maintain operating pressure
on the seal well below discharge pressure for increased
seal life.
9. Oil is injected into the rotor threads to maintain good
volumetric and adiabatic efciency, even at high compres-
sion ratios.
10. Shaft rotation clockwise facing compressor, suitable for
all types of drives. SEE FOLLOWING WARNING.
WARNING
It is mandatory that the coupling center be removed
and the direction of motor rotation be conrmed be-
fore running the compressor. Proper rotation of the
compressor shaft is clockwise looking at the end of the
compressor shaft. Failure to follow this step could re-
sult in backward compressor rotation which can cause
compressor failure or explosion of the suction housing.
COMPRESSOR LUBRICATION SYSTEM
The XJF compressor is designed specically for operation
without an oil pump for high stage service. Boosters and
some low-differential pressure appli cations will require the
pump option.
The lubrication system on an XJF equipped screw compressor
unit performs several functions:
1. Lubricates the rotor contact area, allowing the male rotor
to drive the female rotor on a cushioning lm of oil.
2. Provides lubrication of the bear ings and shaft seal.
3. Serves to remove the heat of compression from the gas,
keeping discharge temperatures low and minimizing refriger-
ant or oil break down.
4. Fills gas leakage paths between or around the rotors with
oil, thus greatly reducing gas leakage and main tain ing good
compressor per formance even at high compres sion ratios.
5. Provides oil pressure for development of balance load on
the balance pistons to reduce bearing loading and increase
bearing life.
OIL PUMP
The XJF screw compressor unit is designed to be self-lu-
bricating. Oil being supplied to the compres sor from the oil
separator is at system head pressure. Within the compressor,
oil porting to all parts of the compressor is vented back to
a point in the compres sor’s body that is at a pressure lower
than compressor discharge pressure. The compressor’s nor-
mal operation makes the compressor unit operate essentially
as its own oil pump. All oil entering the compressor is moved
by the compressor rotors out the compressor outlet and back
to the oil separator. For normal high-stage operation an oil
pump is not required.

070-450 IOM (NOV 13)
Page 6
XJF ROTARY SCREW COMPRESSOR
INSTALLATION - OPERATION - MAINTENANCE
CONSTRUCTION DETAILS
HOUSING: All XJF screw compressor castings are close
grain, pressure tight, grey cast iron, to ensure structural,
mechanical, and thermal stability under all operating
conditions. Ductile iron is also available for special
applications. Contact Johnson Controls–Frick Sales for
additional information.
ROTORS: The rotors are made from the highest quality
rolled steel to exacting tolerances of the latest industry
standard asymmetric prole. The ve-lobed male rotor is
directly connected to the internal gear. The seven-lobed
female rotor is driven by the male on a thin oil lm.
GEAR:
The compressor has an internal gear to speed up
the rotors. Each model has 3 or 4 gear ratios.
BEARINGS: Antifriction bearings with L
10
rated life in
excess of 50,000 hours (using the Frick Superlter™) at
design conditions are used for reduced frictional
horsepower and superior rotor positioning, resulting in
reduced power consumption, particularly at higher
pressure ratios. Cylindrical roller bearings are provided to
handle the radial loads and the thrust loads are absorbed
by four point contact or angular contact bearings. In
addition, thrust balance pistons are provided to reduce the
thrust load and improve bearing life.
SHAFT SEAL: The compressor shaft seal is a single-face
type with a spring-loaded carbon stationary surface riding
against a cast iron rotating seat. The seal is capable of
withstanding static pressure up to 400 psig. During
operation it is vented to low pressure to provide extended
life.
VOLUMIZER II ADJUSTABLE VOLUME RATIO CONTROL:
The Frick XJF compressor
adjusts to the most efcient of
three volume ratios (2.2, 3.5 or 5.0) depending upon system
requirements.
Control of the internal volume ratio eliminates
the power penalty associated with over- or under-
compression. Volume ratio control is achieved by the use of
a slide stop which is a movable portion of the rotor housing
that moves axially with the rotors to control discharge port
location. The slide stop is moved by hydraulic actuation of a
control piston.
STEPLESS CAPACITY CONTROL: Capacity control is
achieved by use of a movable slide valve. The slide valve
moves axially under the rotors to provide fully modulated
capacity control from 100% to 25% of full load capacity.
The slide valve is positioned by hydraulic movement of its
control piston. When in the unloaded position, gas is
bypassed back to suction through a recirculation slot before
compression begins and any work is expended, providing
the most efcient unloading method available for part-load
operation of a screw compressor.
MOTOR MOUNT: The XJF series is designed with a drive
end ange that mates with a cast iron motor mount
(available as a sales order option). The motor mount is
precision machined so that it ensures proper alignment of
the compressor and motor coupling.

070-450 IOM (NOV 13)
Page 7
XJF ROTARY SCREW COMPRESSOR
INSTALLATION
INSTALLATION
DESIGN LIMITS
General information for all of the models is provided below.
Please see CoolWare to determine the limits for a specic
application.
XJF compressors are primarily designed for connecting to
an electric drive motor using a tunnel mount. If the appli-
cation requires it, the compressor can also be driven with
a foot-mounted motor. The tunnel mount ensures proper
alignment of the compressor and motor so that the shaft
seal and coupling will operate properly. The rotor and
bearing design set limitations must not be exceeded (See
Frick Selection Program, CoolWare). Pressure and tem-
perature limits are shown in Frick publication 070.410-
SED. Refer to Johnson Controls-Frick Compressor Control
Panel instruction 090.040-O for additional information on
setpoint limits.
OUTLINE DIMENSIONS
Drawings for reference only can be found on the following
pages. Complete dimensions and access connections can
be found on the outline drawings.
XJF 95 DWG# 534E0458
XJF 120 DWG# 534E0299
XJF 151 DWG# 534E0539
If you do not have these drawings, please request any you
require by contacting Johnson Controls-Frick sales.
The NOTES below apply to the Dimensions and
Compressor Port Location drawings on the following
pages.
1. A metric rectangular parallel key is supplied with each
XJF 95 and 120 compressor. Metric key conforms to din
6885A specication. A standard square parallel key is
supplied with each XJF 151 compressor.
2. Standard voltage for solenoid coils is 110 VAC unless
otherwise specied. Other voltages are available upon
request.
3. Rotation of compressor jackshaft is clockwise when
viewing the shaft end.
4. Solenoid control valves for Volume Ratio Slide Stop (SS)
are included in delivery, including solenoids.
Solenoid control valves for Capacity Control Slide Valve
(SV) are NOT included in delivery. Internal piping is
included. A solenoid control valve kit with gasket can be
ordered or specied separately on the sales order. The
solenoid valve is a standard type D03/CETOP with O-rings
suitable for application (either HNBR or Viton)
5. Motor support is not provided as part of the bare
compressor. When required a motor support kit shall be
specied on the sales order separately.
Approximate mass:
XJF 95: 600 lbm (272 kg)
XJF 120: 845 lbm (383 kg)
XJF 151: 1210 lbm (550 kg)

070-450 IOM (NOV 13)
Page 8
XJF ROTARY SCREW COMPRESSOR
INSTALLATION
XJF 95 DIMENSIONS
2.13 (54)
C
L
DRIVE SHAFT
C
LCOMPRESSOR
5.21 (132.3)
5.27 (133.8)
4.34 (110.4)
8.13 (206.4)
8.25
(209.6)
25.63 (651.1)
2.66 (67.6)
5.12
(130)
12.25 (311.1)
6.06
(153.9)
4.00
(101.6)
6.84
(173.9)
2.06
(52.3)
3.13
(79.5)
11.62
(295.1)
2.75
(69.9)
4.81
(122.2)
C
LSUCTION
8.13
(206.6)
9.38 (238.3)
16.81 (427.1)
SOL-4
SEE NOTE 3
SOL-3
SEE NOTE 3
6.38
(162.1)
3.50
(88.9)
3.19 (81)
4.06
(103.1)
6.56
(166.6)
1.56 (39.6)
6.18
(157)
.3937 (10.000)
.3951 (10.035)
Ø1.3781 (35.004)
Ø1.3785 (35.014)
1.174 (29.82)
1.182 (30.02)
LIFTING
M20 X 2.5-6H
1.31 DP
2.00 (50.8)
1.71 (43.4)
1.20 (30.4)
.25 (6.4) THICK
SEALING DISK
INSTALLED
.25 ( THICK
SEALING DISK
INSTALLED
6.4)
OUT
OUT
TOP
43
10
A
A
VIEW A-A
C
LROTORS
10.69 (271.5 )
3.75 (95.3)
COMPRESSOR
7.56
(192)
6.94
(176.3 )
2.00 (50.8)
MIN DIST REQ'D
FOR SHAFT
SEAL REMOVAL
1.94 (49.3)
AVAILABLE SHAFT
FOR COUPLING
C
L
DISCHARGE
DISCHARGE FLANGE
2½" SOCKET WELD
10.88
(276.3)
C
LSUCTION
SUCTION FLANGE
FABRICATED SQUARE FLANGE
2½" (95S & 95M), 3" (95L)
6.94
(176.2)
8.45
(214.5)
2.50 (63.5)
4.82
(122.4)
C
LDRIVE SHAFT
C
LCOMPRESSOR
18.75
(476.3)
6.84
(173.9)
2.72
(69)
( )
2.81
71.4
2.43 (61.7)
0.94
(23.9)
5.19
(131.8)
2.56
(65)
5.31
(134.9)
1.85
(46.9)
0.50 (12.7 )
0.75 (19.1)
SEAL WEEPAGE
DRAIN TUBE
TO BE PULLED
THROUGH THIS HOLE
Ø.719 (18.3)
10.62
(269.7)
3.66 (92.9)
C
L

070-450 IOM (NOV 13)
Page 9
XJF ROTARY SCREW COMPRESSOR
INSTALLATION
XJF 120 DIMENSIONS
C
LCOMPRESSOR
5.88 (149.4)
6.00 (152.4)
4.96 (126.1)
7.95
(202)
6.56
(166.7)
2.78 (70.6)
0.50
(12.7)
9.57
(243.1)
30.03 (762.7)
1.68 (42.7)
3.90
(99.1)
3.54
(90)
4.75
(120.7)
6.62
(168.1)
4.25
(108)
5.25
(133.4)
1.56 (39.6)
3.50 (89)
2.59 (65.8)
3.65 (92.7)
3.75 (95.3)
13.69
347.7)
3.38
(85.8)
4.88
(124)
1.18 (29.9)
2.56 (65)
1.83 (46.5)
SUCTION C
L
7.95 (202)
9.20 (233.7)
17.19 (436.8)
SOL-4
SEE NOTE 3
SOL-3
SEE NOTE 3
3.50
(88.9)
7.69
(195.2)
3.25
(82.6)
MAIN OIL INJECTION
ORIFICE PLUG LOCATION 0.25 (6.4) THICK
SEALING DISK
INSTALLED
4.18
(106.2)
6.00
(152.4)
6.4 [.25] THICK
SEALING DISK
INSTALLED
LIFTING
M20X2.5-6H
1.62 DP
OUT
OUT
TOP
3
4
A
A
13.00 (330.3)
13.81 (350.8) 7.94 (201.7)
2.59 (65.8)
3.12 (79.4)
6.38
(162.1)
DISCHARGE
C
L
10.13 (257.3)
6.88
(174.8)
11.24 (285.5)
3.69 (93.7)
13.24
(336.3)
2.13 (54.1)
MINIMUM DISTANCE REQUIRED
FOR SHAFT SEAL REMOVAL
2.38 (60.5)
AVAILABLE SHAFT FOR COUPLING
C
LCOMPRESSOR
C
LDISCHARGE
DISCHARGE FLANGE
3" SOCKET WELD
3.25
(82.6)
2.75 (69.9)
∅.718
(18.2)
∅.75 (19.1)
SEAL WEEPAGE DRAIN TUBE TO
BE PULLED THROUGH THIS HOLE
5.62
(142.7)
2.50 (63.5)
SUCTION FLANGE BEFORE
IMPORTANT
PUTTING PACKAGE IN
REMOVE SEALING DISC FROM
OPERATION.
C
LROTORS
21
11.76
(298.8)
C
LSUCTION
6.75
(171.5)
SUCTION FLANGE
FABRICATED SQUARE FLANGE
3" (1750 RPM COMPRESSORS)
4" (3550 RPM COMPRESSORS)
9.72
(246.8)
2.81 (71.4)
10.72
272.2)
2.58 (65.6)
2.00 (50.8)
4.25
(108)
C
LDRIVE SHAFT
C
LCOMPRESSOR
21.73
(551.9)
8.12
(206.3)
1.61
(41)
5.62
(142.7)
9.50 (241.4)
4.03 (102.5)
SUCTION FLANGE BEFORE
IMPORTANT
PUTTING PACKAGE IN
REMOVE SEALING DISC FROM
OPERATION.
.4724 (11.999)
.4741 (12.042)
Ø1.5749 (40.002)
Ø1.5753 (40.013)
1.370 (34.8)
1.378 (35.0)
VIEW A-A
C
L
DRIVE
SHAFT

070-450 IOM (NOV 13)
Page 10
XJF ROTARY SCREW COMPRESSOR
INSTALLATION
XJF 151 DIMENSIONS
SEE DETAIL A
11.31
(287.3)
DRIVE SHAFT 4.98 (126.5)
COMPRESSOR
2.60
(66)
10.70
(271.8)
4.00
(101.6)
4.00
(101.6)
6.09
(154.7) 3.37
(85.6)
8.26
(209.8)
1.31
(33.3)
COMPRESSOR
21.38
(543.1)
9.50
(241.3)
8.38
(212.9) 7.38
(187.5)
SUCT
9.56 (242.8)
8.25
(209.6)
8.25
(209.6)
11.88
(301.8)
4.00
(101.6) 4.00
(101.6)
20.25 (514.35)
12.06
(306.3)
7.50
(190.5)
3.25
(82.6)
MINIMUM DISTANCE
REQUIRED TO
REMOVE SHAFT SEAL
15.79 (401.1)
LIFTING HOLE
M20 X 2.5-6H
1.56 DP
FRICK FABRICATED
SUCTION FLANGE 5"
1.25
(31.8)
4.57
(116.1)
15.73
(399.5)
1.25
(31.8)
15.73
(399.5)
7.13
(181.1)
3.56
(90.4)
2.57
(65.3)
5.63
(143)
11.84 ( )300.7
13.17 ( )334.5
15.73 ( )399.5
8.25
(209.6)
3.50
(88.9)
19.04 (483.6)
6.73
(170.9)
8.10
(205.7)
FORGED 4"
SOCKET WELD FLANGE
8.50
(215.9)
19.04 ( )483.6
0.75
(19.1)
1.88
(47.8)
0.77
(19.6)
1.88
(47.8)
5.77
(146.6)
3.25
(82.6)
3.00
(76.2)
7.50
(190.5) 4.00
(101.6)
1.13
(28.7)
5.75
(146.1)
4.75
(120.7)
3.00
(76.2)
SOL-4
SEE NOTE 3
SOL-3
SEE NOTE 3
2.00
(50.8)
9.50
(241.3)
2.39
(60.7)
DRIVE SHAFT
43.79 (1112.3)
TOP
OUT OUT
VIEW B-B
B
B
DETAIL A
Ø1.999/2.000
(Ø50.77/50.80)
1.703/1.718
(43.25/43.63)
.500/.502
(12.70/12.75)

070-450 IOM (NOV 13)
Page 11
XJF ROTARY SCREW COMPRESSOR
INSTALLATION
PORT CONNECTION SIZE
1* 3/4 - 14 NPTF
2 1/8 - 27 NPTF
3 3/8 - 18 NPTF
4 3/8 - 18 NPTF
5 3/4 - 14 NPTF
7 1/4 - 18 NPTF
8 3/8 - 18 NPTF
10 1/4 - 18 NPTF
11 1/4 - 18 NPTF
12 1/4 - 18 NPTF
16 3/4 - 14 NPTF
18** 1/2 - 14 NPTF
20 1/8 - 27 NPTF
21 3/4 - 14 NPTF
22 1/4 - 18 NPTF
XJF 95 COMPRESSOR PORT LOCATIONS
* Main oil supply needs full oil pressure
** Main oil injection needs regulation valve installed

070-450 IOM (NOV 13)
Page 12
XJF ROTARY SCREW COMPRESSOR
INSTALLATION
XJF 120 COMPRESSOR PORT LOCATIONS
PORT CONNECTION SIZE
1 1 - 11½ NPTF
2 1/4 - 18 NPTF
3 3/8 - 18 NPTF
4 3/8 - 18 NPTF
5 1 - 11½ NPTF
6 1/2 - 14 NPTF
7 1/4 - 18 NPTF
8 1/4 - 18 NPTF
10 1/4 - 18 NPTF
11 1/4 - 18 NPTF
12 1/4 - 18 NPTF
15 3/8 - 18 NPTF
16 3/4 - 14 NPTF
18 1/8 - 27 NPTF
19 1/4 - 18 NPTF
20 1/8 - 27 NPTF
21 3/8 - 18 NPTF
22 1/4 - 18 NPTF

070-450 IOM (NOV 13)
Page 13
XJF ROTARY SCREW COMPRESSOR
INSTALLATION
XJF 151 COMPRESSOR PORT LOCATIONS
PORT CONNECTION SIZE O-RING
1* 1Z\zn - 12 UN-2B 980A0012K66
2 7/16 - 20 UNF-2B 980A0012K58
31Z\zn - 12 UN-2B 980A0012K66
41Z\zn - 12 UN-2B 980A0012K66
51M\, - 12 UN-2B 980A0012K72
6 9/16 - 18 UNF-2B 980A0012K60
71Z\zn - 12 UN-2B 980A0012K66
8 7/16 - 20 UNF-2B 980A0012K58
9 9/16 - 18 UNF-2B 980A0012K60
10 9/16 - 18 UNF-2B 980A0012K60
11 3/4 - 14 NPTF N/A
12** 1Z\zn - 12 UN-2B 980A0012K66
13 1/4 - 18 NPTF N/A
14 1/8 - 27 NPTF N/A
15 1/2 - 14 NPTF N/A
16 9/16 - 18 UNF-2B 980A0012K60
17 1Z\zn - 12 UN-2B 980A0012K66
18 9/16 - 18 UNF-2B 980A0012K60
* Main oil supply needs full oil pressure
** Main oil injection needs regulation valve installed

070-450 IOM (NOV 13)
Page 14
XJF ROTARY SCREW COMPRESSOR
INSTALLATION
HOLDING CHARGE AND STORAGE
Every XJF compressor is pressure and leak tested at the
Johnson Controls–Frick factory and then thoroughly evacu-
ated and charged with dry nitrogen to ensure its integrity
during shipping and short term storage prior to installation.
All compressors must be kept in a clean, dry location to
prevent corrosion damage. Compressors that will be stored
for more than two months must have their nitrogen charge
checked periodically (see pages in GENERAL INFORMATION
for complete instructions).
WARNING
Holding-charge shipping gauges (if mounted) are rated
for 30 psig and are for checking the shipping charge
only. They must be removed before pressure testing
and operating the system. Failure to remove these
gauges may result in catastrophic failure of the gauge
resulting in serious injury or death.
Access valves are bronze and they must be replaced with
steel plugs when package is assembled.
WARNING
THIS EQUIPMENT HAS BEEN PRESSURIZED WITH
NITROGEN GAS. TEMPORARY VALVES AND GAUGES
HAVE BEEN INSTALLED.
1. RELIEVE PRESSURE PRIOR TO OPENING LINES OR
MAKING FIELD CONNECTIONS.
2. REMOVE CHARGING VALVES OR GAUGES PRIOR
TO PRESSURIZING SYSTEM.
3. REFER TO THIS MANUAL FOR ADDITIONAL
INFORMATION.
ESCAPING GAS MAY CAUSE INJURY !
SAE STRAIGHT THREAD O-RING FITTINGS - ASSEMBLY PROCEDURE FOR RXF 58 - 101
1. Inspect components to ensure that male and female
port threads and sealing surfaces are free of burrs, nicks
and scratches or any foreign material.
2. If the O-ring is not pre-installed to the tting on the
male end, install the proper size O-ring.
3. Lubricate the O-ring with a light coating of system oil or
petroleum jelly.
4. Screw the tting into the female port until the hex at
contacts the port face. Light wrenching may be necessary.
5. Tighten to the appropriate torque value shown in the
Assembly Torque Table.
ASSEMBLY TORQUE TABLE
Straight and Adjustable Fittings or Plugs (steel)
Fitting Size SAE Port Thread Size Assembly Torque
Inch lb Foot lb
2 5/16 – 24 65 ± 5 5.5 ± 0.5
3 3/8 – 24 130 ± 10 11 ± 1.0
4 7/16 – 20 170 ± 10 14 ± 1.0
5 1/2 - 20 260 ± 15 22 ± 1.0
6 9/16 – 18 320 ± 20 27 ± 2.0
8 3/4 - 16 500 ± 25 42 ± 2.0
10 7/8 – 14 720 ± 30 60 ± 2.5
12 1Z\zn – 12 960 ± 50 80 ± 5.0
16 1B\zn – 12 1380 ± 75 115 ± 6.0
20 1B\, – 12 2700 ± 150 225 ± 12.0
24 1M\, - 12 3000 ± 160 250 ± 12.0
When performing maintenance or replacing the compressor,
the hydraulic tubing may need to be removed and re-
installed. The following procedure outlines the proper
installation of SAE straight thread ttings to SAE straight
thread ports.
The male and female ends of SAE straight thread O-ring
ports have UN/UNF straight threads. An elastomeric O-ring
is tted to the male end. On assembly, the O-ring is rmly
sandwiched between the angular sealing surface of the
female port and the shoulder of the male end. Sealing is
thus affected and maintained by the O-ring compression
which results from the clamping force generated by the
tightening action. The straight threads do not offer sealing
action; they provide the resistance (holding power) for
service pressure.

070-450 IOM (NOV 13)
Page 15
XJF ROTARY SCREW COMPRESSOR
INSTALLATION
RIGGING AND HANDLING
Figure 3 - Lifting Ring
The compressor can be moved with rigging, using a crane
or forklift, by hooking into the two lifting rings at each end
of the main housings. The compressor lifting rings shall only
be used to lift the compressor itself. See Figures 3 and 4.
FOUNDATION
Each XJF Rotary Screw Compressor is shipped mounted on
a wooden skid, which must be removed prior to unit
installation.
CAUTION
Allow proper spacing for servicing (see Dimensional
Outline Drawing).
The rst requirement of the compressor foundation is that
it must be able to support the weight.
XJF 95 600 lb
XJF 120 845 lb
XJF 151 1,210 lb
Screw compressors are capable of converting large
quantities of shaft power into gas compression in a relatively
small space. The compression process creates relatively
high frequency vibrations that require sufcient mass in the
base to effectively dampen them.
The best insurance for a trouble-free installation is to rmly
anchor the compressor to a suitable foundation using
proper bolting and by preventing piping stress from being
imposed on the compressor. Once the compressor is rigged
into place, its feet must be shimmed to level it. There must
be absolutely no stresses introduced into the compressor
body due to bolting of the feet and anges.
The compressor motor mount is not designed to carry the
unsupported weight of the motor. The full motor weight
must be supported using the motor lifting point during the
motor installation process. After the necessary bracket to
support the motor have been welded into place on the
package and the rear motor feet and the motor mount have
been bolted into place, the weight of the motor can rest on
the support bracket and the motor mount.
In any screw compressor installation, suction and discharge
lines should be supported in pipe hangers (preferably within
2 feet of vertical pipe run) so that the lines won’t move if
disconnected from the compressor. See table for Allowable
Flange Loads.
ALLOWABLE FLANGE LOADS
NOZ. MOMENTS (ft-lbf) LOAD (lbf)
SIZE AXIAL VERT. LAT. AXIAL VERT. LAT.
NPS MRMCMLP VCVL
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 1,000 750 750 650 650 650
8 1,500 1,000 1,000 1,500 900 900
10 1,500 1,200 1,200 1,500 1,200 1,200
14 2,000 1,800 1,800 1,700 2,000 2,000
CUSTOMER CONNECTIONS
As a minimum you must make oil connections to the
locations shown on the compressor port location drawings
in addition to suction and discharge.
Other connections are available for instrumentation and
service as noted on the Dimensional Outline drawing. The
electrical connections for the slide stop and the slide valve
transmitters and the solenoid valve coils must be connected
to your control system .
The oil supply system for the compressor must be designed
for a total pressure drop of no more than 15 psi with a new
oil lter element. Excessive pressure drop in the oil circuit
can prevent proper operation of the slide valve and slide
stop pistons.
COMPRESSOR OIL
WARNING
DO NOT MIX OILS of different brands, manufacturers, or
types. Mixing of oils can cause excessive oil foaming,
nuisance oil level cutouts, oil pressure loss, gas or oil
leakage and catastrophic compressor failure. CoolWare
will select a specic Frick oil for the refrigerant being
used. Depending on the application, a different oil can be
selected provided it is of the proper viscosity and is com-
patible with the refrigerant and compressor elastomers.
OIL PUMP
If your XJF compressor application requires an oil pump, it
is recommended that a strainer be mounted upstream to
protect it. Frick supplied pumps are a positive displacement
gear type that must have a safety relief valve to ensure the
oil pressure will not be more than 50 psi above compressor
discharge pressure for all models.

070-450 IOM (NOV 13)
Page 16
XJF ROTARY SCREW COMPRESSOR
INSTALLATION
COMPRESSOR
MOUNTING
CAUTION
To prevent injury or damage to components, and for
complete details regarding pressurized refrigerant vapor
transfer and recovery, see the current Installation-
Operation-Maintenance Manual for your unit.
1. Place a new gasket on the oil separator ange. (Contact
the Baltimore Parts Center for replacement gaskets, Ph:
800-336-7264). Assemble the new compressor to the tunnel
and hand tighten the bolts in a star pattern. Then torque to
1/3 of table value in star pattern increasing by 1/3’s to full
torque. Refer to Table 3 for torque specications.
2. Set the compressor and motor assembly on the separator
ange and align the oil separator ange bolt holes to the
compressor discharge ange bolt holes while supporting
the assembly with a hydraulic piston underneath the motor.
The hydraulic piston must support the motor weight, motor
support / tunnel weight, plus 1/2 the compressor weight.
Reference Table 2 for compressor weights.
TABLE 2 - COMPRESSOR WEIGHT
XJS/XJF Compressor Weight - Approximate
lb kg
95 600 272
120 845 383
151 1,210 549
3. Insert the bolts through the oil separator ange and into
the compressor discharge ange. Tighten bolts using a star
pattern. Lube bolts then nger tight on all bolts, then torque
to 1/3 of table value in star pattern increasing by 1/3’s to full
torque. Reference Table 3.
4. The motor feet should rise above the support base. If
not, remove the compressor, add another gasket on top of
the oil separator ange and repeat steps 4 & 5.
5. While the assembly is still supported, measure the
clearance between the motor feet and base plate with a
feeler gage. Shim the motor feet to gage reading plus .002”
gap between each motor foot and the support base. Then,
bolt the motor to the mounting base and torque the motor
mounting bolts to 250 ft-lb.
6. Connect all tubing and pipe connections to the
compressor and all wiring to the motor.
7. Remove the lifting assembly.
TABLE 3 - BOLT TORQUE VALUE
Compressor
Model Screw Size Torque
ft-lb NM
XJF 95 1/2 or 5/8 58 79
XJF 120 1/2 or 5/8 58 79
XJF 151 5/8 or 3/4 144 195
COMPRESSOR/MOTOR COUPLING REQUIREMENTS.
XJF compressors are arranged for direct motor drive and
require a exible drive coupling to connect the compressor
to the motor.
If you are using the Johnson Controls – Frick motor mount,
the mount is machined to ensure that motor to compressor
alignment is in specication (see the above “MOTOR
MOUNTING” section for mounting details).
If you are using a foot mounted motor, it is essential that
the coupling be properly aligned to ensure proper bearing
and seal performance.
1. Coupling must be selected and installed so that it
doesn’t transmit any axial load to the compressor
shaft.
2. Set up the minimum distance between compressor
shaft and motor shaft to allow for seal removal (see
Outline drawings).
3. Coupling must be able to take up any misalignment
between motor and compressor. It is critical to the
life of the shaft seal that misalignment is kept to the
minimum possible value. Be sure to follow the coupling
manufacturer’s guidelines for checking and correcting
any misalignment. See the next section for Johnson
Controls–Frick requirements.
COUPLING ALIGNMENT REQUIREMENTS
(FOOT MOUNTED ONLY)
Coupling alignment must be performed prior to start-
up. After the compressor has been installed on the job
site, alignment must be checked again and if necessary
corrected prior to start-up. After a few hours operation,
the alignment must be checked while the package is still
hot. Correct hot alignment is critical to ensure the life of the
shaft seal and compressor bearings.
Maximum radial runout is .004” total indicator reading.
Maximum axial runout is .004” total indicator reading.
A dial indicator or another appropriate measuring device is
to be used to determine the Total Indicator Runout.
Indicator bracket sag must be checked as all brackets have
some exibility. The best way to measure this is to attach
the dial indicator and bracket on a pipe at the coupling span
distance. Zero the indicator in the 12:00 position, and rotate
the pipe so the indicator is in the 6:00 position. The reading
on the indicator in the 6:00 position is the bracket sag. This
value must be included in the dial indicator readings when
afxed to the coupling for an accurate alignment.
OIL HEATER(S)
Your package must be equipped with oil heaters that
provide sufcient heat to prevent condensation from
occurring during shutdown cycles.

070-450 IOM (NOV 13)
Page 17
XJF ROTARY SCREW COMPRESSOR
INSTALLATION
OIL FILTER(S)
Your package must be equipped with full-ow oil ltration.
Typical oil lter specication β5 = 75 according to ISO 4572
is required to obtain the recommended oil cleanliness class
16/14/11 according to ISO 4406. Frick SuperFilters™ can be
ordered separately.
OIL COOLING REQUIREMENTS
Compressor oil needs to be cooled to control the discharge
temperature, maintain proper oil viscosity and to preserve
the life of the oil. Normally the discharge temperature will
be in the 170° - 180°F range (see CoolWare™).
One application that typically requires higher discharge
temperatures (as high as 250°F) is natural gas gathering at
the wellhead 1. Moisture is normally present in the gas and
it is imperative that the discharge temperature be at least
30°F higher than the discharge dew point temperature for
the gas. Run Coolware with the “Water Saturated” block
checked to get the discharge dew point temperature for
your application. Oil temperatures as high as 170°F can be
used to achieve the necessary discharge temperature to
prevent moisture from condensing in the oil separator.
1 Contact Johnson Controls–Frick for additional information
for natural gas compression - availability of bearings for
high temperature applications - standard bearings have
limitations per Coolware that must be observed.
The main oil injection line must have a regulating valve to
permit adjustment of the oil ow to maintain the desired
discharge temperature at all times.
The use of a three-way mixing valve is recommended to
keep the oil temperature in the normal range of 120° -
140°F. The valve will provide warm oil to the compressor
quickly, reducing the pressure drop caused by cold, viscous
oil. This ensures proper oil ow and temperature over the
full range of operating conditions.
ECONOMIZER - HIGH STAGE
The economizer option provides an increase in system capac-
ity and efciency by subcooling liquid from the condenser
through a heat exchanger or ash tank before it goes to the
evapora tor. The subcooling is provided by ashing liquid in
the economizer cooler to an intermediate pressure level.The
intermediate pressure is provided by a port located part way
down the compres sion process on the screw compressor.
As the screw compressor unloads, the economizer port will
drop in pressure level, eventually being fully open to suc-
tion. Because of this, an output from the microproces sor is
generally used to turn off the supply of ashing liquid on a
shell and coil or DX economizer when the capacity falls below
approximately 60%-70% (85%-90% slide valve position). This
is done to improve compressor operating efciency. Please
note however that shell and coil and DX economizers can be
used at low compressor capaciti es in cases where efcien-
cy is not as important as ensuring that the liquid supply is
subcooled. In such cases, the economi zer liquid solenoid can
be left open whenever the com pressor is running.
Due to the tendency of the port pressure to fall with de-
creasing compressor capacity, a back-pressure regulator
valve (BPR) is generally required on a Flash Economizer
System (Figure 6) in order to maintain some preset pressure
dif ference between the subcooled liquid in the ash vessel
and the evaporato rs. If the back-pressure regulator valve is
not used on a ash economizer, it is possible that no pressure
difference will exist to drive liquid from the ash vessel to the
evaporators, since the ash vessel will be at suction pressure.
In cases where wide swings in pressure are anticipated in
the ash econo mizer vessel, it may be necessary to add an
outlet pressure regulator to the ash vessel outlet to avoid
overpressurizing the economizer port, which could result
in motor overload. Example: A system feeding liquid to the
ash vessel in batches.
The recommended economizer systems are shown in Figures
4 – 7. Notice that in all systems there must be a strainer
and a check valve between the economizer vessel and the
economizer port on the compressor. The strainer prevents
dirt from passing into the compressor and the check valve
prevents oil from owing from the compressor unit to the
econo mizer vessel during shutdown.
CAUTION
Other than the isolation valve needed for strainer cleaning, it
is essential that the strainer be the last device in the
economizer line before the compres sor. The strainer must
be strong enough to handle the gas pulsations from the
compressor. Johnson Controls-Frick recommends an R/S
or Hansen strainer. Also, piston-type check valves are
recom mended for installation in the economizer line, as
opposed to disc-type check valves. The latter are more
prone to gas-pulsation-induced failure. The isolation and
check valves and strainer should be located as closely as
possible to the compressor, preferably within a few feet.
Figure 4 - Shell And Coil Economizer System
Figure 5 - Direct Expansion Economizer System
For refrigeration plants employing multiple compressors on
a common economizing vessel, regardless of economizer
type, each compressor must have a back-pressure regulat-
ing valve in order to balance the economizer load, or gas
ow, between compressors. The problem of balancing load
becomes most important when one or more compressors

070-450 IOM (NOV 13)
Page 18
XJF ROTARY SCREW COMPRESSOR
INSTALLATION
run at partial load, exposing the economizer port to suction
pressure. In the case of a ash vessel, there is no need for
the redundancy of a back-pressure regulating valve on the
vessel and each of the multiple compressors. Omit the BPR
valve on the ash economizer vessel and use one on each
compressor, as shown in Figure 7.
Figure 6 - Flash Economizer System
Figure 7 - Multiple Compressor Flash Economizer System
LIQUID INJECTION OIL COOLING
The liquid injection system provided on the unit is self-con-
tained but requires the connection of the liquid line sized as
shown in the table.
High-stage compressor units may be supplied with single-port
(low Vi, side, or closed thread) or dual-port (low Vi and high Vi),
liquid injection oil cooling. Single port will be furnished for low
compression ratio operation and dual port for high compres-
sion ratio operation. Booster compressor units use single-port
(High Vi), liquid injection oil cooling due to the typically lower
compression ratios.
The control system on high-stage units with dual-port, liquid
injection oil cooling switches the liquid refrigerant supply to
the high port when the compres sor is operating at higher
compression ratios (3.5 Vi and above) for best efciency.
Where low compres sion ratios (low condensing pressures)
are anticipated, thermo syphon or water-cooled oil cooling
should be used.
Liquid line sizes and the additional receiver volume (quanti-
ty of refrigerant required for 5 minutes of liquid injection oil
cooling) are given in the following table:
CONDITIONS: High Stage at 0°F Evap, and 95°F Cond, 10°F
suction superheat; Booster at -40°F Evap, 95°F Cond, 20°F
Intermediate, and 10°F suction superheat; R-507 unloaded
slide valve.
XJF
MODEL
LIQ. LINE SIZE* 5 MIN
SUPPLY
POUNDS
LIQUID
VOLUME
CU. FT
REFRIG PIPE
SCH 80
TUBING
OD
R-717
HIGH
STAGE
95 3/8 – 12 0.3
120 1/2 – 33 0.9
151 3/4 – 65 1.8
R-507
HIGH
STAGE
95 3/8 1/2 24 0.4
120 3/8 1/2 60 1.0
151 1/2 5/8 99 1.6
R-717
BOOSTER
95 3/8 – 3 0.1
120 3/8 – 8 0.2
151 3/8 – 14 0.4
R-507
BOOSTER
95 No oil heat of rejection
at this condition
120
151
* 100 ft. liquid line. For longer runs, increase line size accordingly.
CAUTION
It is imperative that an uninterrupted high-pres sure
liquid refrig erant be provided to the injection system
at all times. Two items of EXTREME IMPORTANCE are
the design of the receiver/liquid injection supply and
the size of the liquid line. It is recommended that the
receiver be oversized sufciently to retain a 5-minute
supply of refrigerant for oil cooling. The evaporator
supply must be secondary to this considera tion. Failure
to follow these requirements causes wire draw which
can result in damage to the expansion valve, loss of oil
cooling, and intermittant oil cooling. One method of
ac complishing this is described below.
DUAL DIP TUBE METHOD
The dual dip tube method uses two dip tubes in the re ceiv-
er. The liquid injection tube is below the evaporator tube to
assure continued oil cooling when the receiver level is low.
See Figure 8.
Figure 8
DEHYDRATION / EVACUATION TEST
Evacuate the system to 1000 microns. Valve off the vacuum
pump and hold vacuum for one hour.
Pass – Vacuum cannot rise more than 500 microns during
one hour hold period.
Fail – Vacuum rise is more than 500 microns during one
hour hold period. Identify and repair any system leaks.
Repeat vacuum test until requirements are met.

070-450 IOM (NOV 13)
Page 19
XJF ROTARY SCREW COMPRESSOR
INSTALLATION
ELECTRICAL INSTALLATION
CAPACITY SLIDE VALVE TRANSMITTER
The slide valve transmitter (Figure 9) measures the position
of the slide valve (SV) and sends a 4 to 20mA signal to your
control system. See Figure 10. The controller will adjust the
position of the SV according to the motor load set point.
The correct position is important to properly load the
compressor and motor. It is important not to overload the
compressor and motor. Observe the maximum power input
and ensure design limitations are not exceeded. Connect to
+/- and signal as shown in the wiring diagram, Figure 10.
Refer to Frick compressor panel instructions for calibration
procedure 090.040-O.
Figure 9 - Slide Valve Transmitter
Figure 10 - Wiring Diagram for Slide Valve Transmitter
COMPRESSOR HYDRAULIC SYSTEM
The hydraulic system of the XJF compressor utilizes oil pres-
sure from internally drilled passages in the compressor casing
to selectively load and unload the compressor by applying this
pressure to the actuating hydraulic piston of the movable slide
valve (MSV). It also uses oil pressure to actuate a hydraulic
piston that moves the movable slide stop, Volumizer II. This
allows adjustment of the compressor volume ratio, (Vi) while
the compressor is running.
CAPACITY CONTROL
COMPRESSOR LOADING: The compressor loads when MSV
solenoid coil YY2 is energized and oil ows from the solenoid
valve through the needle valve (HV2) to compressor port 2,
where it enters the load side of the slide valve piston. This
equalizes the force on the slide valve piston and discharge
pressure on the slide valve area loads the compressor. See
Figure 11.
Figure 11 - Hydraulic Schematic
COMPRESSOR UNLOADING: The compressor unloads when
MSV solenoid YY1 is energized and oil is allowed to ow
from compressor port 2 thru the needle valve to the MSV
solenoid. This allows discharge pressure on the slide valve
piston to unload the slide valve as the piston moves outward.
ADJUSTMENT (Capacity Control): A needle valve (HV2)
is provided to adjust slide valve travel time, preventing
excessive slide valve “hunting”. HV2 should be adjusted to
restrict oil ow to the compressor port so that slide valve
travel time from full load to full unload, or vice versa, is a
minimum of 30 seconds.
NOTICE
A change in operating conditions, such as winter-to-
summer operation, may require readjustment of slide
valve travel time.
VOLUMIZER II Vi CONTROL
The XJF compressor is equipped with a special internal
control that automatically adjusts the compressor volume
ratio to the most efcient of three available steps, (2.2, 3.5,
or 5.0 volume ratio). This gives the compressor the ability
to operate at varying operating conditions while minimizing
power consumption by avoiding over or undercompression.
Solenoid valves 3 and 4 (See Figures 12 - 14 and location
on P & I diagram represented by YY3 and YY4) control the
Volumizer II volume ratio control. Oil is internally ported to
apply hydraulic pressure to two stepping pistons in order
to move the moveable slide stop to the optimum position.
The following chart shows the logic of solenoid operation
to adjust the volume ratio.
Vi SOLENOID 3 / YY3 SOLENOID 4 / 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.
1. Conrm 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 cur-
rent Slide Valve and 0% Slide Valve positions. The difference
between these voltages must be in the 1.35 - 1.65 Vdc range.

070-450 IOM (NOV 13)
Page 20
XJF ROTARY SCREW COMPRESSOR
INSTALLATION
3. Set the compressor Vi to 3.5, then record the voltage that
is shown on the Slide Valve calibration screen for the cur-
rent Slide Valve and 0% Slide Valve positions. The difference
between these voltages must be in the 0.95 - 1.15 Vdc range.
4. Set the compressor Vi to 5.0, then record the voltage that
is shown on the Slide Valve calibration screen for the cur-
rent Slide Valve and 0% Slide Valve positions. The difference
between these voltages must be in the 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 consump-
tion, noise, vibration, or excessive oil foaming. See Figures
12 - 14 for correct installation of gaskets and location of
solenoids.
OUT
OUT
GASKET INSTALLATION SIDE VIEW
PRESSURE
PRESSURE
COMMON
COMMON
VENT
YY3
YY4
Figure 12 - XJF 95 Vi Control
Figure 13 - XJF 120 Vi Control
Figure 14 - XJF 151 Vi Control
LOW AMBIENT OPERATION
It is recommended that package oil separators be insulated
as a minimum requirement to preserve the heat generated
by the oil heaters, to prevent condensation and secure
lubrication at start-up.