03991-001-1-01-02 290gle Iom

INSTRUCTION MANUAL
GEA FES CUSTOMER:
PESQUERA CAPRICORNIO S. A.
LIMA, PERU
P.O. NO. 001-0020416
END USER:
PESQUERA CAPRICORNIO
LIMA, PERU
GEA FES PROJECT NO. 03991-001
-02 COMPRESSOR MODEL 290GLE

GL SERIES SCREW
COMPRESSOR PACKAGES
Preface
This manual provides detailed instructions for the installation, operation and maintenance of
FES GL Series screw compressor packages. The compressor package will provide optimum
performance if applied to a properly designed refrigeration system. Specific questions
concerning these requirements can be answered by an FES certified representative or factory
personnel. Proper installation, operation and regular maintenance will provide the best and most
dependable equipment life.
GL Series packages are leak tested at the factory and are shipped with a holding charge of dry
nitrogen to prevent contamination from the atmosphere. During installation into the
refrigeration system, it is normally not necessary to leak test the compressor package on site
except when required by prevailing codes or standards. However, prior to charging the system
with refrigerant, the system, including the compressor package, should be evacuated in
compliance with site requirements or other recognized procedures outlined in documents such as
ANSI/IIAR, IIAR Bulletin 110, ASHRAE Handbook "Refrigeration" etc.
To ensure that the compressor is not exposed to liquid carryover in the suction gas, it is very
important to review piping layouts. The compressor is a vapor pump and can be damaged by
liquid refrigerant in the suction gas. Control schemes, accumulators, heat exchangers, defrost
cycles, etc. should be checked to ensure that only dry gas within the operating limits enters the
compressor suction.
The entering vapor temperature to the compressor should be 10°F superheated above the
refrigerant saturated suction temperature to ensure no liquid refrigerant is present in the suction
gas.
GEA Refrigeration North America, Inc. – York, PA
3475 Board Road
York, PA 17406
(717) 767-6411 or 1-800-888-4337
Texas Regional Branch Office

18574 Van Road
Houston, TX 77049
(281) 456-8500 or 1-800-677-5746
California Regional Branch Office

4220 Brew Master Drive
Ceres, CA 95307
(209) 538-6850 or 1-800-666-4337
Arkansas Regional Branch Office

780 W. Randall Wobbe Lane
Springdale, AR 72764
(479) 751-6440 or 1-800-396-3449
GL SERIES
COMPRESSOR PACKAGE
INSTRUCTION MANUAL
1. INSTALLATION
2. PACKAGE OPERATION
3. CONTROL PANEL OPERATION
4. COMPRESSOR STARTUP PROCEDURE
5. MAINTENANCE
6. COMPONENT LITERATURE
7. DATA SHEET/SPARE PARTS
GL SERIES SCREW
COMPRESSOR PACKAGES
SECTION 1 INSTALLATION
TABLE OF CONTENTS
PAGE
Introduction ...........................................................................................................................1
Compressor Package Identification ....................................................................................1
Job Site Inspection and Damage Claims.............................................................................1
Foundation .............................................................................................................................1
Rigging, Moving, and Skid Removal ...................................................................................2
Initial Installation .................................................................................................................2
Motor Mounting and Alignment for Field Mounted Motor .............................................2
Required Tools ......................................................................................................................3
Coupling Installation ............................................................................................................3
Coupling Removal.................................................................................................................5
Motor Mounting and Preliminary Alignment Procedure .................................................6
Shimless Motor Mounts........................................................................................................8
Coupling Final Alignment Procedure .................................................................................8
Storage and Holding Charge..............................................................................................11
Compressor Oil ...................................................................................................................11
Oil Charge............................................................................................................................11
Oil Heaters ...........................................................................................................................12
Liquid Injection Oil Cooling ..............................................................................................12
TX Valve Liquid Injection Cooling ...................................................................................16
IntelliSOC™ Injection Oil Cooling ...................................................................................17
Thermosiphon Oil Cooling .................................................................................................17
Economizer ..........................................................................................................................21
GForce Control Panel Installation Guide .........................................................................21
Control Power Wiring .........................................................................................22
Control Power Supply .........................................................................................22
Grounding.............................................................................................................22
General ..................................................................................................................24
GL SERIES SCREW
COMPRESSOR PACKAGES
SECTION 1 INSTALLATION
Introduction
This section contains information and procedures for installing the GL Series screw compressor
package.
The GL Series screw compressor package is factory assembled, wired, and leak tested. Installation
consists primarily of establishing refrigerant, water and electrical services to the package. Rigging,
installation, field wiring and mounting of customer supplied motors, and field piping is the responsibility
of the contractor and/or customer.
Compressor Package Identification
The Model number is explained below:
180 GL B
Model
180, etc.
GL Series
Duty
Blank – High Stage
B – Booster
E - Economized
This information, along with the FES contract number, is contained on the data label mounted on the
inside of the control panel door. When parts or service information are needed, the data from this label
should be included with the inquiry. There is a data plate located on the compressor that contains
information pertaining to the design of the compressor.
Job Site Inspection and Damage Claims
Cartons, boxes and all exposed components should be examined upon receipt at the job site. The
packing list should be checked to see that all listed components have been received.
Damage and shortage claims must be made by the consignee and the carrier should be notified
immediately so that an inspection and claim form can be completed. The FES Sales Administration
Department, York PA, should be notified of any damage or shortage claim.
Foundation
GL Series screw compressor packages are shipped mounted on wood skids, which must be removed
prior to installation. Since the screw compressor is internally balanced, no foundation mass is required
except that which is structurally required to handle the package weight. A level mounting surface is
required and the unit should be bolted to this surface after installation. Grouting may be necessary to
achieve satisfactory results. Elevated housekeeping pads are a good practice but are not required.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Document: GL-33
Revision: A
1 Effective: 04-08
Structural steel mounted units require grouting under the entire support base. Foundation floors or
elevated structures should be evaluated to determine that they do not have natural frequencies coincident
with compressor run speed or rotor pass gas pulsation frequencies. This is a separate analysis from
vibration transmission to adjacent structures.
Note: If the package is to be installed on a non-rigid foundation, specific isolation may be required.
Rigging, Moving and Skid Removal
The screw compressor package can be handled by crane or similar lifting device by placing lifting hooks
into the four (4) lifting lugs provided on the package. Adjustments to the rigging will be required to
allow for the package center of gravity, which can vary significantly if no motor is provided on the
package.
The package can be moved by forktruck using forks to push against and under the skids. Under no
circumstances should the forks be used to push against the oil separator, piping, legs, or compressor.
If the compressor package is lifted by crane the skids can be unbolted and removed prior to setting the
compressor on its foundation.
If the package is to be skidded into position the skids can be removed by using a 5 ton jack to lift one
end of the compressor package and unbolting the skid on that end. The skids should then be spread and
the compressor package lowered. Repeat this procedure for the other end.
Initial Installation
After the compressor package is in place it must be leveled by using a reliable bubble level on the
compressor mounting support angles to check both directions. This procedure was followed during the
initial assembly at the factory, and it will ensure the compressor package is properly positioned.
The suction strainer and discharge connection flanges are not to be used for leveling the package.
Factory mounted motors have been aligned, but alignment must be checked at startup.
Motor Mounting and Alignment for Field Mounted Motor
Shimless Motor Mounts
The screw compressor package is shipped with the shimless motor mounts attached to the pre-drilled
support angles.
The compressor hub of the coupling is mounted on the compressor shaft. The remainder of the coupling
is shipped loose.
Block and Shim Style Mounts
The screw compressor package is shipped with the motor support angles welded to the oil separator
support plates. The motor mounting blocks, shims, alignment bars with bolts, tie down bolts, lock
washers, flat washers, and shims are shipped loose. The motor mounting blocks are drilled and tapped.
The compressor hub of the coupling is mounted on the compressor shaft. The remainder of the coupling
is shipped loose.
Document: GL-33
Revision: A
Effective: 04-08 2
Figure 1-1: Flexible Disc Spacer Coupling
Required Tools
The following tools are required in addition to common hand tools:
A. Dial indicator, accurate and readable to 0.001 inches, with clamps for attaching the indicator to
the coupling hubs.
B. Micrometer
C. Feeler gauges
D. Torque wrench
E. Metric hex bit socket (6mm, 8mm & 10mm)
Coupling Installation
This compressor package is supplied with a flexible disc style coupling. This is a spacer type coupling
consisting of three pieces, tow hubs and a center member. The center member can be removed and
installed without the need for special tools. The disc design allows for low flexing forces and high
overload capacity. The compressor hub is a unique clamped style design using a B-LOC locking
assembly installed on the I.D. of the hub. This device provides a frictional force on the compressor shaft
and will transmit the torque supplied by the motor. The motor hub uses a conventional key to transmit
torque.
The procedure for installing the coupling is as follows.
A. Clean hub bores and shafts. Remove any nicks or burrs. Measure the bore and shaft diameters
to assure proper fit.
B. The compressor hub has a B-LOC locking assembly installed on the I.D. of the hub. The
device is supplied lightly oiled and ready for installation. When reinstalling a used unit, make
sure that all slits are aligned and the screws, taper, shaft and bore contact areas are lightly
oiled. Do not use Molybdenum Disulfide (e.g., Molykote, Never-Seeze or similar
lubricants) in any Locking Assembly installation.
Document: GL-33
Revision: A
3 Effective: 04-08
C. Install key on motor shaft and install motor hub.
D. Thoroughly clean the compressor shaft (Do not use grease or spray lubricant on the shaft or
on the contact areas of the B-LOC device). Install compressor hub with B-LOC assembly
onto the compressor shaft. Locate compressor hub so the correct “C” dimension is maintained
(Reference Figure/Table 1-2). The B-LOC assembly should be installed such that the
tensioning screws are flush with the face of the hub flange.
E. The procedure for tightening the tension screws must be followed exactly as outlined
below, or serious damage can result. Hand tighten all screws and visually confirm the hub is
aligned correctly. Use torque wrench and set it approximately 5% higher than specified
tightening torque Ts. Tighten locking screws in either a clockwise or counterclockwise
direction using only ¼ turns (i.e. 90°) until ¼ turns can no longer be achieved. Continue to
apply overtorque for two more passes. Reset torque wrench to specified torque Ts and check
all locking screws. No screw should turn at this point, otherwise repeat overtorque for two
more passes.
F. Install center member by inserting bolts from center member side of flange. Be sure that the
flat washers are properly installed on the disc packs. Tighten bolts uniformly until torque Tb is
met.
Coupling “C” “A” “B” “D” “E”

Compressor Package
Size (in) (in) (in) (in) (in)
180GL, 230GL, 290GL 52-262 3.25 6.62 3.00 2.88 4.50
400GL, 475GL, 565GL 52-312 3.75 7.81 3.38 3.38 5.25
52-312 4.20 7.81 3.38 3.38 5.25
675GL, 800GL
52-350 4.20 8.69 3.38 3.75 5.88
1025GL 3.75
52-350 4.20 8.69 4.25 5.88
(Horizontal H.S.)
1025GLB, 1210GLB, 3.75
52-350 4.20 8.69 4.25 5.88
1435GLB
1025GL, 1210GL, 1435GL 3.75
52-350 4.875 8.69 4.25 5.88
(Vertical H.S.)
1770GLB, 2110GLB 52-375 7.00 9.69 4.00 4.00 6.50
Figure/Table 1-2: Coupling Dimensions
Document: GL-33
Revision: A
Effective: 04-08 4
Coupling Removal
A. Remove bolts holding the disc packs to the motor and compressor hubs.
B. Loosen the setscrew above keyway on motor hub and slide hub back far enough so the center
member (with disc packs attached) can be removed through the shaft ends. Once the center
member is removed, the motor hub can be removed though the shaft ends.
C. Extreme care must be used when removing the compressor hub. Refer to Figure 1-3 for the
following steps.
D. Remove the tensioning screws from the B-LOC locking assembly. Transfer the required
number of screws into the jacking holes of the clamp collar (Item 1).
E. Some screws will contact the center collar (Item 3) and will only go in half way. Other screws
will go in further and are used to release the inner clamping collar (Item 2).
F. Start by releasing collar (Item 1) by progressively tightening the jacking screws that are in half
way. The screws will appear to be tight after only one pass of tightening without any
noticeable separation of the clamp collar. This is normal – continue to apply torque in a
clockwise or counterclockwise manner until the clamp collar springs loose.
G. Release the center collar (Item 3) by repeating procedure outlined above for item 1. The
screws for this procedure are the ones that screw in deeper.
H. Once the clamping collars are fully released from the center collar, the coupling and B-LOC
assembly can be removed together (There is no need to remove the B-LOC cartridge from the
coupling hub).
Figure 1-3: B-LOC Assembly
Document: GL-33
Revision: A
5 Effective: 04-08
Compressor Hub
Coupling
Size Shaft Dia. TS
Thread
(mm) NM (ft-lb)
262 60 M6 X 45 17 (12.5)
312 80 M6 X 45 17 (12.5)
80 M6 X 45 17 (12.5)
350
90 M8 X 60 40 (30)
375 110 M8 X 60 28 (21)
Table 1-4: Torque Specifications for Tensioning Screws
Coupling TB
Size NM (ft-lb)
52-262 40 (30)
52-312 55 (40)
52-350 130 (95)
52-375 176 (130)
Table 1-5: Torque Specifications for Coupling Bolts
Motor Mounting and Preliminary Alignment Procedure

A. Mount all four mounting blocks on the motor feet with the tube sleeve spacer inserted as
shown in Figure 1-6 or wrap the tie down bolts with 0.0625 inch shim stock. Install a 0.25
inch shim pack as shown and snug the tie-down bolt on each foot. Lift the motor and place it
on the motor support angles.
B. Remove the center spacer from the compressor coupling, if mounted. Mount the other
coupling half on the motor shaft. If difficulty is encountered while installing the hub, check
shaft and coupling hubs for burrs and fit key in both halves of the keyway. The key must have
a uniform tight fit in both the shaft and coupling hub keyway. DO NOT ATTEMPT to drive
either hub on either shaft because serious damage to the ball bearings may result.
Document: GL-33
Revision: A
Effective: 04-08 6
Figure 1-6: Motor Foot Mounting Typical
C. Refer to Table 1-7 for motor and compressor shaft gap requirements. If the lengths of the
motor and compressor shafts are such that the center member can be removed at the shaft gap
shown in Table 1-7, the motor can be mounted based on the shaft gap dimension. If the center
member cannot be removed with the gap shown, the motor must be positioned so that the
coupling hubs can be moved on their respective shafts to allow for removal of the center member
without moving the compressor or motor. In such cases the shaft gap will be greater than the
dimension shown in Table 1-7. Minimum shaft engagement for the hubs must be at least 90% of
hub length.
Compressor Min. Shaft Gap

Model (in.)
180GL - 290GL 3.50
400GL - 565GL 4.00
675GL, 800GL, 1025GL 4.50
1025GLB - 1435GLB 4.50
1025GL - 1435GL
5.25
(Vertical, H.S.)
1770GLB, 2110GLB 7.0
Table 1-7: Required Motor to Compressor Shaft Gap
D. Check motor height. If the motor is too high relative to the compressor, remove shims as
required. Four alignment brackets with bolts are provided. The brackets should be welded to
the motor support angle as shown in Figure 1-6. The alignment bracket will facilitate
positioning of the motor for angular alignment. All motor assemblies must have permanent
means of jacking the motors into position for vertical alignment.
E. Rough align for both parallel as well as angular alignment by using a dial indicator.
F. Once rough alignment is complete, weld the motor mounting blocks on the motor support
angle. Weld one block at the rear, then weld the diagonally opposite block. Next weld the
other rear block and then the remaining front block. Weld all four sides of the mounting block,
Document: GL-33
Revision: A
7 Effective: 04-08
welding approximately one inch at the corners. Weld one side at a time in the above sequence
as quickly as possible. The purpose of this procedure is to prevent distortion. Allow to cool to
room temperature. Dowelling of the motor is not required.
G. Remove the tie down bolts and the tube sleeve spacers or shim stock wrapping around the tie
down bolts. Install the tie down bolts again. Final alignment procedure must be performed
before the package is ready for operation.
Note: If shimless motor mounts are used, place motor onto mounts and follow the alignment
procedure only as outlined above. Adjustment of the shimless motor mounts is outlined in the
following section.
Shimless Motor Mounts
Shimless motor mounts are available for all GL Series compressor packages. Mounting is similar to
conventional block motor mounts except that the shimless motor mounts are bolted to the angle, not
welded. Each shimless motor mount has provisions for jacking the motor horizontally and vertically.
Horizontal adjustment is accomplished by turning the lateral adjustment bolts as required.
Vertical adjustment is accomplished by first removing the top hold down nut, and loosening the bottom.
Once this is done, a metric wrench can be applied to the top of the bolt. Turning the bolt clockwise will
raise the motor, while turning the bolt counter-clockwise will lower it. One-quarter turn will raise or
lower the motor foot 0.010 inches.
Note: An extension bar may be required for use on the wrench to exert enough force to raise the
motor.
Figure 1-8: Shimless Motor Mounting (SMM)
Coupling Final Alignment Procedure

To ensure satisfactory performance and life from the compressor shaft seal and the motor and
compressor bearings, a final alignment procedure must be performed. Whether the coupling was aligned
at the factory or field installed, it must have a final alignment done after the package is installed and
piped. Improper piping procedures can cause stress on the compressor casing making alignment
impossible. The coupling must have a final alignment check prior to start up and again after a few hours
of operation. This "HOT" check after several hours of operation is required. Another check should be
made after one week of operation. The procedure used for final alignment is as follows:
Document: GL-33
Revision: A
Effective: 04-08 8
A. Remove the coupling guard. Check the runout of the compressor hub. With a dial indicator
base attached to the compressor, and the dial indicator reading off the hub rim, rotate the
coupling assembly 180 degrees. Note the runout. Rotate the assembly another 180 degrees to
the original position. Adjust the dial indicator to read the hub face. Rotate the assembly and
note the runout. Repeat this procedure for the motor hub. A runout in excess of 0.003 inches
should be reported to the FES factory.
B. Check for motor soft feet. With the indicator base attached to the motor support angles, and
the dial indicator reading off the top of a motor foot, loosen the tie down bolt and note the
indicator reading. Any movement in excess of 0.002 inches must be corrected using shims if
mounting blocks are used, or by adjusting the vertical adjustment bolt if shimless motor
mounts are used. Repeat this procedure with the other three feet to ensure that each motor foot
is in solid contact with the base.
NOTE: BE SURE TO MINIMIZE THE AMOUNT OF SHIMS USED. Example: If a 0.005 inch, a
0.003 inch, and a 0.002 inch were used, then replace them with one shim 0.010 inch thick.
C. With the coupling assembled, mount the dial indicator on the compressor hub and take an
indicator reading on the coupling hub as shown in Figure 1-9. Due to the span of the spacer
coupling, indicator sag may be significant, and the indicator readings must be corrected to
include the sag.
1. To eliminate confusion, turn the coupling in only one direction while taking readings.
2. Take five readings, 0 degrees, 90 degrees, 180 degrees, 270 degrees, and 360 degrees on both
the periphery (for parallel) and face (for angular). The indicator should return to its original
position after the coupling has been rotated 360 degrees.
NOTE: Sleeve bearing motors or any motor with measurable play must be monitored with a dial
indicator to ensure that no motor shaft axial movement takes place when face readings are taken. If
the motor is fitted with sleeve bearings, the motor's magnetic center must be determined from the
manufacturer's recommendations or by scribing the uncoupled motor's running position at a suitable
place on the shaft. The shaft must be held on its magnetic center when aligning the motor. This can
be done by clamping the two hubs with a 5/8 inch diameter all thread rod and double nuts.
D. Align the motor so that the total indicator reading (TIR) on the periphery and the face does not
exceed 0.002 inches misalignment. With reference to Figure 1-10, the following applies to all
screw compressor applications.
1. Align the motor first for angular in elevation. This alignment is adjusted with shims to
provide a maximum 0.002 inch TIR at the top.
2. Align the motor next for parallel in elevation. This alignment is also adjusted with shims
and should be a maximum 0.002 inch higher than the compressor.
3. Align the motor angular in plan next.
4. Finally, align the motor parallel in plan.
E. Record the alignment readings.
F. Verify that the distance between the coupling hub faces ("C" from Figure/Table 1-2) is correct.
Also the shaft gap should be checked to be in accordance with Table 1-7.
NOTE: When the motor is field mounted the customer is responsible for aligning the motor as
prescribed on pages 2 through 8. The FES representative will check the final alignment before
starting the compressor package to ensure the motor was aligned properly.
Document: GL-33
Revision: A
9 Effective: 04-08
Figure 1-9: Typical Dial Indicator Mounting
Figure 1-10: Types of Coupling Misalignment
G. Run the compressor at least two hours to allow the package to reach its normal operating
temperature. Stop the compressor and immediately check the alignment (keep the coupling
installed). The motor must be aligned so that the TIR on the periphery and face does not
exceed 0.002 inch with the package at its normal operating temperature. This check will be
done by an authorized FES Service Representative at start up.
H. Install the coupling guard.
Document: GL-33
Revision: A
Effective: 04-08 10
Storage and Holding Charge
GL Series compressor packages are shipped with a holding charge of dry nitrogen to prevent
contaminants from entering the package following the factory pressure test and evacuation. Since the
package is sealed, it is suitable for short-term storage before installation. Caution should be exercised
when opening the package to safely release the nitrogen charge.
When packages are stored, they are to be kept in a clean dry location. If packages are to be stored for
prolonged periods of time the package should be checked to be sure a positive nitrogen pressure is
maintained. The factory should be consulted for specific recommendations when extended storage
(greater than two months) is expected.
Care should also be used to protect the microprocessor and sensors from damage during storage.
Compressor Oil
The oil charge shipped with the compressor package was selected to meet the application requirements
as supplied at the time of order. Questions concerning suitability can be answered by referring to FES
Document ENG-5 "FES Refrigeration Oils-Properties and Applications" and Document ENG-6 "FES
Recommended Oil Specifications."
Oil Charge
GL Series compressor packages have sight glasses for observing oil level. The normal fill level is to the
top of the upper sight glass. For separators with two sight glasses, the normal operating level is the
center of the lower sight glass. For separators with three sight glasses, the operating level is the center
of the middle sight glass. There are two methods for adding oil to the oil separator. If the compressor
package has had the refrigerant charge removed, the oil fill can be opened to atmosphere and oil poured
or pumped into the oil separator. If the compressor is charged with refrigerant, a pressure type pump
must be used to add oil. This can be accomplished by attaching a refrigerant duty pressure hose to the
oil charging connection, located on top of the oil separator, and using a pressure type pump to pump oil
into the separator.
Devices used to trap and return oil must be filled with oil prior to compressor package operation. The
same pressure type pump and hose can be used for this.
The compressor package also has an oil level sight glass located near the bottom of the separator on the
discharge end of the package. This sight glass should remain empty during normal operation. If an oil
level is observed during operation, it is an indication of liquid refrigerant carryover or a malfunction in
the line returning oil to the compressor and primary side of the separator.
The approximate oil charge for the compressor packages is shown in Table 1-11 below.
Document: GL-33
Revision: A
11 Effective: 04-08
Oil Charge
Separator Size (gallons)
Liq. Inj. TSOC
24" Dia. X 120" WSL 85 105
30" Dia. X 120" WSL 115 135
30" Dia. X 144" WSL 130 150
36" Dia. X 144" WSL 185 205
36" Dia. X 146-1/4" WSL 270 300
42" Dia. X 146-1/4" WSL 190 210
42" Dia. X 162" WSL 210 230
48" Dia. X 162" WSL 257 277
Table 1-11: Approximate Oil Charge

Oil Heaters
Standard GL Series compressor packages are equipped with two 1200 watt oil heaters mounted on the
oil sump. These heaters are sized to maintain a safe minimum oil temperature during a shut down cycle
in normal indoor ambient conditions. If the package is installed in an environment other than heated
indoors, these heaters will not provide sufficient heat to allow the oil to reach a safe compressor start
temperature. These low ambient conditions require special consideration and the FES factory should be
consulted before installation.
The heaters operate only when the compressor is in the off cycle. The heaters are thermostatically
controlled and are energized any time 120 volt control voltage is applied to the package and the
compressor is not operating. To prevent the heaters from being energized, 15 amp circuit breakers 2CB
and 3CB must be switched to the off position.
NOTE: Do not apply control power without oil in the oil separator unless oil heater circuit breakers
are switched off. Failure to observe this precaution will result in the destruction of the heater
elements.
Liquid Injection Oil Cooling
High pressure oil is used in the screw compressor to lubricate the bearings and to cool the compressor
discharge gas. The oil also seals the space between the rotors to prevent "blow-back" and provides
muffling of the noise caused by discharging gas. By injecting high pressure refrigerant liquid into the
compressor, the gas-oil mixture is cooled by the latent heat of the refrigerant liquid, thus omitting the
need for a separate externally cooled oil cooler.
The proper operation of liquid injection oil cooling is dependent on having an uninterrupted supply of
high pressure liquid refrigerant available at all times. Several methods of ensuring this are available.
Whatever method is used, the liquid refrigerant delivery line must be adequately sized and the liquid
source must retain a reserve liquid supply beyond other system needs so that an additional five minute
liquid refrigerant supply is available for liquid injection feed.
If the system condensing pressure is less than 100 psig or greater than 225 psig the application should be
referred to the FES factory.
There are three suggested methods for meeting the criteria set forth in the proceeding paragraphs. The
first of these is shown in Figure 1-12. This arrangement uses a float switch to close the main plant
Document: GL-33
Revision: A
Effective: 04-08 12
liquid solenoid valve if the receiver level drops below the necessary level to supply the compressor
liquid injection feed requirements.
The second method utilizes a separate liquid injection receiver that has been sized to maintain a liquid
level sufficient to maintain a five-minute supply for compressor oil cooling. This method is illustrated
in Figure 1-13.
The third arrangement uses a receiver with a second liquid injection feed dip tube, located below the
main plant supply dip tube. The compressor will receive a liquid injection supply even after the main
system supply is below its minimum operating level. This arrangement is shown in Figure 1-14.
The proper line size for delivery of the liquid injection supply is very important. Also the liquid
injection supply volume must be adequate. Table 1-15 provides the recommended supply volume and
line sizes. The supply volume is based on a nominal five minutes supply of liquid to the compressor.
The liquid injection oil cooling piping on the compressor package is self contained and needs only to be
connected to a source of high pressure liquid as described in the proceeding paragraphs. The specially
charged thermostatic expansion valve bulb must be installed in thermowell provided on the compressor
discharge (being careful not to damage the connecting capillary tube and sensing bulb). Refer to Figure
1-16 for typical compressor package liquid injection piping.
Figure 1-12: Liquid Injection Feed Arrangement Number 1
Document: GL-33
Revision: A
13 Effective: 04-08
Document: GL-33
Revision: A
Effective: 04-08 14
LIQUID INJECTION OIL COOLING REQUIREMENTS
HIGH STAGE BOOSTER

SURGE VOLUME LINE SIZE SURGE VOLUME LINE SIZE
FES (CU. FT.) (IPS SCH. 80) (CU. FT.) (IPS SCH. 80)
MODEL REFRIGERANT
R-717 2.8 ¾ 0.5 ½
180GL
R-22 N/A N/A N/A N/A
R-717 3.6 ¾ 0.6 ½
230GL
R-717 4.3 1 0.7 ½
290GL
R-717 5.5 1 0.9 ½
400GL
R-717 6.3 1 0.9 ½
475GL
R-717 7.5 1 1.2 ¾
565GL
R-717 8.9 1-¼ 1.4 ¾
675GL
R-717 10.5 1-¼ 1.6 ¾
800GL
R-717 13.4 1-½ 2.1 ¾
1025GL
R-717 15.9 1-½ 2.5 ¾
1210GL
R-717 18.8 1-½ 2.9 ¾
1435GL
R-717 36.4 2 3.5 1
1770GL
R-717 43.3 2 4.2 1
2110GL
Table 1-15: Liquid Injection Feed Requirements
Document: GL-33
Revision: A
15 Effective: 04-08
Figure 1-16: Typical GL Series Liquid Injection Arrangements
TX Valve Liquid Injection Cooling

For single high stage compressor applications, the thermal expansion valve is externally equalized to a
predetermined constant pressure intermediate to the discharge and suction pressure. This pressure is
maintained by the use of an outlet pressure regulating valve. A small amount of discharge gas is
metered through the pressure regulator and returned to suction.
For dual high stage compressor packages, one outlet pressure regulator is used in conjunction with the
two TX valves to provide a source of constant pressure at the TX valve equalizer port. Discharge gas is
used in the same manner as on a single high stage compressor package.
For booster applications, the high pressure gas connection must be taken from a high side source. It is
the same as single high stage in all other aspects.
For dual booster compressor arrangements, the high pressure gas connection is taken from a high side
source. It is the same as dual high stage in all of the aspects.
For two-stage compressor packages, only the high stage compressor requires liquid injection. If the
booster can run by itself, liquid injection is required for the booster.
NOTE: Some compressor sizes employ a dual TX valve arrangement for liquid injection feed. This
arrangement varies depending on compressor size. Piping schematics supplied with the compressor
package, along with the Operation section of this manual, should be referred to for operating details.
Document: GL-33
Revision: A
Effective: 04-08 16
IntelliSOC™ Liquid Injection Cooling
IntelliSOC™ liquid injection does not require a constant pressure source like a TX valve. IntelliSOC™
provides the same function as a TX valve by only monitoring the compressor discharge temperature.
The control panel will send a 4-20mA signal to the IntelliSOC™ control valve to regulate the discharge
temperature.
Thermosiphon Oil Cooling
Thermosiphon oil cooling utilizes liquid refrigerant from the condenser to remove heat from the oil.
Liquid refrigerant is fed by gravity to the oil cooler where it is vaporized by the warm oil. The
refrigerant vapor returns to the condenser where it is recondensed. The oil heat is rejected directly to the
condenser and therefore requires no external cooling fluid or compressor capacity.
Many variations are possible in constructing a suitable thermosiphon oil cooling system, but the basic
system will always include a liquid refrigerant receiver or reservoir at condensing temperature and
pressure and a shell and tube oil cooler (400 psig DWP shell side and 300 psig tube side). A typical
arrangement for thermosiphon oil cooling is shown in Figure 1-17.
The following are general guidelines based on good engineering practice and experience. Every
installation is unique and therefore will require specific design consideration. It is the responsibility of
the system designer and/or installer to determine how these and other guidelines shall apply.
NOTE: Refer to the FES Engineering Data Sheet for the oil cooler heat of rejection (OCHR) specific
to the applicable model and design operating conditions.
A. The oil cooler must be provided with at least a five minute uninterrupted liquid refrigerant
supply, independent of all other system liquid requirements and regardless of system operating
status. The receiver should be sized such that it will operate at a level of half full at the design
minimum supply volume (see Table 1-18). It is strongly recommended that an independent
auxiliary receiver (as shown in Figure 1-17) be installed to provide liquid refrigerant to the oil
cooler. This vessel should be designed and installed in accordance with ASME, ASHRAE, and
IIAR codes or standards. The auxiliary receiver shall be fitted with a dual relief valve
assembly. A drain connection should be provided at the lowest level in the vessel.
Document: GL-33
Revision: A
17 Effective: 04-08
Figure 1-17: Typical Thermosiphon Oil Cooler Piping
B. If isolation valves are installed in the refrigerant lines to or from the oil cooler, then a suitable
pressure relief device must be incorporated so as to safely relieve excess pressure from the
refrigerant-side of the cooler due to hydrostatic pressure, fire, or some other abnormal
condition.
C. Total net positive liquid supply head to the cooler must be sufficient to overcome pressure
losses in the cooler, pipes, valves, and fittings at the design circulation rate. The oil coolers
have been designed such that six to ten feet of head is sufficient for most applications if lines
are properly sized.
NOTE: Excessive high head (over 25 feet) can cause elevated saturation temperatures resulting in
performance loss. On such installations, a throttling valve must be installed on the inlet piping.
D. As a general rule, the liquid supply line from the condenser to the receiver should be sized for a
maximum velocity of 100 ft/min (see Table 1-19). The vapor return line from the receiver to
the condenser should be sized for a maximum pressure loss of 0.2 psid/100ft for R-717 and
0.15 psid/100ft for R-22 (see Table 1-20). The liquid supply line to the thermosiphon oil
cooler and the liquid/vapor return line from the cooler should be sized per Table 1-21.
Document: GL-33
Revision: A
Effective: 04-08 18
OCHR R-717 R-22
(MBH) (cu.ft.) (cu. ft.)
50 0.2 0.8
100 0.5 1.6
300 1.4 4.7
600 2.8 9.4
900 4.2 14.0
1200 5.6 18.7
1500 7.1 23.4
2000 9.4 31.2
2500 11.8 39.0
3000 14.1 46.8
3500 16.5 54.6
4000 18.8 62.4
4500 21.2 70.2
5000 23.5 78.0
Based on 5 min., 95°F Saturated Liquid
Table 1-18: Minimum Liquid Supply Volume
R-717 OCHR R-22 OCHR

Pipe Size
(MBH) (MBH)
½ 173 52
¾ 320 96
1 531 160
1-¼ 947 285
1-½ 1305 393
2 2478 747
2-½ 3529 1063
3 5451 1643
Based on 100 ft/min., 95°F Saturated Liquid
Table 1-19:Maximum Capacities for Liquid Line from Condenser to Receiver
Document: GL-33
Revision: A
19 Effective: 04-08
R-717 OCHR R-22 OCHR
Pipe Size
(MBH) (MBH)
1-¼ 136 44
1-½ 206 66
2 400 128
2-½ 638 204
3 1128 361
4 2305 737
5 4114 1318
6 6651 2128
8 13615 4354
Based on 95°F Saturated Vapor
Table 1-20: Maximum Capacities for Vapor Line from Receiver to Condenser
OCHR LIQ. LIQ/VAP

(MBH) IN OUT
Up to 60 ¾ 1-½
61 to 300 1 2
301 to 600 1-½ 3
R-717
601 to 900 2 4
901 to 1500 3 5
1501 to 2700 3 6
2701 to 4800 4 8
Up to 60 1 2
61 to 300 2 3
301 to 600 3 4
R-22
601 to 900 4 6
901 to 1500 4 8
1501 to 2700 6 10
2701 to 4800 8 12
Based on 95°F Saturated Condensing Temperature
Table 1-21: Thermosiphon Line Size Requirements To/From Oil Cooler
Document: GL-33
Revision: A
Effective: 04-08 20
E. Horizontal liquid supply lines to the thermosiphon coolers shall be properly vented to allow
generated gas to escape, or be arranged to provide sewer flow into the cooler allowing
generated gas to migrate back to the liquid source without obstructing liquid flow.
F. R-717 systems require oil to be regularly drained from the lowest point of each system.
NOTE: The thermostatic valve element is installed in the valve. The element is to be immersed in oil
for at least two minutes prior to exposure to ammonia.
Economizer
The economizer option is not intended for use on part load or unsteady load applications. When applied
to full steady load applications it provides liquid subcooling with little compressor capacity or bhp
penalty. However, below 60% to 70% of compressor capacity the economizer is ineffective and
requires additional controls for operation. The economizer option should not be applied to systems with
widely fluctuating loads or frequent defrost cycles. Two typical economizer systems are illustrated in
Figure 1-22.
Figure 1-22: Two Common Economizer Systems
GFORCE CONTROL PANEL INSTALLATION GUIDE

NOTE: This section must be read in its entirety prior to proceeding with the installation of the
control panel.
The following instructions are intended for use by qualified, competent personnel, experienced in the
installation and wiring of electrical control panels. This installation guide provides the basic instructions
which must be followed when installing the GForce Control Panel. It is the responsibility of the installer
to comply with the requirements of all codes and standards applicable to the job site and facility, and all
applicable State and Local laws, rules, and regulations when installing this control panel.
Document: GL-33
Revision: A
21 Effective: 04-08
CAUTION: Failure to install the panel in accordance with the instructions contained in this guide
will void all warranties for this product, and may result in significant damage to the control panel
and/or the associated equipment. In addition, improper installation may result in serious personal
injury or electrocution.
A. Control Power Wiring
The gauge of the main power wiring to the panel (L1 and 102) must be sized to meet or exceed the
values listed below.
GForce Single
(w/one 1200W oil heater) ....................................................................... #10 AWG
GForce Single
(w/two 1200W oil heaters)...................................................................... #10 AWG
GForce Single
(w/three 1200W oil heaters)...................................................................... #8 AWG
GForce Dual
(w/three 1200W oil heaters)...................................................................... #8 AWG
NOTE: A separate ground wire is also required for each panel and must be at least #12 AWG
copper.
B. Control Power Supply
FES recommends the 115 VAC (+ 10 volts) control power be supplied from a separate control power
transformer sized and installed in accordance with FES Field Wiring and Starter Specification ENG-3.
The neutral of the secondary (115 VAC) side of the control voltage transformer must be grounded. This
ground should run to the same source (ground bus) as the microprocessor.
Never run control wiring in conduit or raceways containing power wiring (i.e. motor supply leads, 3-
phase supplies, etc.)
C. Grounding
On compressor packages, the compressor motor must be grounded per FES Field Wiring and Starter
Specification ENG-3 using a separate copper conductor sized in accordance with all electrical codes
applicable to the job site. Conduit grounds are not acceptable.
The oil pump motor must also be grounded per FES Specification ENG-3 using a separate copper
conductor sized in accordance with all applicable electrical codes. Conduit grounds are not acceptable.
The GForce control panel must be grounded to the same ground or to the voltage transformer using a
separate single uninterrupted copper conductor sized per the power wiring guidelines listed above the
installed per the applicable FES field wiring diagrams. Conduit grounds are not acceptable.
The starter panel and the control voltage transformer must be grounded to a true earth ground (i.e. one
supplied by the utility company). A separate copper conductor is recommended.
NOTE: Refer to Figure 1-23 for the correct grounding method. Figures 1-24 and 1-25 are examples
of typical improper grounding techniques.
Document: GL-33
Revision: A
Effective: 04-08 22
Figure 1-23: Proper Grounding
Figure 1-24: Improper Grounding – “Daisy Chaining”
Figure 1-25: Improper Grounding – Grounding Interconnections prior to Starter Panel
Document: GL-33
Revision: A
23 Effective: 04-08
D. General
DO NOT use the control panel as a junction box. The only field wires that should enter the panel are
those required for its operation.
DO NOT mount any contactors, switches, or any other inductive loads on or in the control panel.
Any inductive devices (solenoids, contactors, etc.) installed within 15 ft. wire run and connected to the
GForce, must be suppressed with a properly installed Metal Oxide Varistor or MOV (FES Part No. 725-
000330-000). The MOV should be installed directly to the leads of the device and as close to the device
as possible as shown in Figure 1-26.
All AC connections should enter the panel as close to their termination point as possible. AC wiring
must be prevented from making direct or incidental contact with the circuit board or any of the low
voltage connection cables. FES GForce panels are designed with most, if not all, of the control voltage
connections located at the top of the panel. All field wiring should be contained in the top and left
portion of the panel and away from potentially sensitive areas surrounding the General Purpose I/O
board.
Any additional DC devices (e.g. process temperature input) must be connected using shielded cable with
the shield grounded at the device end only.
All pressure transducer should have their shield-wire cut off.
Figure 1-26: MOV Installation
Document: GL-33
Revision: A
Effective: 04-08 24
GL SERIES SCREW
COMPRESSOR PACKAGES
SECTION 2 PACKAGE OPERATION
TABLE OF CONTENTS
PAGE
Introduction ...........................................................................................................................1
Design Limitations ................................................................................................................1
Compressor ............................................................................................................................2
Compressor Lubricating System .........................................................................................2
Compressor Oil Separating System ....................................................................................2
Compressor Oil Cooling Systems ........................................................................................4
Single Port Liquid Injection Oil Cooling ............................................................................4
Dual Port Liquid Injection Oil Cooling ..............................................................................5
IntelliSOC™ Liquid Injection Oil Cooling.........................................................................6
Jordan Valve Liquid Injection Cooling ............................................................................10
Outlet Pressure Regulating Valve Adjustment ................................................................10
Compressor Hydraulic System (Fixed VI) .......................................................................10
Compressor Hydraulic System (Variable VI) ..................................................................12
GL SERIES SCREW
COMPRESSOR PACKAGES
SECTION 2 PACKAGE OPERATION
Introduction
This section provides information for properly operating the GL Series screw compressor package. The
package systems covered in this section include the lubricating, oil separating, oil cooling, and hydraulic
systems.
NOTE: This section must be read and understood prior to startup or operation of the package.
Design Limitations
The GL Series screw compressor packages are designed to operate within the limits shown below:
General Design Limits

Discharge
Maximum Pressure .......................................................................................................................................................................... 270 psig
Maximum Temperature ...................................................................................................................................................................... 225 °F
Suction
Maximum Pressure at 100% Capacity (2.6 Vi) ............................................................................................................................. 103 psig
(3.6 Vi) ............................................................................................................................... 45 psig
(4.8 Vi) ............................................................................................................................... 15 psig
(5.5 Vi) ................................................................................................................................. 5 psig
Oil
Minimum Temperature ........................................................................................................................................................................ 90 °F
Maximum Temperature ...................................................................................................................................................................... 155 °F
Liquid Injection
Minimum Liquid Supply Pressure .................................................................................................................................................. 100 psig
General Operating Parameters

Discharge Pressure Cutout
R-717 High Stage Unit .................................................................................................................................................................... 225 psig
R-22 High Stage Unit ...................................................................................................................................................................... 270 psig
Booster Unit ...................................................................................................................................................................................... 65 psig
Discharge Temperature Cutout
Liquid Injection Units ........................................................................................................................................................................ 175 °F
Externally Cooled Units ..................................................................................................................................................................... 225 °F
Suction Pressure Cutout
Set to Saturated Pressure Corresponding to 10 °F
Below Suction Setpoint.
Oil Pressure
Operating Pressure, Above Discharge .............................................................................................................................................. 40 psig
Maximum Pressure, Above Discharge ............................................................................................................................................. 72 psig
Oil Temperature - Normal Operating
Externally Cooled Units ..................................................................................................................................................................... 130 °F
Liquid Injection Cooled Units............................................................................................................................................................ 150 °F
Oil Temperature Cutouts
Upper ............................................................................................................................................. (Liquid Injection / IntelliSOC) 175 °F
Upper ................................................................................................................................................................ (External Cooling) 155 °F
Lower .................................................................................................................................................................................................... 90 °F
Oil Sump Temperatures
R-717 Minimum Above Saturated Discharge Temperature ................................................................................................................ 20 °F
R-22 Minimum Above Saturated Discharge Temperature .................................................................................................................. 30 °F
Maximum Cutout ............................................................................................................................................................................... 225 °F
Table 2-1: Operating Limitations

Document: GL-2
Revision: G
1 Effective: 01-11
Compressor
The FES GL Series screw compressor is a positive displacement, helical-rotor axial flow compressor
designed for use with high pressure refrigerants. The compressor contains the following major features.
A. The compressor casting is high grade low porosity cast iron precision machined for minimal
clearance about the periphery of the rotors.
B. Two intermeshing male and female rotors machined from steel. The male rotor has five lobes and
drives the female rotor which has six lobes.
C. Duplex angular contact ball bearings and a balance piston are used to handle thrust loads. Radial
bearings are steel backed babbit lined sleeve bearings.
D. The mechanical shaft seal is a single carbon seal lubricated by supply oil which is cooled and
filtered.
E. Capacity control from 10% to 100% using a slide valve assembly.
F. Shaft rotation is CLOCKWISE facing the compressor shaft.
Compressor Lubricating System
The lubricating system of the GL Series compressor package performs the following major functions:
A. Provides lubrication to the bearings and mechanical shaft seal.
B. Provides motive force to move the unloader piston.
C. Provides oil to the balance piston which adds to the life of the bearings.
D. Provides compressor cooling.
E. Quiets compressor noise and reduces vibration.
F. Creates an oil seal between the rotors preventing rotor contact and gas bypassing.
Oil for the compressor bearings, shaft seal, and capacity control is supplied by an oil pump. Oil from
the separator is delivered through a strainer to the pump suction where it is pumped through an oil filter
to the oil header to be delivered to the compressor. Injection oil is supplied to the compressor by
positive gas differential pressure. Injection oil is split from the pumped oil after the strainer and before
the pump suction. A differential pressure regulator is utilized to control oil pressure to bearings, seal,
and capacity control by returning overfeed to the oil separator. The regulator reference location is
located near the compressor to minimize piping losses on the compressor oil pressure. If external oil
cooling is used, the pump pulls the oil through the cooler before pumping it through the oil filter.
Injection oil is diverted from the main compressor flow after the cooler and before the pump.
Compressor Oil Separating System
Because GL Series compressors use oil to cool, seal and lubricate, oil becomes mixed with the
refrigerant gas and must be separated from the refrigerant stream before entering the rest of the
refrigerating system. FES uses a highly efficient two stage oil separator design that removes almost all
of the oil from the refrigerant. The first stage removes over 99% of the entrained oil and acts as a
reservoir for the oil pump. Vertical separator designs have a stainless steel mesh pad in the first stage.
The refrigerant gas entrained oil mist is separated in the second stage. The second stage utilizes
coalescing elements to agglomerate the oil mist into droplets which can be accumulated. The oil is then
removed via a line from the secondary side of the separator to a port on the suction strainer. The rate of
return of the oil from the secondary side is controlled by a needle type regulating valve.
Document: GL-2
Revision: F
Effective: 09-10 2
The oil separator is an FES exclusive design with a guarantee on oil usage. Two or three sight glasses
are provided to ascertain oil level in the first stage. The second stage is provided with a manway to
allow service on the separator. A sight glass is provided to determine oil level in the secondary side.
This sight glass should remain empty during normal operation. If an oil level is maintained while
operating then the oil return system or the compressor are in need of service. The Maintenance section,
Section 5, of this manual should be referred to for instructions. See Figure 2-1 and Figure 2-2.
Figure 2-1: Typical Horizontal FES Oil Separator Schematic
Document: GL-2
Revision: G
3 Effective: 01-11
Figure 2-2: Typical Vertical FES Oil Separator Schematic
Compressor Oil Cooling Systems

The GL Series compressor packages can be equipped with various oil cooling arrangements. Among
these are liquid injection or externally cooled by a water cooled oil cooler or by a thermosiphon oil
cooler. Oil cooling is provided to maintain oil at a constant temperature range as recommended in Table
2-1. The cooling systems are self controlled and automatically adjust for compressor loading and
unloading.
Single Port Liquid Injection Oil Cooling
The single port liquid injection arrangement is designed to deliver refrigerant to one factory determined
liquid injection port on the compressor. The port is selected based on design conditions so that optimum
performance is provided during operation. The functional description of each case is is described below,
and illustrated in Figure 2-3.
For case 1, the liquid solenoid valve (3) is opened when the compressor is operating. This allows
refrigerant liquid feed to the thermal expansion control valve (5) so that the compressor discharge and
oil temperature can be controlled. The control valve (5) has a sensing bulb (9) inserted into the
compressor discharge gas stream that causes the valve to modulate the amount of refrigerant introduced
into the compressor. As the oil cooling load changes due to changing system requirements, the control
valve (5) modulates to maintain constant discharge and oil temperatures.
Case 2 operates in the same manner as case 1, except a refrigerant bypass line and hand control valve
(B) are supplied. This bypass line is supplied in cases where the oil cooling load is slightly greater than
the available capacity of the automatic control valve (5). Because the excess load does not warrant a
Document: GL-2
Revision: F
Effective: 09-10 4
larger or second control valve, a bypass is used. The bypass is normally open and the automatic control
valve (5) is allowed to modulate to control the major portion of the heat load.
Case 3 is the same as case 1, except two control valves (5 and 10) are used in parallel to provide
refrigerant feed control to the liquid injection cooling for the compressor. The dual arrangement is used
because one valve could not provide enough capacity or could not cover the wide range of cooling
requirements without performing erratically.
Case 4 is the same as case 3, except that a bypass is provided. The bypass performs the same function
as explained for case 2. The bypass is open for normal operation.
Dual Port Liquid Injection Oil Cooling
Because it is possible to operate at different suction conditions to suit changes in system operating
requirements, a choice of two liquid injection ports is available so that compressor performance is
maximized. As illustrated in Figure 2-4, the operation is the same as discussed for single port operation
(refer to previous cases 1 through 4 for operational details), except that a manual selection of liquid
injection port must be made to match the suction operating level. A change in liquid injection port
selection is necessary only if the compressor is expected to run for extended periods of time at a
different than usual operating condition.
The two liquid injection ports are H1 (Low Vi) and H2 (High Vi).
Figure 2-3: Single Port Liquid Injection Oil Cooling
Document: GL-2
Revision: G
5 Effective: 01-11
Figure 2-4: Dual Port Liquid Injection Oil Cooling
IntelliSOCTM Liquid Injection Cooling

The IntelliSOCTM valve station uses a motorized control valve in lieu of the conventional Sporlan
thermostatic expansion valve. Discharge temperature is sensed by a temperature probe located in the
compressor discharge pipe. Refer to Figure 2-5 for an operational schematic. The control panel reads
the temperature and sends a 4-20mA signal to the IntelliSOCTM control valve. The valve will modulate
automatically to maintain desired temperature. Single and dual port operation is the same as for TX
valve stations. Follow the procedure below to set up the IntelliSOCTM Valve for operation.
Figure 2-5: IntelliSOC™ Liquid Injection Oil Cooling
Document: GL-2
Revision: F
Effective: 09-10 6
First reset the valve to the manufacturers default settings:
1. Turn off power to the valve.
2. Press and hold the “UP” and “DOWN” arrows at the same time, refer to Figure 2-6.
3. Apply power to the valve while the “UP” and “DOWN” arrow keys are being pressed.
4. Release the “UP” and “DOWN” keys.
5. If the valve is operating correctly, the display will be alternately flashing between a “CA” message
and an “A1” message. All of the parameters except one have been set at this time. (The appearance
of the “A1” message indicates the parameter has not been set.)
The remaining parameter must be set at this time:
1. Depress the “ROUND” key and hold it for two seconds (This process provides access to the valve
operating.
2. Depress the “UP” key until the “i10” message is visible on the screen.
3. Press the “ROUND” key to enter the “i10” screen. The “i10” is used to enter the password that is
required to gain access to the protected settings of the valve. This parameter is set to a “0” by the
factory reset which was performed earlier.
4. Press the “UP” or “DOWN” arrow keys as needed until the “i10” password setting is an “11”.
5. Press the “ROUND” button key to return to the parameter list display where the “i10” message will
once again be displayed.
6. Press the “UP” or “DOWN” arrow keys as needed until the “i26” message appears on the screen.
7. Press the “Round” key to enter the “i26” screen set. The initial setting for the i26 parameter after a
parameter reset is a “00”.
8. Press the “UP” arrow key to change the “00” setting to a setting that is appropriate for this valve /
actuator combination*:
01 = ICM20 with ICAD 600 Actuator

* The ICM number can be found on the expansion valve and the ICAD number can be found on the
expansion valve motor.
Document: GL-2
Revision: G
7 Effective: 01-11
9. Press the “ROUND” key to return to the operating parameters list for the valve. The i26 message
should be displayed at this time.
10. Press and hold the “ROUND” key for two continuous seconds to return the valve to normal
operating mode.
11. The display on the valve will now display the current valve position.
12. Supply a continuous 4 mA signal to the valve for a period of 1 minute to allow the valve to calibrate
itself internally.
13. The programming of the valve is now complete and it is ready to operate.
Figure 2-6: ICAD Actuator
Document: GL-2
Revision: F
Effective: 09-10 8
ICM VALVE CALIBRATION
Display Factory
Description Min. Max. Unit Comments
Name Setting
ICM OD ICM Valve Opening Degree is displayed during normal operation.
- 0 100 - %
(Opening Degree) Running display value (see i01, i05)
Internal main switch
1: Normal operation
Main Switch i01 1 2 1 - 2: Manual operation. Valve Opening Degree will be flashing. With
the down arrow and the up arrow push buttons the OD can be entered
manually.
Operation Mode
1: Modulating – ICM positioning according to Analog Input (see i03)
Mode i02 1 2 1 -
2: ON/OFF – operating the ICM valve like an ON/OFF solenoid
valve controlled via Digital Input. See also i09.
Type of Analog Input signal from external controller
1: 0 – 20 mA
Analog Input Signal i03 1 4 2 - 2: 4 – 20 mA
3: 0 – 10V
4: 2 – 10V
Speed can be decreased. Max speed is 100%
Not active when i01 = 2
If i02 = 2 the display will indicate speed in display. Low, Med and
Speed at ON/OFF and
i04 1 100 100 % High also means ON/OFF operation.
Modulating Mode
If i04 <= 33, Low is displayed
33 < if i04 < 66, Med is displayed
If i04 > = 67 High is displayed
Not active before i26 has been operated.
Always auto reset to 0.
Automatic Calibration i05 0 1 0 -
CA” will flash in the display during calibration, if Enter push button
has been activated for two seconds.
Type of A0 signal for ICM valve position
0: No signal
Analog Output Signal i06 0 2 2 -
1: 0 – 20 mA
2: 4 – 20 mA
Define condition at power cut when fail safe is installed
1: Close valve
Fail Safe i07 1 4 1 - 2: Open valve
3: Maintain valve position
4: Go to OD given by i12
Define function when DI is ON (short circuited DI terminals) when
i02 = 2
Digital Input Function i09 1 2 1 -
1: Open ICM valve (DI = OFF = > Close ICM valve)
2: Close ICM valve (DI = OFF = > Open ICM valve)
Enter password to access password protected parameters: i26
Password i10 0 199 0 -
Password = 11
Old alarms will be listed with the latest shown first. Alarm list can be
Old Alarms i11 A1 A99 - - reset by means of activating down arrow and up arrow at the same
time for 2 seconds.
Only active if i07 = 4
OD at Powercut i12 0 100 50 - If fail safe supply is connected and powercut occurs ICM will go to
entered OD.
NB: Password protected. Password = 11
At first start up A1 will flash in display. Enter valve type
0: No valve selected. Alarm A1 will become active.
1: ICM20 with ICAD 600
ICM Configuration i26 0 6 0 - 2: ICM25 with ICAD 600
Table 2-7: ICM Valve Calibration
Document: GL-2
Revision: G
9 Effective: 01-11
Jordan Valve Liquid Injection Cooling
Compressor models 1025GL, 1210GL, and 1435GL high stage will have either a Liquid Injection Valve
Station similar to Figure 2-3, case 3, (Double Sporlan TX Valve), IntelliSOC™, or will have a high flow
Jordan Valve Liquid Injection Valve Station. The Jordan Valve Liquid Injection Valve Station can be
identified by the name “Jordan Valve” on the actuator nameplate (See Figure 2-8, item 3).
For the Jordan Valve Liquid Injection Valve Station, the liquid solenoid valve (1) is opened when the
compressor is operating. This allows refrigerant liquid feed to the Jordan Valve Temperature Regulator
(2) which controls the compressor discharge and oil temperature. The Jordan Valve (2), has a sensing
bulb (4) inserted into the oil separator in contact with the discharge gas stream. An increase in
temperature will begin to vaporize the liquid fill in the sensing bulb and create a pressure on the
actuator. The actuating pressure will modulate the valve until temperature setpoint is reached. The
Jordan Valve Liquid Injection Valve Station does not require pilot pressure to assist the actuator. Both
valve stations are piped to the H1 (Low Vi) compressor port.
Figure 2-8: Jordan Valve Liquid Injection Oil Cooling
Outlet Pressure Regulating Valve Adjustment

To adjust the outlet pressure regulating valve (OPRV), install an accurate pressure gauge downstream of
the outlet pressure regulating valve in the pressure tap provided. A throttling valve is provided
downstream of the outlet pressure regulating valve and should be initially set ¼ turn open. Set the
OPRV so the gauge reads 60 – 70 psig (to increase oil temperature, turn the adjustment clockwise; to
decrease oil temperature, turn the adjustment counter-clockwise).
Compressor Hydraulic System (Fixed VI)
The compressor uses hydraulic power to operate the capacity control system. When the compressor is
fully loaded, the slide valve will be against the slide stop. Unloading starts when the slide valve is
moved away from the slide stop thereby creating an opening for gas to bypass back to suction. High
pressure oil is used to load and unload the compressor.
Document: GL-2
Revision: F
Effective: 09-10 10
Movement of the slide valve is accomplished by pressurizing one side of the hydraulic piston and
venting the other. The functional description of loading and unloading is described below and illustrated
in Figure 2-9.
Figure 2-9: Compressor Hydraulic System (Fixed VI)
Loading: To load the compressor, solenoids Y1 and Y4 are energized. Oil is ported through the
load/unload assembly to port L on the compressor, allowing compressor connection K to vent back to
compressor port G that is at suction pressure.
Unloading: To unload the compressor, solenoids Y2 and Y3 are energized. Oil is ported through the
load/unload assembly to port K on the compressor, allowing compressor connection L to vent back to
Metering valves S5 and S7 adjust the load rate. S7 is a coarse adjustment and is generally maintained 2
turns open from its closed state. S5 is the fine adjustment used to increase or decrease the rate of
loading. S7 can be opened further, if required. Metering valve S6 adjusts the unload rate. The time to
fully load the compressor and the time to fully unload the compressor should be approximately 30-60
seconds. Refer to Figure 2-10 for valve and solenoid locations.
NOTE: Protective cap must be removed to adjust metering valve. Replace cap after adjustment is
made.
Figure 2-10: Capacity Control Solenoid Block

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11 Effective: 01-11
Compressor Hydraulic System (Variable VI)
The compressor uses hydraulic power to operate the capacity control system and the Vi control system.
Movement of the capacity control slide valve (primary slide) is accomplished by pressurizing one side
of the hydraulic piston and venting the other. Movement of Vi control slide (secondary slide) is
accomplished by pressurizing or venting the Vi control piston. Both the primary slide and the secondary
slide movement are controlled by the control panel (refer to the Control Panel Operation Section of this
manual). The functional description of the capacity control and Vi control is described below and
illustrated in Figure 2-11.
Loading: To load the compressor, solenoids Y1 and Y4 are energized. Oil is ported through the
capacity control block to port L on the compressor, allowing compressor connection K to vent back to
Unloading: To unload the compressor, solenoids Y2 and Y3 are energized. Oil is ported through the
capacity control block to port K on the compressor, allowing compressor connection L to vent back to
compressor port G that is at suction pressure. Metering valves S5 and S7 adjust the load rate. S7 is
generally maintained at 2 turns open from its closed state. It can be opened further if required to
increase the rate of loading. Metering valve S6 adjusts the unload rate. The time to fully load the
compressor and the time to fully unload the compressor should be approximately 30-60 seconds. Refer
to Figure 2-12 for valve and solenoid locations.
Figure 2-11: Compressor Hydraulic System
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Effective: 09-10 12
Vi Control: To increase the Vi, solenoid valve Y6 is energized. Oil is ported through the Vi control
block to port M on the compressor, moving the secondary block in the direction of increasing Vi. The
Vi is decreased when solenoid valve Y5 is energized and oil is vented back to the compressor through
port G, allowing the secondary slide to move in the direction of decreasing Vi. Metering valves S24 and
S25 are used to adjust the speed of the secondary slide. These valves should be adjusted so that the rate
to fully increase and decrease the Vi is approximately 45 seconds.
Figure 2-12: VI Control Solenoid Block
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13 Effective: 01-11
CONTROL PANEL
GForce™ OPERATION
FOR FES G AND X SERIES COMPRESSORS
TABLE OF CONTENTS
Introduction ..................................................................................................................................... 1
Menu Bar ........................................................................................................................................ 2
Compressor Display ....................................................................................................................... 3
Uploading of a Graphic for the Compressor ............................................................................ 4
OmniView ....................................................................................................................................... 5
Parameter Entry ....................................................................................................................... 6
Classic View ................................................................................................................................. 10
Detail Displays .............................................................................................................................. 11
Analog Data ........................................................................................................................... 12
Transducer Calibrations ................................................................................................ 14
Digital Data ............................................................................................................................ 22
Panel Settings ........................................................................................................................ 24
Suction Pressure Parameters ................................................................................................ 25
Process Temperature Parameters......................................................................................... 27
Discharge Parameters ........................................................................................................... 29
Remote Slide Valve Parameters............................................................................................ 31
Control Selection Parameters ................................................................................................ 32
IntelliSOC Valve Control Parameters .................................................................................... 35
Lubrication System Parameters, Inlet Oil and Oil Separator ................................................. 36
Variable Vi Control Parameters ............................................................................................. 38
Compressor Motor Parameters ............................................................................................. 39
Variable Speed Compressor Motor Control .................................................................. 39
Benshaw Motor Starter Communications ...................................................................... 39
Power Parameters ................................................................................................................. 41
PLC Sequencing Interface (Remote Sequence Slave) ......................................................... 43
Slide Valve Output Parameters ..................................................................................... 43
Digital Remote Sequence Slave Option ........................................................................ 43
Economizer Control Parameters ............................................................................................ 45
Hot Gas Bypass Control Parameters..................................................................................... 45
Alarms .................................................................................................................................... 46
Shutdowns ............................................................................................................................. 49
Control Descriptions ..................................................................................................................... 53
Compressor Start Sequence of Operation ............................................................................ 53
Compressor Stop Sequence of Operation ............................................................................. 55
Forward Capacity Control ...................................................................................................... 56
Reversed Capacity Control .................................................................................................... 57
Low Suction Pressure Overload ............................................................................................ 58
Discharge Pressure Overload ................................................................................................ 59
Motor Current Overload, Fixed Speed Drive ......................................................................... 60
Compressor Lubrication System Control ............................................................................... 62
Compressor Slide Valve Control ............................................................................................ 64
Compressor Variable Vi Control ............................................................................................ 65
GL/GLX Series Variable Vi Control ............................................................................... 65
GM Series Variable Vi Control ....................................................................................... 67
GS Series Variable Vi Control ....................................................................................... 68
IntelliSOC™ Discharge Temperature Control ....................................................................... 69
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Appendix A: Table of Figures ....................................................................................................... 70
Appendix B: Revisions ................................................................................................................. 71
Supporting Documents
GForce™ Control Panel Operation, refer to MCP-209 GForce™ Compressor Control Panel
Manual. This document describes features common to compressor applications of the GForce
control panel. This includes descriptions of the GForce™ hardware, Historical Data functions,
service functions and email features.
Network Setup, MCP-170 GForce™ Network Installation & User's Guide.
Register Map, MCP-171 GForce™ Communications Protocol.
There are several factory configurable options available on the GForce™ Compressor Control
Panel that are described in separate documents.
Variable Speed Compressor Motor Control, MCP-171 Addendum to GForce™ Operation for
Variable Speed Compressor Drive.
Benshaw Motor Starter Communications, MCP-221 Addendum to GForce™ Operation for

Benshaw Motor Starter Communications.
Oil Return Control, refer to the project specific addendum included with this document.
Pump Down Control, MCP-177 Addendum to GForce™ Operation for Pump Down Control.
Dual Oil Pumps, MCP-208 Addendum to GForce™ Operation for Dual Oil Pump Control.
Miscellaneous Parameters, refer to the project specific addendum included with this document.
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General Information
Introduction
This manual provides detailed information for operating the FES GForce™ compressor control panel installed on
FES G and X Series compressor packages. The FES GForce™ control panel is a computer based system that
continuously monitors the compressor package operation for optimum performance and reliability. Refer to MCP-
209 for general GForce™ Control Panel information including hardware description, historical data collection and
service functions.
The front of the control panel features a 15” full color LCD with a resistive touch screen as the user interface. The
Emergency Stop switch is wired directly to both the Compressor Motor and Oil Pump Motor starters as well as to
an input on the controller. The Emergency Stop switch should not be used during normal operation to stop the
compressor. Power for the panel computer can only be turned off at a breaker inside the panel.
Figure 1 GForce™ Touch Screen with Overlay
The panel operates in one of three modes: Graphical, Tabular and Classic. Graphical Mode displays an image of
the compressor package. Data is displayed in groups on those images relating to the physical location of the
instruments on the compressor package. Tabular mode displays all of the current instrument readings, digital I/O
states, operating and alarm parameters, alarms, shutdowns and operating modes all on one screen. Classic
Mode displays Suction Pressure, Discharge Pressure, Oil Pressure and Slide Valve Position on analog gauges
with Compressor control buttons and indicators.
Historical Data can be displayed in either tabular or graphical formats. System manuals and drawings are
available on-screen using an embedded PDF viewer.
Operating parameter settings can be saved to and recalled from a removable USB memory device to allow
greater operating flexibility. Software update utilities are included on the panel, program updates are handled
through the USB port.
All of the features and functions of the control panel are available remotely via an Ethernet connection. The
display on the remote computer is an exact duplicate of the local screen.
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Main Windows
Menu Bar
Figure 2 Example Menu Bar
Compressor
Selects the Compressor View graphical display.
OmniView
Selects the OmniView tabular data display. Note: OmniView is grayed-out on the example because that is
the current display mode.
Classic View
Selects the Classic gauges and buttons graphical display.
Displays
Displays submenu for direct navigation to associated groups of data and parameters.
Historical Data
Displays submenu for spreadsheet and line graph views of system data over time.
Documentation
Displays submenu to browse manuals, drawings and other documents for this system.
Intranet
Selects the remote viewing screen.
Service
Displays the submenu for service related functions.
User Level
Allows selection of the current user level. Passwords are required to enter a new level.
The Panel Settings icon is visible in the lower right-hand corner of all three main windows,
touch this icon to go directly to the language and units selection window.
Figure 3 Panel Settings Icon
The display of the GForce™ control panel switches to a screen saver mode after eight minutes of inactivity on the
touch screen. The backlight is switched off one minute later. To reactivate the backlight the operator may touch
anywhere on the screen. This touch turns on the backlight and brings up a screen saver graphic. A second touch
brings up the control window, this second touch is not acted upon by the control panel.
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Main Windows
Compressor Display
The Compressor Display shows an image of a generic compressor package with operating data and parameters
grouped by function. All status indicators and control buttons all for user control are provided on this screen.
Figure 4 Compressor View Screen
The group of buttons/indicators on the right is the Operating Mode Controls. This group is used to start or stop the
compressor, or to place the Control Panel in ‘REMOTE’ control mode to allow it to be controlled by a Sequencer
or a PLC. The Oil Pump button can be used to run an Oil Pump Test if the user level is set to ‘Service’. The Alarm
and Shutdown buttons flash if an annunciation is present. Touching either button will bring up the alarm or
shutdown details. The ALARM and SHUTDOWN screens are described in the ‘DISPLAYS’ section of the manual.
At the bottom of the screen are the capacity control buttons and indicators. ‘AUTO’ allows the internal capacity
control logic to adjust the slide valve. ‘HOLD’ maintains the current slide valve position. ‘LOAD’ and ‘UNLOAD’
allow direct control of the slide valve by the operator. ‘EXTERNAL’ allows a PLC or other device to control the
slide valve position via hard wired connections.
Each of the framed groups of analog data and digital states provide access to the operating parameters
associated with those values. Touching a group will open a detail screen to view or update the parameters. Refer
to the ‘DISPLAYS’ section of the manual for details on each of these screens.
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Main Windows
Uploading of a Graphic for the Compressor
The compressor image displayed may be changed to more closely match the unit on which the control panel is
installed. This picture is least likely to be distorted if 650 x 500 pixels. The default ‘generic’ image or the image of
the FES package can be restored by deleting the custom graphic.
1. Insert a Removable USB Device into the processor assembly, containing the picture of the compressor
package.
2. On the menu bar, touch on “Service”, and scroll down to “File Manager”.
3. In the file manager, touch on the “Graphic” Tab.
4. On the removable drive, highlight the filename of the picture of the compressor.
5. Touch on the arrow button pointing to the left. This will Upload the picture into the control panel.
6. Touch the close button on the upper right, and your new image should be displayed in the center of the
“Compressor” display.
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Main Windows
OmniView
The OmniView provides access to all of the controls, transducer readings, operating parameters and
annunciations in the system. This screen is divided into eight areas on standard compressors. An optional third
parameter area is used on custom configurations. The upper left frame displays data pertinent to the current
operating state of the machine as well as some factory configuration settings. Below that section is the control
keypad/status display. The center column shows the Analog Data at the top followed by the states of the Digital
I/O racks. The lower two frames show Alarm and Shutdown annunciations. The right hand column shows
Operating Parameters, Alarm Parameters and Miscellaneous parameters if this is a custom configuration. To view
all of the data in a given frame, it may be necessary to use the scroll bar provided on the right-hand side of that
frame.
Figure 5 OmniView
This window provides an easy migration path for those operators familiar with the legacy FES Micro control
panels. The frames on this window duplicate the functions of the Detail Displays that are explained later in this
manual. The graphics screens and menu bar provide direct navigation to functionally oriented groups of analog
values and operating parameters.
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Main Windows
Parameter Entry
To change an Operating, Alarm or Miscellaneous Parameter setting, touch the
desired value to open the Data Entry Keypad. Enter the desired value and
press [Enter], the new setting will be stored and the next value in the list will be
displayed. The minimum and maximum limits of the entry are displayed at the
bottom of the keypad. When editing pressure values that change units at 0, the
2
[+/-] button changes to [Psi/”Hg] or [kgcm /mmHg]. This keypad is also used to
modify parameters on the detail displays.
The panel must be in ‘User’ or ‘Service’ mode to change parameter values. A

warning message is displayed if an attempt is
made to change a parameter and the panel is in
‘Basic’ mode.
Figure 6 Parameter Entry Keypad
Figure 7 User Level Restriction
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Main Windows
OPERATING DATA
The Operating Data Frame (Figure 8) shows important analog data and status information so the user can easily
monitor compressor operation. This frame is read-only, data cannot be modified from this frame.
Figure 9 GM Vi Slide Position
Figure 8 Operating Data Frame

Figure 10 Slide Valve Maximum
The current control variable is displayed in large numerals just below the communications indicator. Slide valve
load and unload activity is indicated with and arrow graphic showing 'LD' and 'UL'. A graphic representing the
current position of the slide valve and Vi slide(if this is a variable Vi GM machine, Figure 9) is shown to the left
of the Load/Unload status indicator. If the slide valve is prevented from going to its minimum or maximum by a
parameter setting, an indicator on the bar will appear at the limit (Figure 10). While the compressor is operating,
overload conditions are signaled by the appearance of 'Discharge Pressure', 'Low Suction', or 'Motor Current' in
the upper left corner of the frame. During an overload condition, the compressor will automatically limit loading
of the slide valve, or unload the slide valve, if necessary to prevent a shutdown. 'Discharge Pressure' will
appear during a high discharge pressure overload. 'Low Suction' will appear during a low suction pressure
overload, while operating in process temperature control. 'Motor Current' will appear during a high motor
current overload. The first line of data indicates the current capacity control mode and setpoint. The amount of
anti-recycle time remaining for the compressor motor and oil drain timers are displayed next. Elapsed
compressor motor run time and the kWh accumulated by the compressor motor are monitored and displayed.
The factory configured compressor type and model number are next. For Variable Vi compressors the model
number must be set as described in the Variable Vi control section on page 52. The next line shows the
refrigerant used for control panel calculations. The Operating Mode for the compressor is used to display the
current compressor configuration (booster or high stage). The next two items are the Vi control mode and the
type of compressor motor starter, fixed or variable speed. Variable Vi and variable speed Compressor Motor
Drive are available as factory configured options. The status of the Power Fail Reset is shown as the last item in
this group. This is enabled or disabled based on an Operating Parameter. Project and program revision
information is available at the end of the table.
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Main Windows
KEYPAD AND STATUS INDICATORS
An array of 24 combination control keys/indicator lamps is below the

Operating Data Display. Not all of these keys/indicators are used in all
applications. The standard configuration is described below, additional
keys/indicators will be described in the job specific Controls Addendum.
Some of these buttons are duplicated on other views.
A communications status indicator is shown below the keypad, flashing

yellow indicates solid communications from the processor assembly to
the I/O board, steady red indicates a communications fault.
Figure 11 Keypad Frame
[Stop] is used to stop the compressor.
[Local Start] is used to place the compressor in local control mode. The compressor may not start immediately
when this button is touched. Unexpired Anti-Recycle time or a de-energized permissive start input will prevent the
compressor from starting. If the permissive start input is not energized the button will flash. If the control panel is
in ‘Cycle’ mode and the suction pressure is below the ‘Suction Pressure Lower’ the [Local Start] button will be ‘on’
and the compressor will not be running. The compressor may be started in this mode by pressing the [Local Start]
button a second time.
[Remote] puts the control panel in a mode where a remote sequencer or PLC has the ability to start, stop and set
capacity control setpoints. If ‘Low Suction Cycling’ is enabled this button will flash when attempting to do a remote
start.
The [Oil Pump] button is on when the compressor oil pump is running. This button can also be used to test the oil
pump. When the compressor is stopped, pressing this button will start the oil pump for testing and slide valve
calibration. While running in test mode the [Oil Pump] button flashes.
[Alarm Clear] flashes yellow if there is an alarm annunciation logged in the alarms window. Touching this button
when an alarm is present will clear the selected alarm from the alarms window.
[Shutdown Clear] flashes red if there is a shutdown annunciation logged in the shutdowns window. Touching this
button when a shutdown is present will clear the selected shutdown from the shutdowns window.
[Auto] places the control panel in automatic capacity control mode, slide valve position is adjusted based on either
suction pressure or process temperature.
[Hold] will keep the slide valve at its current position.
[Load] will cause the control panel to move to move the slide valve to the fully loaded position.
[Unload] will cause the control panel to move to move the slide valve to the fully unloaded position.
[External] places the capacity control in a mode where external hard-wired signals from a PLC directly control the
position of the slide valve. Overloads are still functional.
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Main Windows
[Alarm Off] acknowledges an alarm or shutdown annunciation. The annunciation remains in the alarms or
shutdowns window until cleared. If an external alarm or shutdown indicator is provided it is deactivated.
[Anti-Recycle] is on if there is unexpired Anti-Recycle time. If an attempt is made to start the compressor with the
Anti-Recycle time remaining, this button flashes yellow.
[Oil Separator Heater] is on when the oil separator heaters are energized. Touching this button performs no
function.
[Power Fail Reset] is on during a power fail reset startup sequence. Touching this button performs no function.
Additional buttons and/or indicators may be assigned for special applications, refer to the project specific
addendum included with this document.
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Main Windows
Classic View
The Classic View screen provides a basic monitor and control screen configured like an electro-mechanical
control panel. Gauges for Suction Pressure, Discharge Pressure and Oil Pressure, a Slide Valve Position
indicator and compressor runtime hours counter are provided. Large Start/Stop/Remote and operating mode
buttons/indicators complete the display.
Figure 12 Classic View Window
The control mode and capacity control buttons function the same as those on the OmniView. The [Alarm] and
[Shutdown] buttons are equivalent to the [Alarm Clear] and [Shutdown Clear] buttons on the OmniView.
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Detail Displays
Detail Displays
The detail displays are accessed from the ‘Displays’ item on the Menu Bar. The frames of the OmniView depict
the same data and parameters in a tabular format similar to the FES Micro III Microprocessor Controller.
Figure 13 Detail Display Menu
There is only one level of navigation to the detail displays, touch the ‘Close’ button to return to one of the main
displays after viewing any of the detail displays.
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Detail Displays
Analog Data
The Analog Data Window and Analog Data Frame on
the OmniView show the current readings from analog
transducers located throughout the compressor
package, values calculated by the controller and
analog signals being sent to drives, actuators and
positioners. The numbers to the left of the transducer
name are the GP I/O board ID and channel to which
the transducer or analog output is assigned. If the
Control Panel is in Service Mode, then calibration of
analog transducers can performed. If the GForce™
processor assembly cannot communicate with the GP
I/O board analog values are displayed as “???”. If a
channel is out of range high or low then the row will be
highlighted yellow.
Figure 14 Analog Data Window
Figure 15 Analog Data Frame
Figure 14 shows the Analog Data Window, Figure 15 on the right is the Analog Data Frame on the OmniView.
Possible entries on the Analog Data Window and Frame are listed below. Some of these items are optional and
may not be shown on every compressor package.
Control Suction Pressure – Gauge pressure at the suction of the compressor (1TD).
Discharge Pressure – Gauge pressure at the discharge of the oil separator (2TD).
Oil Differential Pressure – Difference between Inlet Oil (3TD) and Discharge Pressure (2TD). Used for
oil pressure-related shutdowns. No calibration necessary.
Inlet Oil Pressure – Gauge oil pressure at the compressor's inlet (3TD).
Oil Filter Differential Pressure – Differential across the oil filter. For G Series and IntelliSOC or Liquid
Injection cooled X Series machines, 4TD-3TD. For thermosiphon or externally cooled X Series machines,
2TD-5TD. In the 2TD-5TD configuration a parameter is available to offset any piping losses. No
calibration necessary.
Oil Filter Inlet Pressure– Oil pressure at the oil filter inlet (4TD).
Oil Filter Outlet Pressure– Oil pressure at the oil filter outlet (Optional 5TD based on oil piping).
Oil Separator Temperature – Oil separator temperature (1T).
Inlet Oil Temperature – Oil temperature at the inlet of the compressor (2T).
Discharge Temperature – Discharge temperature (3T).
IntelliSOC Valve Position – the current relative position of the Oil Cooling Valve, 0.0% is fully closed
and 100.0% is fully open (Optional).
Suction Temperature – Suction temperature (4T). Used only for display.
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Detail Displays
Process Temperature (Suction Control) – Process temperature (5T). Process Temperature Control
Mode (Optional).
Slide Valve Position – Slide valve position between fully unloaded (0%) and fully loaded (100%).
Slide Valve % of Maximum Travel – Slide valve position adjusted for current Vi Mode, for GL/GLX
series variable Vi machines only. See “Control” section of this manual for additional information.
Slide Position Indicator – current signal from the output of the Slide Valve Position indicator. No
Motor Current – Amps (RMS) flowing through the compressor motor current, this must be a 4-20 mA
signal that is connected to channel 8 of GP I/O Board ID#1, scaled using the ‘’Motor Current Maximum”
operating parameter. This number must match the output range of the 4-20mA signal provided by the
starter. For example, assume the full load amps of the motor times the service factor is 430A. The starter
manufacturer specifies a scaling of 0-500A equals 4-20 mA. The “’Motor Current Maximum” is then set
to 500A. If the existing motor starter does not provide a 4-20mA signal, an optional CT to 4-20mA
converter is installed in the panel and wired to channel 8 of GP I/O Board ID#1.
Compressor Motor PID % – the output of the compressor motor speed PID relative to the range of
control of the VFD, 0% = 4mA output, 100% = 20 mA. (Optional)
VFD Motor Speed – The current speed in rpm of the compressor motor, may be calculated based on
the output to the VFD or on a feedback signal from the VFD. No calibration necessary. (Optional)
kW Demand – Instantaneous energy usage calculated using the compressor motor current and kW
Metering Ratio Operating Parameter. No calibration necessary.
kW Average Usage – Average energy usage during the previous kilowatt hour Sampling Period. No
Volume Index (Vi) – Calculated ideal volume index (from 1TD, 2TD). No calibration necessary.
Maximum Primary Slide Position (formerly Vi Scalc) – Maximum primary slide valve position for
GL/GLX series variable Vi compressors only. See “Control” section of this manual for additional
information.
Ideal Vi Slide Position (formerly Vi VSopt) – This is where the secondary slide it to be positioned to
achieve the optimum Vi setting for GM series compressors only. See “Control” section of this manual for
additional information.
Vi Slide Position – Position of the Vi Slide, for GM series variable Vi compressors only. See “Control”
section of this manual for additional information.
Vi Slide Position Indicator – current signal from the output of the Vi Slide Position indicator. For GM
series Variable Vi compressors only. No calibration necessary.
Optimum Vi (formerly Vi Viopt) – optimum calculated Vi value used to switch between increasing or
decreasing Vi. For GS series variable Vi compressors only. See “Control” section of this manual for
additional information.
Midpoint of Vi Range (formerly Vi Viswitch) – Vi value used to switch between increasing or decreasing
the Vi. If the Optimum Vi > Switch Point the Vi slide is unloaded. For GS series variable Vi compressors
only. See “Control” section of this manual for additional information.
Panel Temperature – Panel temperature measured on GP I/O Board ID#1.
Line Voltage – Voltage powering the GForce™ control panel.
Additional Analog Points may be assigned for special applications, refer to the project specific
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Detail Displays
Transducer Calibrations
GEA FES recommends that transducer calibrations be checked at least once annually.
Calibrations must also be verified whenever a GPIO board is service or replaced.
CALIBRATION OF A PRESSURE TRANSDUCER (TD):
1. Ensure that the control panel is in Service mode and the compressor is
Stopped.
2. Touch the desired pressure entry to bring up the calibration keypad.
3. Attach a calibrated gauge (or digital multimeter attachment) to the
appropriate pressure transducer's service valve.
4. Remove the service valve's cover and open the service valve.
5. Read the actual pressure on the gauge or digital multimeter.
7. Enter the actual pressure on the keypad. Minimum and maximum limits
are shown at the bottom of the keypad. If the measured pressure is outside
these limits it is a sign that the transducer is damaged, miswired, or of the
wrong type. Range limits are the current electrical reading ±10% of the
transducer's range.
Figure 16 Calibration Keypad
8. Press the [Enter] key.

9. Calibration of this pressure transducer is complete
CALIBRATION OF A TEMPERATURE TRANSDUCER (T):

Standard FES temperature probes are Integrated Circuit Temperature Detectors (ICTDs). ICTDs should
not be confused with other types of temperature measuring devices such as RTDs, thermocouples or
thermistors because they are not equivalent to any of them. An ICTD temperature probe consists of an
electronic device that is imbedded in the probe which allows a very small current to pass that is
proportional to the temperature of the device. The probe can be calibrated using a single point calibration
method because the rate of change of the current passed through the ICTD vs. the temperature is linear
(the slope is constant).
1. Ensure that the control panel is in Service mode and the compressor is Stopped.
2. Touch the desired temperature entry to bring up the calibration keypad.
3. Locate the desired temperature probe on the package and open its electrical box.
4. Loosen the screw that retains the hold down tab. Rotate the hold down tab out of the way.
5. Slide the temperature probe out of its well and immerse it in an ice water bath with a calibrated
thermometer (or digital multimeter attachment). The ice water should be predominantly ice with just
enough water to cover the Ice. The temperature of the ice and water mixture will approach the triple
point of the water (~32.02°F/0.01°C).
6. Allow both to stabilize in the ice water bath (approximately 3 minutes). Agitate to reduce settling time.
7. Read the actual temperature on the thermometer or digital multimeter. If a calibrated measurement
device is not available, the channel should be calibrated to 32.0°F/0.0°C once the reading has
stabilized.
8. Enter the actual temperature on the keypad. Minimum and maximum limits are shown at the bottom
of the keypad. If the measured temperature is outside of these range limits it is a sign that the
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Detail Displays
transducer is damaged, miswired, or of the wrong type. Range limits are the current electrical
reading ±40.0F°/22.2C°.
9. Press the [Enter] key.
10. Calibration of this temperature transducer is complete.
SLIDE VALVE CALIBRATION SCREENS

GForce™ Revisions 8.0 and later
A single screen is used and the capacity control buttons on the OmniView
are not used.
Revisions prior to 8.0
Two different calibration screens are used to calibrate the slide valve. If
calibrating from the OmniView use the [Load] and [Unload] keys on that
main window to move the slide valve into position. When calibrating from
the Analog Data window, [Load] and [Unload] keys are provided on the
calibration window. In these older revisions the [OK] button must be
touched to save setting and close the window.
Figure 17 Slide Valve Calibration
In early 2011 a new FES introduced a new slide valve position sensor. This
sensor includes a hardware calibration feature on the position sensor. The
sensor should be calibrated before calibrating the GForce™ Panel. If the
machine is equipped with the older black slide valve position sensor, skip to
GForce™ Control Panel Slide Valve Input Calibration. There are several
versions of this indicator, if the ‘Batch no’ on the label does not begin with ‘1.2’
contact the FES Service Department for assistance.
Figure 18 Slide Valve Position Sensor
Notes:
Open load/unload needle valves fully (rate valves) prior to beginning the calibration. Return load/unload needle
valves to their original positions after calibration to ensure proper slide valve movement.
When the indicator is initially powered, the LED indicators will not light up for several seconds, this is normal.
Allow the indicator to warm up for at least one minute prior to starting calibration.
All LED activity in the slide valve indicator will automatically cease approximately five minutes after power was
applied to the indicator. A momentary press of the pushbutton turns LEDs back on and resets the five minute
timer.
Green LED Activity (Valid only after the calibration has been completed):
• Flash at ½ second intervals at slide valve <1%
• ON steady at slide valve >99%
• OFF at slide valve positions between 1% and 99%
GFORCE SLIDE VALVE POSITION SENSOR CALIBRATION WITH EXTERNAL OIL PUMP
2. Loosen the setscrews on the sides of the transducer and turn the device so the small cover is readily
visible. An inspection mirror may be used in lieu of rotating the transducer.
3. Remove the small round cover from the transducer
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4. Before proceeding the transducer must have been powered for at least one minute.
5. The red LED should be flashing at about a ½ second rate if the indicator is functional. Ignore any green
LED activity until the calibration is complete.
6. Initiate Oil Pump Test by touching the [Oil Pump] button.
7. Touch the [Unload] button and wait about 90 seconds for the slide valve to fully unload. (Smaller
machines may not require the full 90 seconds to unload.) Note: the values displayed on the GForce
screen should be ignored until calibration of the transducer is complete. Ignore the green LED until
calibration is complete
8. The calibration button on the transducer is positioned between the two LEDs. Push and hold the
calibration button for five seconds, both LEDs should be off.
9. Press the pushbutton one time and release it. The red LED will now turn ‘On’, and remain ‘On’, for
approximately 3 seconds while the zero calibration point is stored. DO NOT move the slide valve until the
red LED turns off.
10. Touch the [Load] button and wait about 90 seconds for the slide valve to fully load. (Smaller machines
may not require the full 90 seconds to load.) This process must be completed quickly because the
indicator will abandon the calibration after a period of time. Please note the red LED will flash
approximately ¼ second every 5 seconds indicating the indicator is active and that the calibration has not
been fully completed.
11. Once the compressor is fully loaded, push the calibration button twice, and the red LED will flash rapidly
for approximately 3 seconds. Do not attempt to move slide valve until red LED turns ‘Off’. When the red
LED stops flashing the loaded position is set. At this time the sensor will have an output of 20mA. This
can be verified on the Analog Data screen.
12. Unload and load the machine a few times to confirm calibration. Refer to the ‘Slide Position Indicator’ on
the GForce screen. It should track the slide valve between 4.0 mA and 20.0mA.
13. Exit oil pump test by touching the [Oil Pump] button.
14. Reinstall the cover
15. If the transducer was rotated, restore it to the original orientation and tighten the setscrews.
16. Return load/unload needle valves to their original positions to ensure proper slide valve movement.
17. Continue by calibrating the GForce™ control panel to the transducer.
GFORCE GM VI SLIDE VALVE POSITION SENSOR CALIBRATION
2. Open Vi Increase/Vi Decrease needle valves fully (rate valves) prior to beginning the calibration.
7. Start the compressor.
8. Touch the [Vi Decrease] button. Wait until the Vi slide reaches the low Vi position. Note: the values
displayed on the GForce screen should be ignored until calibration of the transducer is complete. Ignore
the green LED until calibration is complete.
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approximately 3 seconds while the zero calibration point is stored. DO NOT move the Vi slide until the red
LED turns off.
11. Touch the [Vi Increase] button and wait until the Vi slide valve reaches the high Vi position. This process
must be completed quickly because the indicator will abandon the calibration after a period of time.
Please note the red LED will flash approximately ¼ second every 5 seconds indicating the indicator is
active and that the calibration has not been fully completed.
12. Once the compressor at the high Vi position, push the calibration button twice, and the red LED will flash
rapidly for approximately 3 seconds. Do not attempt to move the Vi slide until red LED turns ‘Off’. When
the red LED stops flashing the loaded position is set. At this time the sensor will have an output of 20mA.
This can be verified on the Analog Data screen.
13. Decrease and increase the Vi a few times to confirm calibration. Refer to the ‘Vi Slide Position Indicator’
on the GForce screen. It should track the slide valve between 4.0 mA and 20.0mA.
14. Stop the compressor.
17. Return Vi Increase/Vi Decrease needle valves to their original positions to ensure proper slide valve
movement.
GFORCE SLIDE VALVE POSITION SENSOR CALIBRATION WITHOUT EXTERNAL OIL PUMP
6. Verify that the compressor is physically fully unloaded as much as possible. The GForce™ will prevent
the compressor from starting if the slide valve position displayed is greater than 70%. The Slide Valve
Position may have to be temporarily recalibrated to 0% to get the machine to start.
7. Start the Compressor and wait until the compressor is running and oil pressure has been established.
8. Touch the [Unload] button and wait about 90 seconds for the slide valve to fully unload. (Smaller
machines may not require the full 90 seconds to unload.) Note: the values displayed on the GForce
screen should be ignored until calibration of the transducer is complete. Ignore the green LED until
calibration is complete
approximately 3 seconds while the zero calibration point is stored. DO NOT move the slide valve until the
red LED turns off.
11. Touch the [Load] button and wait about 90 seconds for the slide valve to fully load. (Smaller machines
may not require the full 90 seconds to load.) This process must be completed quickly because the
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indicator will abandon the calibration after a period of time. Please note the red LED will flash
approximately ¼ second every 5 seconds indicating the indicator is active and that the calibration has not
been fully completed.
12. Once the compressor is fully loaded, push the calibration button twice, and the red LED will flash rapidly
for approximately 3 seconds. Do not attempt to move slide valve until red LED turns ‘Off’. When the red
LED stops flashing the loaded position is set. At this time the sensor will have an output of 20mA. This
can be verified on the Analog Data screen.
13. Unload and load the machine a few times to confirm calibration. Refer to the ‘Slide Position Indicator’ on
the GForce screen. It should track the slide valve between 4.0 mA and 20.0mA.
14. Stop the compressor by touching [Stop].
17. Return load/unload needle valves to their original positions to ensure proper slide valve movement.
GFORCE™ CONTROL PANEL SLIDE VALVE INPUT CALIBRATION
GFORCE™ SLIDE VALVE INPUT CALIBRATION FOR COMPRESSORS WITH EXTERNAL PUMP:
2. Initiate Oil Pump Test by touching the [Oil Pump] key.
3. Touch the 'Slide Valve %' entry to bring up the calibration pad.
4. Touch the [Unload] button. Wait until the slide valve reaches the fully unloaded position. The 'Slide
Position Indicator ' should stabilize at 4.0 mA (GM, GL/GLX and GS built after June 2008) or 20.0
mA(GS built prior to June 2008) when the compressor is fully unloaded.
5. Touch the [0%] button, the corresponding slide valve position sensor output has been recorded as the
fully unloaded position.
6. Touch the [Load] button. Wait until the slide valve reaches the fully loaded position. The 'Slide
Position Indicator' should stabilize at 20.0 mA (GM, GL/GLX and GS built after June 2008) or 4.0
mA(GS built prior to June 2008) when the compressor is fully loaded.
7. Touch the [100%] button, the corresponding slide valve position sensor output has been recorded as
the fully loaded position.
9. Touch the [Unload] button again. The compressor should fully unload and the indicated Slide Valve
% should track with it. Touch the [Load] button to fully load the compressor and observe the Slide
Valve %.
10. If the Slide Valve % appears to track the ‘Slide Position Indicator’, the calibration is complete. Touch
the [X] close the calibration widow.
11. Touch the [Oil Pump] key to terminate Oil Pump Test.
12. Otherwise, repeat the procedure. Ensure that the Slide Position Indicator reading changes smoothly
between full unload and full load.
13. Allow the compressor to remain stopped for several minutes so excess oil can drain.
GFORCE™ VI SLIDE VALVE INPUT CALIBRATION FOR GM SERIES COMPRESSORS
1. Calibrate or confirm that the primary slide valve has been calibrated.
2. Put the control panel in Service mode.
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3. Start the compressor.
4. Touch on the 'Vi Slide Valve %' entry to bring up the calibration pad. Automatic or manual control of the Vi
slide is suspended.
5. Touch the [Unload] button. Wait until the Vi slide reaches the low Vi position. The 'Vi Slide Indicator'
should stabilize at 4.0 mA when the slide is completely unloaded.
6. Press the [0%] button, the corresponding slide valve position sensor output has been recorded as the
7. Touch the [Load] button. Wait until the Vi slide valve reaches the high Vi position. The 'Vi Slide Indicator'
should stabilize at 20.0 mA when the slide is completely loaded.
8. Press the [100%] button, the corresponding slide valve position sensor output has been recorded as the
fully loaded position.
9. Press the [Unload] key again. The Vi slide should fully unload and the indicated Vi Slide position (%)
should track with it. Press the [LOAD] key to fully load the Vi slide and observe the Vi Slide position (%).
10. If the Vi Slide % appears to track with the Vi Slide Indicator, the calibration is complete. Touch the [X] to
close the calibration widow.
11. Automatic or manual control will resume depending on the control parameter setting.
12. Calibration of the Vi slide is complete.
13. The compressor may be taken out of Service mode and stopped if desired.
GFORCE™ SLIDE VALVE INPUT CALIBRATION FOR GM/GS COMPRESSORS W/O EXTERNAL PUMP:
THIS CALIBRATION CAN ONLY BE DONE FROM THE OMNIVIEW SCREEN!
2. Touch the 'Slide Valve %' entry to bring up the calibration pad.
3. Verify that the compressor is physically fully unloaded as much as possible. The GForce will allow the
compressor to start if it has a slide valve reading less than 70.0%. Otherwise, the slide valve mechanism
must be mechanically adjusted to less than 70% to allow the Compressor to be initially started.
4. Start the Compressor and wait until the compressor is running and oil pressure has been established.
5. Touch the [Unload] button. Wait until the slide valve reaches the fully unloaded position. The 'Slide
Position Indicator' should stabilize at 4.0 mA when the compressor is fully unloaded.
7. Touch the [Load] button. Wait until the slide valve reaches the fully loaded position. The ' Slide Position
Indicator ' should stabilize at 20.0 mA when the compressor is fully loaded.
fully loaded position.
9. Touch the [Unload] button again. The compressor should fully unload and the indicated Slide Valve %
should track with it. Touch the [Load] button to fully load the compressor and observe the Slide Valve %.
10. If the Slide Valve % appears to track the ‘Slide Position Indicator’ the calibration is complete. Touch the
[OK] button to close the calibration widow.
11. If the Slide Valve % appears to track with the mechanical indication (if equipped with this feature),
calibration is complete. Touch the [X] to close the calibration widow.
12. If desired, the compressor may be stopped at this point.
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CALIBRATION OF THE COMPRESSOR MOTOR CURRENT:
THIS CALIBRATION CAN ONLY BE DONE FROM THE OMNIVIEW SCREEN!
If this panel is NOT equipped with the CT to 4-20 mA converter option (shown as 1CT on line 133 of the control
diagram), skip to the appropriate calibration procedure. Verify that the Operating Parameter, ‘Motor Current
Maximum’ is the first number of the CT Ratio. For example, enter 500 for a 500:5 CT. If the CT Ratio is xxx:1,
lock out motor and control panel power, and remove 1CT from DIN Rail. Open cover of the CT by pushing on
the darker plastic next to the wire inserts and sliding the lighter plastic away from the board. In the following
figures, the positions of the dip switches must be changed from those shown in Figure 19, to those in Figure 20
(Turning switches 1 and 2 off, and 3 on).
ON DIP ON DIP
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
Figure 19 XXX:5 CT setting Figure 20 XXX:1 CT setting
After the dip switches are in the positions matching the picture on the right, slide the case back onto the board
(make sure the board is inside the slits made for it to slide in). Then reposition 1CT back onto the terminal Rail.
FOR GForce™ PROGRAMS PRIOR TO REVISION 5.1
1. Check the Operating Parameter, ‘Motor Current Maximum’ Verify that this setting matches the range of
the starter or transmitter 4-20 mA output.
2. Ensure that the compressor is ready to Run or Running already.
3. Touch the 'Motor Current' entry to bring up the calibration pad.
4. If not already Running, start the compressor in either Local or Remote mode. Load to 100% if possible,
but at least 50 %.
5. Touch the [Hold] button to maintain a constant slide valve position.
6. Put the hand-held clamp of an amp probe around one of the compressor's motor leads or refer to the
motor amp display on the starter if it is so equipped.
7. Enter the measured motor current.
8. Touch the [Enter] button.
9. Press the [Unload] button to unload the slide valve.
10. Stop the compressor if desired.
FOR GForce™ PROGRAMS REVISION 5.1 AND LATER

A two point calibration for motor current was added in Program Revision 5.1, this calibration can only be
completed from the OmniView screen because the compressor must be started and loaded during the procedure.
1. Check the Operating Parameter, ‘Motor Current Maximum’ Verify that this setting matches the range of
the starter or transmitter 4-20 mA output.
2. Ensure that the compressor motor is stopped and the motor current reading is stable. The reading may or
may not be at 0.0A.
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3. Touch the 'Motor Current' entry to bring up the calibration pad.
4. Touch the [0 Amp] button to set the zero point. Do not close the
keypad at this time.
5. Start the Compressor by touching the [Local Start] button. Wait for
the force unload timers to time-out.
6. Touch the [Load] button to load the machine as much as possible.
Fully loaded provides the best calibration, 50% is the minimum
recommended to complete this procedure.
7. Touch [Hold] to keep the motor current from changing
8. Put the hand-held clamp of an amp probe around one of the
compressor's motor leads or refer to the motor amp display on the
starter if it is so equipped.
9. Enter the measured motor current.
Figure 21 Motor Current Calibration
10. Touch the [High Amp] button to set the upper value for the calibration. This is not the maximum value that
can be displayed, simply a reference point for calculations. Close the keypad if all calibrations are
complete.
11. Press the [Unload] key to unload the slide valve.
12. Stop the compressor if desired.
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Digital Data
The Digital Data Window and Digital Data Frame
show the current state of the modules on the I/O
rack(s). The Digital Data Window is a graphical
representation of the I/O rack, touch a module to get
detailed information about that module. AC modules
are black and yellow, DC modules are red and white.
On the OmniView Digital Data Frame use the scroll
bar to navigate through the list.
Figure 22 Digital Detail Screen
Figure 23 Digital Data Frame
In the Digital Data frame the numbers in the columns on the left are the General Purpose I/O board ID number,
the I/O Rack number and then the module number. The following is a list of standard Digital Data entries, I/O
Modules may not be installed in all locations.
Remote Start/Stop Input, Module 1-1 – states are On or Off. If the control panel is in Remote Mode
energizing this input will begin a Start Sequence. De-energizing the input will Stop the Compressor.
Auxiliary Shutdown #2 Input or Motor Thermal Shutdown, Module 1-2 – states are Normal and
Shutdown. If configured as Auxiliary Shutdown #2; when de-energized ‘Auxiliary Shutdown #2’ is
annunciated after a five second delay, the compressor motor is stopped. If configured as Motor Thermal
Shutdown this input is connected to a panel mounted motor PTC thermistors monitor. Some VFD
installations required this input. (Optional)
SFC Solenoid Output, Module 1-4 – states are On or Off. (standard on X Series compressor packages)
Signal from a panel mounted motor thermal monitor.
Low Oil Level Input, Module 1-5 – Oil Separator Low Oil Level switch input, states are Normal or Low.
When de-energized indicates a Low Oil Level condition in the Oil Separator, a shutdown will occur.
(Optional)
Hot Gas Bypass Solenoid Output, Module 1-6 – states are On or Off. (Optional)
Economizer Solenoid Output or Subcooler Solenoid Output, Module 1-7 – Economizer or Subcooler
Solenoid Output, On or Off. (Optional)
Oil Cooling Output or IntelliSOC™ Shutoff Solenoid or Oil Injection Hot Gas Solenoid, Module 1-8
– states are On or Off. (Optional, refer to control descriptions)
Vi Decrease Solenoid, Module 1-9 – states are On or Off. (Optional, for Variable Vi machines only)
Vi Increase Solenoid, Module 1-10 – states are On or Off. (Optional, for Variable Vi machines only)
Unload Solenoid Output, Module 1-11 – Compressor slide valve Unload Solenoid(s), states are On or
Off. Some compressors have one unload solenoid, some have two.
Load Solenoid Output, Module 1-12 – Compressor slide valve Load Solenoid, states are On or Off.
Some compressors have one unload solenoid, some have two.
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Compressor Starter Output, Module 1-13 – states are On or Off.
Compressor Interlock Input, Module 1-14 – Compressor Motor Starter auxiliary contact input, states
are On or Off.
Oil Pump Starter Output, Module 1-15 – states are On or Off. Only present on machines with an
external Oil Pump.
Oil Pump Interlock Input, Module 1-16 – Oil Pump Starter auxiliary contact input, states are On or Off.
Only present on machines with an external Oil Pump.
Oil Separator Heater Output, Module 1-17 – states are On or Off. (Oil separator heater control is part
of the standard GForce™ control package, if this feature is not required it may be disabled and this
module is not present).
Alarm Status Output, Module 1-18 – states are Normal or Alarm. Normally On, this output is de-
energized if there are any Alarms present. (Optional)
Shutdown Status Output, Module 1-19 – Shutdown Status Output, On or Off. States are Normal and
Shutdown. Normally On, this output is de-energized if there are any Shutdowns present.
Auxiliary Alarm Input, Module 1-20 – states are Normal or Alarm. When de-energized ‘Auxiliary Alarm’
is annunciated immediately. The compressor motor is not stopped. (Optional)
Auxiliary Shutdown #1 Input, Module 1-21 – states are Normal and Shutdown. When de-energized
‘Auxiliary Shutdown #1’ is annunciated after a five second delay, the compressor motor is stopped.
Emergency Stop Input, Module 1-22 – states are Normal and Shutdown. When de-energized
‘Emergency Stop’ is annunciated immediately, the compressor motor is stopped. NOTE: the panel
mounted Emergency Stop switch directly de-energizes the Compressor Motor and Oil Pump Motor
Starter outputs and addition to the software controlled shutdown.
Fast Unload Solenoid Output, Module 1-23 – states are On or Off. This solenoid is used to break the
slide valve free when it is being unloaded from a high position (>99%) or when trying to move the slide
valve below 5% when the compressor is starting and stopping. (Optional)
Suction Bypass Solenoid Output, Module 1-24 – states are On or Off. Allows the discharge pressure
port on the compressor to be bypassed to the suction pressure port for a period of time when the
compressor starts to reduce the starting torque on the motor. (Optional)
Anti-Recycle Timing Output, Module 2-1 – states are On or Off. This output is energized when there is
anti-recycle time remaining for the compressor motor. (Optional)
Remote Enabled Output, Module 2-2 – states are On or Off. This output is energized when the
GForce™ control panel is placed in Remote Mode and capacity control is set to External. (Optional)
Slide Valve #1 Output, Module 2-3 – states are On or Off. This output is energized or de-energized
based on user adjustable Operating Parameters. (Optional)
Slide Valve #2 Output, Module 2-4 – states are On or Off. This output is energized or de-energized
based on user adjustable Operating Parameters. (Optional)
External Load Input, Module 2-5 – states are On or Off. If capacity control is in External Mode,
energizing this input will cause the compressor to load. (Optional)
External Unload Input, Module 2-6 – states are On or Off. If capacity control is in External Mode,
energizing this input will cause the compressor to unload. (Optional)
Additional Digital I/O may be assigned for special applications, refer to the project specific addendum
included with this document.
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Panel Settings
The Panel Settings window allows the operator to select the control panel language, select the pressure and
temperature units, edit the panel description string and to set the date and time. It is not necessary to stop the
compressor to change units. The panel descriptor string is displayed on all screens to aid in identifying the
compressor selected when using remote viewing.
Figure 24 Panel Settings Window
‘Startup Screen’ sets the screen that is displayed at power-up. The desired screen may be selected by the
operator from the available options. For this application as a reciprocating compressor panel FES recommends
selecting the ‘Reciprocating Compressor Control’ screen.
‘Auto Logoff’ may be turned on to change the access level back to User or Basic mode after a predetermined
time. The panel must be in service mode to change this setting.
‘Basic User Level Compressor Start/Stop Options’ allows an operator to select the level of compressor control
granted to Basic Level users. The panel must be in service mode to change this setting.
‘Enable Touch Gesture’ will enable/disable touch gesture. You can flick to navigate between the 3 main screens.
‘Enable Analog Fault Alarms’ will determine if Analog Input/Output channels with generate an alarm when there is
a channel fault.
Touching the [Edit] key to the right of ‘Panel Description’ displays a keyboard to enter the panel description string.
This string may be up to twenty characters in length.
Touching the [Edit] key to the right of ‘Date/Time’ displays the time with a single group of numbers hi lighted. Use
the up and down arrows to adjust the value.
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Detail Displays
Suction Pressure Parameters
This group displays all of the parameters associated with Suction Pressure Control. These parameters can also
be found in the Operating and Alarm Parameters frames on the OmniView. The current actual Suction Pressure is
displayed at the top of the window. A red dot icon indicates a parameter that if exceeded will annunciate and shut
down the compressor, the yellow dot icon indicates that there will be an alarm annunciation only.
Figure 25 Example Suction Pressure Parameters window
These parameters can also be found in the ‘SUCTION PRESSURE’ group in the ‘CONTROL/SHUTDOWN
PARAMETERS’ frame of the OmniView window. The compressor is controlled using these parameters when
‘Suction Pressure Control’ is selected.
Two suction pressure setpoints are available for controlling the compressor package. Each of the setpoints has
its own set of parameters for complimentary functions. One of the two sets of control parameters can be selected
by a parameter in the ‘CONTROL’ group or by an optional factory configured digital input.
Suction (1 or 2) Pressure Setpoint is the suction pressure to be maintained when the compressor is in Auto
capacity mode.
Suction (1 or 2) Pressure Upper is the suction pressure where a stopped compressor will automatically startup if
the ‘Low Suction Pres 0=Shtdn/1=Cycle’ Operating Parameter is set to ‘1’ (Cycle). If it is set to ‘0’ (Shutdown),
this parameter is not used
Suction (1 or 2) Pressure Lower is the suction pressure where a running compressor will automatically stop. If
the ‘Low Suction Pres 0=Shutdown/1=Cycle’ Operating Parameter is set to ‘0’ (Shutdown), a shutdown will be
annunciated. If it is set to ‘1’ (Cycle), it will cycle off and re-start if the suction pressure rises above the Suction
Pressure Upper Operating Parameter. See 'Low Suction Pressure' Shutdown.
Suction (1 or 2) Pressure Prop Band sets the width of the differential pressure band above and below the
Suction Pressure Dead Band used for proportionally loading and unloading the compressor.
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Suction (1 or 2) Pressure Dead Band sets the width of the pressure band, half above the suction pressure
setpoint and half below, where no capacity control adjustments are performed.
Low Suction Pres 0=Shtdn/1=Cycle should be set to ‘0’ (Shutdown) if a shutdown annunciation should be
issued when the compressor encounters suction pressure lower than the Suction Pressure Lower Operating
Parameter. This selection should be set to ‘1’ (Cycle) if the compressor should cycle off instead, and restart when
the suction pressure exceeds the Suction Pressure Upper Operating Parameter.
These parameters can also be found in the ‘SUCTION PRESSURE’ group in the ‘ALARM PARAMETERS’ frame
of the OmniView. These alarms are only active in ‘Suction Pressure Control’ mode.
Suction (1 or 2) Pressure Upper is the suction pressure where the 'High Suction Pressure' alarm annunciation
will occur.
Suction (1 or 2) Pressure Lower is the suction pressure where the 'Low Suction Pressure' alarm annunciation
will occur.
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Detail Displays
Process Temperature Parameters
This group is optional and is displayed only if Process Temperature Control is specified by the customer. This
group displays all of the parameters associated with Process Temperature Control. These parameters can also
be found in the Operating and Alarm Parameters frames on the OmniView. The current actual Process
Temperature is displayed at the top of the window. A red dot icon indicates a parameter that if exceeded will
annunciate and shut down the compressor, the yellow dot icon indicates that there will be an annunciation only.
Figure 26 Example Process Temperature Parameters window
These parameters can also be found in the ‘PROCESS TEMPERATURE’ group in the ‘CONTROL/SHUTDOWN
PARAMETERS’ frame of the OmniView window. The compressor is controlled using these parameters when
‘Process Temperature Control’ is selected.
Two process temperature setpoints are available for controlling the compressor package. Each of the setpoints
has its own set of parameters for complimentary functions. One of the two sets of control parameters can be
selected by a parameter in the ‘CONTROL’ group or by an optional factory configured digital input. There is only
one set of Low Suction and Load Control parameters that is common to both sets of temperature setpoints.
Process (1 or 2) Temperature Setpoint is the process temperature to be maintained when the compressor is in
Auto capacity mode.
Process (1 or 2) Temperature Upper is the process temperature where a stopped compressor will automatically
startup if the ‘Low Process Temp 0=Fail/1=Cycle’ Operating Parameter is set to ‘1’ (Cycle). If it is set to ‘0’ (Fail),
this parameter is not used.
Process (1 or 2) Temperature Lower is the process temperature where a running compressor will automatically
stop. If the ‘Low Process Temp 0=Fail/1=Cycle’ Operating Parameter is set to ‘0’ (Fail), a shutdown will be
annunciated after 10 continuous seconds. If it is set to ‘0’ (Cycle), it will cycle off and re-start if the process
temperature rises above the Process Temperature Upper Operating Parameter. See 'Low Process Temperature'
Shutdown.
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Process (1 or 2) Temperature Prop Band sets the width of the differential temperature band above and below
the Process Temperature Dead Band used for proportionally loading and unloading the compressor.
Process (1 or 2) Temperature Dead Band sets the width of the temperature band, half above the Process
Temperature Setpoint Operating Parameter and half below, where no capacity control adjustments are
performed.
Low Process Temp 0=Shtdn/1=Cycle should be set to ‘0’ (Shutdown) if a shutdown annunciation should be
issued when the compressor encounters process temperature lower than the Process Temperature Lower
Operating Parameter. This selection should be set to 1(Cycle) if the compressor should cycle off instead, and
restart when the process temperature exceeds the Process Temperature Upper Operating Parameter.
Process Temp Control Low Suction sets the lowest suction pressure allowable during process temperature
control. If suction pressure drops below this parameter during operation, a shutdown will be annunciated. See
'Low Suction Pressure' Shutdown.
Process Temp Control Prop Band sets the suction pressure where proportional unloading of the slide valve
must take place to avoid a low suction pressure shutdown during process temperature control. If the suction
pressure remains below this parameter for 5 continuous minutes, a shutdown will be issued. See 'Low Suction
Pressure Overload' Shutdown.
Process Temp Control Ld Adjust sets the suction pressure where load pulses are proportionally limited to avoid
low suction pressure during process temperature control.
These parameters can also be found in the ‘PROCESS TEMPERATURE’ group in the ‘ALARM PARAMETERS’
frame of the OmniView. These alarms are only active in ‘Process Temperature Control’ mode.
Process (1 or 2) Temperature Upper is the process temperature where the 'High Process Temperature' alarm
annunciation will occur.
Process (1 or 2) Temperature Lower is the process temperature where the 'Low Process Temperature' alarm
annunciation will occur.
Process Temp Control Low Suction sets the lower limit for suction pressure before a 'Low Suction Pressure'
alarm annunciation will occur.
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Detail Displays
Discharge Parameters
This group displays all of the Discharge Pressure Control Parameters. A red dot icon indicates a parameter that if
exceeded will annunciate and shut down the compressor, the yellow dot icon indicates that there will be an alarm
annunciation only.
Figure 27 Example Discharge Parameters windows
These parameters can also be found in the ‘DISCHARGE’ group in the ‘CONTROL/SHUTDOWN PARAMETERS’
frame of the OmniView window. The left-hand screen shot shows a compressor configured for suction pressure or
process temperature capacity control. The right-hand screen shot is for discharge pressure capacity control.
High Discharge Pressure Shutdown establishes the upper limit for discharge pressure. If discharge pressure
exceeds this parameter at any time, a shutdown will occur. Discharge pressure must be at least 10 PSI lower
than this parameter to start the compressor, or a shutdown will occur. See 'High Discharge Pressure' Shutdown.
Discharge Pressure Prop Band sets the width of a pressure band below the Discharge Pressure Maximum. If
discharge pressure rises above (Discharge Pressure Maximum - Discharge Pressure Prop Band Operating
Parameters), then proportional unload pulses will occur. If discharge pressure does not fall below the pressure
band within 5 minutes, a shutdown will occur. See 'Discharge Press Overload' Shutdown.
Discharge Temp Upper is the high temperature limit for the compressor's discharge. If the discharge
temperature exceeds this parameter at any time, a shutdown will occur. See 'High Discharge Temp' Shutdown.
The Following Parameters are only displayed when factory option for Discharge Pressure Control is enabled.
Discharge (1 or 2) Pressure Setpoint is the discharge pressure to be maintained when the compressor is in
Auto capacity mode.
Discharge (1 or 2) Pressure Upper is the discharge pressure where a running compressor will stop. If the ‘High
Discharge Pressure 0=Shutdown/1=Cycle’ Operating Parameter is set to ‘0’ (Shutdown), a shutdown will be
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annunciated. If it is set to ‘1’ (Cycle), it will cycle off and re-start if the suction pressure drops below the Discharge
Pressure Lower Operating Parameter. See 'High Discharge Pressure' Shutdown.
Discharge (1 or 2) Pressure Lower is where a stopped compressor will automatically startup if the ‘High
Discharge Pressure 0=Shutdown/1=Cycle’ Operating Parameter is set to ‘1’ (Cycle). If it is set to ‘0’ (Shutdown),
this parameter is not used
Discharge (1 or 2) Pressure Prop Band sets the width of the differential pressure band above and below the
Discharge Pressure Dead Band used for proportionally loading and unloading the compressor.
Discharge (1 or 2) Pressure Dead Band sets the width of the pressure band, half above the Discharge pressure
setpoint and half below, where no capacity control adjustments are performed.
High Discharge Pressure 0=Shutdown/1=Cycle should be set to ‘0’ (Shutdown) if a shutdown annunciation
should be issued when the compressor encounters discharge pressure higher than the ‘Discharge Pressure
Upper’ Operating Parameter. This selection should be set to ‘1’ (Cycle) if the compressor should cycle off
instead, and restart when the discharge pressure drops below the Discharge Pressure Lower Operating
Parameter.
These parameters can also be found in the ‘DISCHARGE’ group in the ‘ALARM PARAMETERS’ frame of the
OmniView display.
Discharge Pressure Maximum establishes the warning point for high discharge pressure. If discharge pressure
exceeds this parameter at any time, a 'High Discharge Pressure' alarm will be annunciated.
Discharge Temp Upper is the high temperature warning point for the compressor's discharge. If the discharge
temperature exceeds this parameter at any time, a 'High Discharge Temp' alarm will be annunciated.
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Remote Slide Valve Parameters
This group allows the operator to set limits to protect the compressor when operating in remote slide valve control
mode. The Slide Valve Setpoint may be sent to the panel via communications or a factory configured analog
input.
Figure 28 Example Remote Slide Valve Parameters window
These parameters can also be found in the ‘REMOTE SLIDE VALVE’ group in the ‘CONTROL/SHUTDOWN
PARAMETERS’ frame of the OmniView window. In the OmniView, the group is only displayed when Remote
Slide Valve Control is enabled by setting the ‘Control Mode 0=SP/1=T/2=DI/3=SV/4=DP’ parameter to 3.
Remote Slide Valve Control Low Suction sets the minimum suction pressure allowable during remote slide
valve control. If suction pressure drops below this parameter during operation, a shutdown will be annunciated.
See 'Low Suction Pressure' Shutdown.
Remote Slide Valve Control Prop Band sets the suction pressure where proportional unloading of the slide
valve must take place to avoid a low suction pressure shutdown during remote slide valve control. If the suction
pressure remains below this parameter for 5 continuous minutes, a shutdown will be issued. See 'Low Suction
Pressure Overload' Shutdown.
Remote Slide Valve Control Load Adjust sets the suction pressure where load pulses are proportionally limited
to avoid low suction pressure during remote slide valve control.
These parameters can also be found in the ‘REMOTE SLIDE VALVE’ group in the ‘ALARM PARAMETERS’
frame of the OmniView. These alarms are only active in Remote Slide Valve Control’ mode.
Remote Slide Valve Control Low Suction sets a low suction pressure alarm point during remote slide valve
control. If suction pressure drops below this parameter during operation, an alarm will be annunciated. See 'Low
Suction Pressure' Alarm.
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Control Selection Parameters
This group allows the operator to select the mode of capacity control for the compressor and to set other values
relating to capacity control.
Figure 29 Example Control Selection Parameters window
These parameters can also be found in the ‘CONTROL’ group in the ‘CONTROL/SHUTDOWN PARAMETERS’
frame of the OmniView window. The configuration of this window may change based on factory configuration and
operator selections. Some parameters in the OmniView group may be grayed out based on other selections
within the group, these parameters are not needed for the selected mode of operation.
Control Mode 0=SP/1=T/2=DI/3=SV/4=DP determines whether the compressor controls capacity based on
suction pressure (0), process temperature (1) or discharge pressure (4). Optionally, a factory-configured digital
input (2) (Pressure/Temperature Input) may be used to make the selection between suction pressure and
process temperature control. The selection for Remote Slide Valve control (3) Discharge Pressure control (4) are
factory configured options. In Figure 29 the Discharge Pressure Control option has not been enabled and is
shown grayed-out.
Control Mode Point 0=DI/1=PNT1/2=PNT2 determines which set of Suction Pressure, Process Temperature or
Discharge Pressure Parameters is used to control capacity. An entry of 1 Selects Suction Pressure/Process
Temp/Discharge Pressure 1 Parameters. An entry of 2 Selects Suction Pressure/Process Temp/Discharge
Pressure 2 Parameters. Optionally, a factory-configured digital input (PNT1/PNT2 Input) may be used to make the
selection (0). This input selects Setpoint 1 when de-energized and Setpoint 2 when energized.
Capacity Control Direction 0=Normal/1=Reverse to reverse capacity control operation including VFD PID
control. Typically set to 0 (Normal) for Suction Pressure/Process Temperature Control and set to 1(Reverse) for
Discharge Pressure Control.
Capacity Load/Unload Period sets the maximum width of a capacity control pulse. All proportional load or
unload pulse calculations utilize this parameter.
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Slide Valve Position Minimum prevents the compressor slide valve from unloading below this value when in
Auto capacity mode.
Slide Valve Position Maximum prevents the compressor slide valve from loading above this value when in Auto
capacity mode.
Load Limit 0=None/1=Pulse/2=SP/3=SV selects the parameters used for Load Pulse Limiting. ‘Pulse’ limiting
allows the operator to enter the maximum load pulse applied to the compressor during pulldown. ‘SP’ or ‘Ramp to
Suction Setpoint’ limiting limits loading to bring the Suction pressure down at a rate determined by the operator.
‘SV’ or ‘Ramp to Maximum Slide Valve’ sets the amount of time that the compressor will take to reach a fully
loaded condition.
Unload Slide Valve Before Stop 0=No/1=Yes will try to unload the slide valve when a stop command is issued
before stopping the compressor. Hitting the stopped button when the compressor is this state, will abort the
process. If the slide valve doesn’t unload in 5 minutes see ‘Compressor Slide Valve Unload’ shutdown.
Max Load Pulse During Pulldown displayed only when the ‘Ld Limit’ parameter is set to ‘1’ for Pulse Limiting.
This parameter sets the maximum load pulse that can be issued during Load Limiting. Once Load Limiting is
inactive, the compressor returns to normal loading. To disable Load Limiting entirely, set this parameter to the
same value entered into the Capacity Load/Unload Period Operating Parameter. In addition, set the Allow
Normal Loading? 0=No/1=Yes Operating Parameter to 1 (Yes), and set the Allow Normal Loading After % to 0%.
Allow Normal Loading? 0=No/1=Yes Displayed only when the ‘Ld Limit’ parameter is set to ‘1’ for Pulse Limiting.
This parameter forces the compressor to remain in Load Limiting, regardless of slide valve position, with a ‘0’ (No)
entry. With a ‘1’ (Yes) entry, Load Limiting is active until the slide valve position exceeds the ‘Allow Normal
Loading After’ operating parameter.
Allow Normal Loading After displayed only when the ‘Ld Limit’ parameter is set to ‘1’ for Pulse Limiting. This
parameter sets the slide valve position where Load Limiting is disabled if the Allow Normal Loading? 0=No/1=Yes
Operating Parameter is set to ‘1’ (Yes). If Allow Normal Loading? 0=No/1=Yes is set to 0 (No), this parameter is
not used.
Ramp to Suction Setpoint per Min displayed only when the ‘Ld Limit’ parameter is set to ‘2’ for Ramp to Suction
Setpoint Limiting. This parameter sets the rate at which the Suction Setpoint is reduced from the Suction Pressure
measured at startup, down to the Suction Pressure Setpoint when ‘Ramp to Suction Setpoint’ is selected. The
rate is set in pressure units per minute.
Ramp to Max Slide Valve Over displayed only when the ‘Ld Limit’ parameter is set to ‘3’ for Ramp to Slide Valve
Limiting. This parameter set the amount of time that it takes for the slide valve to reach the fully loaded position.
Time is set in minutes.
Booster/High Stage, 0=Bstr/1=HS/2=DI determines the operating mode of the compressor. This parameter is
displayed for GM, GS, and GL/GLX swing (booster/high stage) compressor packages. Setting this parameter to a
‘0’ configures the compressor for booster operation. Setting this parameter to a ‘1’ configures the compressor for
high stage operation. Setting the parameter to a ‘2’ configures the panel to examine the state of an input module
to determine the compressors operating mode. The input module is an option that must be factory configured. It
is used to alter oil pump operation for swing applications without requiring the operator to change this parameter.
Remote Mode Control Setpoint 0=Control Parameter / 1=Communications determines if the setpoints for the
compressor will be based on operating parameters or values received from the sequencer. Communications
should only be used when using a GForce system panel with compressor sequencing.
The following parameters are only displayed on the OmniView.
High Slide Valve Fast Unload Time displayed only when enabled in factory configuration. This parameter sets
the time in seconds that the Fast Unload Solenoid Output will be energized when the compressor is unloading
from above 99% slide valve position to break the slide valve free.
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Suction Bypass Delay Time displayed only when enabled in factory configuration. This parameter sets the time
in seconds that the Suction Bypass Solenoid Output will be energized to allow the discharge pressure port of the
compressor to be bypassed to the suction pressure port.
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IntelliSOC Valve Control Parameters
Discharge Temperature Setpoint - This parameter is the Compressor Discharge Temperature that the user
desires to maintain. As the Compressor Discharge Temperature rises above this value the IntelliSOC™
Valve will be opened more, as the Compressor Discharge Temperature drops below this value, the
IntelliSOC™ Valve will be closed more. Range is 120ºF to 175ºF with a default value of 150ºF. Except for
GL/GLX compressors in applications using refrigerants other than R717, the minimum value for the setpoint is
150ºF.
Minimum Position For Valve - this is the minimum position that the PID will close the IntelliSOC™ valve.
Range is 0.0 to 100.0%.
Proportional Constant - This parameter represents the controller gain and is defined as the ratio of the
measurement change to a corresponding change in output. This constant determines the overall
response of the PID equation because it is used by all portions of the equation (including reset and rate
gain constants). Initially, before adjusting to meet system conditions, this value should be set to 50.0.
Range is 0.0 to 500.0.
Integral Constant - This parameter represents the reset gain and determines the gain as a function of
distance from the setpoint and the amount of time the error has existed. The reset response is simply the
error multiplied by the time interval that the error has existed. The area under the curve forms the reset
(integral) gain portion of the equation. Please note that the PID reset gain has an inverse relationship to
the speed of control (making the PID integral constant larger will slow the overall system response).
Initially, before adjusting to meet system conditions, this value should be set at 85.0. Range is 0.0 to
500.0
Derivative Constant - This parameter represents the rate gain and determines the system response by
examining the slope of the error signal. If the slope of the error signal is constant, the rate gain
contribution to the overall output will be zero. A rapid change in the error signal will produce a
corresponding change in rate gain. In this way, the rate gain can be used to “anticipate” what the error
will be at some future time. This anticipation makes the rate gain particularly useful in dampening the
system to control oscillations caused by sudden dramatic changes in the error signal. Setting the
derivative gain to small values will minimize the effect of the derivative gain and the systems ability to
react to sudden changes in the error signal. Setting the rate (derivative) gain too large can actually
contribute to oscillations in the system. Initially, before adjusting to meet system conditions, this value
should be set at 1. Range is 0.0 to 30.0.
USE CAUTION WHEN OPERATING THIS VALVE MANUALLY.

Enable Test/Manual Mode 0=No, 1=Yes - Enables the user to “Test” or manually control the
IntelliSOC™ Valve. For normal operation, this should be set at 0.
Test/Manual Mode Position - Sets the “Test” or manually controlled position of the IntelliSOC™ Valve.
Range is 0.0 to 100.0%
Calibrate Time Before Valve Bleed - This is the time required by the IntelliSOC™ valve to achieve the
fully unloaded position before being allowed to open to the minimum position. Typical setting for this
parameter is 30.0 seconds. Range is 5.0 to 90.0 seconds.
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Lubrication System Parameters, Inlet Oil and Oil Separator
These two groups of parameters allow the operator to setup lubrication system pressure and temperature limits.
Some critical parameters for the lubrication system are fixed and cannot be changed. Refer to the ‘Compressor
Lubrication System Control’ section of this document for a detailed explaination of this system. A red dot icon
indicates a parameter that if exceeded will annunciate and shut down the compressor, the yellow dot icon
indicates that there will be an alarm annunciation only. Prior to revision 4.0 these two groups were displayed
together under the ‘Inlet Oil’ parameters.
Figure 30 Example Lubrication System Parameters windows
These parameters can also be found in the ‘INLET OIL’ and ‘OIL SEPARATOR’ groups in the
‘CONTROL/SHUTDOWN PARAMETERS’ frame of the OmniView window.
OmniView ‘INLET OIL’ group:

Oil Filter Pressure Drop, Max sets the tolerable drop across the oil filter. The pressure drop is measured as the
difference between the oil filter inlet and compressor inlet oil pressures. When the compressor is running and the
pressure drop exceeds this parameter for 30 seconds after a two minute delay at startup, a shutdown will occur.
See 'Hi Oil Filter Differential' Shutdown.
Oil Filter Pressure Piping Loss Adjustment Factor Displayed for X Series machines with thermosiphon or
other external oil cooling methods or in applications without an Oil Filter Inlet Pressure Transducer (4TD). This
value is used to compensate for pressure losses due to piping and/or an oil cooler. The value should equal the
difference between Discharge Pressure (2TD) and the pressure at the inlet to the oil filter. On X Series packages,
the ‘Oil Filter Pressure Piping Loss Adjustment Factor’ can be determined by taking the difference between the
Discharge Pressure (2PT) and the reading at the oil filter inlet port (OMC valve 470); reference Piping Schematic
for valve location.
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Inlet Oil Temperature Upper sets the high temperature limit for the oil feeding the compressor's inlet. When the
compressor is running and the inlet oil temperature exceeds this parameter for two minutes after a two minute
startup delay, a shutdown will be issued. See 'Hi Inlet Oil Temperature' Shutdown.
Inlet Oil Temperature Lower sets the low temperature limit for the oil feeding the compressor's inlet. When the
compressor is running and the inlet oil temperature fails to exceed this parameter for five seconds during Run
after a two minute startup delay, a shutdown will occur. See 'Lo Inlet Oil Temperature' Shutdown.
OmniView ‘OIL SEPARATOR’ group:

(Oil separator heater control is part of the standard GForce™ control package, if this feature is not required it may
be disabled and these parameters are not present).
Oil Separator Heater Setpoint is the temperature to be maintained in the oil separator by the oil heaters. A fixed
+1.5° hysteresis is used for control. Typically, the oil heater only operates when the compressor is stopped.
Optionally, the oil heaters may be factory-configured to operate when the compressor is running for certain
refrigerants.
Oil Separator Temp Upper sets the high temperature limit for the oil separator. The oil separator temperature is
compared to this parameter when the compressor is stopped, or about to be started. If the oil separator
temperature exceeds this parameter, a shutdown will occur. See 'Hi Oil Separator Temp' shutdown.
Oil Separator Temp Lower sets the low temperature limit for the oil separator. The oil separator temperature is
compared to this parameter at startup. If the oil separator temperature fails to exceed this parameter, then a
shutdown will be issued. See 'Lo Oil Separator Temp' Shutdown.
These parameters can also be found in the ‘INLET OIL’ and ‘OIL SEPARATOR’ groups in the ‘ALARM
PARAMETERS’ frame of the OmniView.
OmniView ‘INLET OIL’ group:

Oil Filter Pressure Drop, Max sets the maximum drop across the oil filter before a 'Hi Oil Filter Differential' alarm
is annunciated. This alarm is active only when the compressor is running, after a two minute delay at startup.
The pressure drop is measured as the difference between the oil filter inlet and compressor inlet oil pressures.
Inlet Oil Temperature Upper sets the high temperature limit for the oil feeding the compressor's inlet when it is
running. If the inlet oil temperature exceeds this parameter after a two minute delay at startup, a 'Hi Inlet Oil
Temperature' alarm will be annunciated.
Inlet Oil Temperature Lower sets the low temperature limit for the oil feeding the compressor's inlet during Run.
If the inlet oil temperature fails to exceed this parameter after a two minute delay at startup, a 'Low Inlet Oil
Temperature' alarm will be annunciated.
OmniView ‘OIL SEPARATOR’ group:

Oil Separator Temp Upper sets the high temperature limit for the oil separator. The oil separator temperature is
compared to this parameter when the compressor is being stopped, or started. If the oil separator temperature
exceeds this parameter, a 'Hi Oil Separator Temp' alarm will be annunciated.
Oil Separator Temp Lower sets the low temperature limit for the oil separator. The oil separator temperature is
compared to this parameter at startup. If the oil separator temperature is below this parameter, a 'Lo Oil
Separator Temp' alarm will be annunciated.
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Variable Vi Control Parameters
These parameters are not displayed if the compressor is fixed Vi.
Compressor Model Selection (only displayed on the OmniView screen) the model number of the
compressor must be entered for the Variable Vi control to operate properly. This number can be
found on the compressor nameplate. The value displayed is a code number. Touching the value
while in Service Mode brings up a pull-down menu with a list of available models for the factory
configured compressor family.
NOTE: G Series Compressor Model numbers have changed since the release of the GForce control
panel. In legacy panels the Model number was comprised of a letter followed by two numbers i.e., H-
51. The new numbering scheme is comprised of a series of letters and numbers, i.e. HR-H2655. The
selections provided in the pull-down menu encompass the new model nomenclature along with a
reference to the old nomenclature enclosed in parenthesis. This combination will also be displayed in
the Operating Data section of the OmniView display is the area designated for Compressor Model
Number and will change along with changes made to this Operating Parameter.
Figure 31 Compressor Model Figure 32 Compressor Model Selection

Selection (prior to version 6.9) (version 6.9 and above)
Vi Operating Mode (0=Auto/1=Manual) is used to control the Vi operating mode for a compressor
equipped with variable Vi. Setting this parameter to a ‘0’ selects automatic Vi control based on the
current operating conditions. Setting this parameter to a ‘1’ selects manual Vi control of the
compressor. In manual mode, the Vi is fixed at the value of the “Variable Vi Control, Manual Vi
control, Vi Setting” Operating Parameter.
Manual Vi Control Vi Setting represents the desired Vi setting when the Vi is being controlled
manually (Vi Operating Mode set to a ‘1’). This parameter is not used when the Vi Control is in
automatic mode (Vi Operating Mode set to a 0).
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Compressor Motor Parameters
This group displays all of the Compressor Motor Control Parameters. A red dot icon indicates a parameter that if
exceeded will annunciate and shut down the compressor, the yellow dot icon indicates that there will be an alarm
annunciation only.
Variable Speed Compressor Motor Control

Refer to MCP-171 GForce™ Addendum to GForce™ Operation for Variable Speed Compressor Drive.
Benshaw Motor Starter Communications

Refer to MCP-221 GForce™ Addendum to GForce™ Operation for Benshaw Motor Starter Communications.
Figure 33 Example Compressor Motor Parameters window
These parameters can also be found in the ‘COMPRESSOR MOTOR’ group in the ‘CONTROL/SHUTDOWN
PARAMETERS’ frame of the OmniView window.
IMPORTANT! To avoid injury or damage to equipment, the parameters within this topic must be set according to
the motor manufacturer's recommendations.
Example calculations assume a motor FLA of 484A for a non-VFD motor.

Motor Current Upper should be set to Full Load Amps X Service Factor. Use a 1.15 service factor for non-VFD
motors and a 1.0 service factor for VFD motors. If motor current exceeds this parameter, the slide valve will be
unloaded.
(484FLA)(1.15SF) = 556.6 Amps

These proportional unload pulses will take place until motor current is reduced below (Motor Current Upper -
Motor Current Dead Band Operating Parameters). If motor current remains above the Motor Current Upper
Operating Parameter for 30 seconds, a shutdown will be issued. See 'High Motor Current' Shutdown.
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Motor Current Lower should be set to Full Load Amps. When motor current rises above this parameter, load
pulses are proportionally limited as the current rises toward (Motor Current Upper - Motor Current Dead Band
Operating Parameters). In addition, motor current in excess of 10% Motor Current Lower Operating Parameter
must be detected within 8 seconds of Startup, or a shutdown will occur. See 'Compressor Start' Shutdown.
Motor Current Dead Band should be set to at least Full Load Amps X Service Factor X 2%. This parameter is
subtracted from the Motor Current Upper Operating Parameter to form a dead band where no load pulses will be
issued.
(484FLA)(1.15)(0.02) = 11.1 Amps

If system conditions cause motor current to rise above the Motor Current Upper Operating Parameter, then
proportional unload pulses will take place until motor current is reduced below the dead band. If motor current
cannot be reduced below the dead band within 5 minutes, a shutdown will occur. See 'Motor Current Overload'
Shutdown.
Anti-Recycle Period establishes the minimum time that must elapse between compressor starts.
Accumulated Compressor Runtime records the number of operating hours.
Motor Current Maximum sets the upper limit(scaling) of the motor current input. This value must match the
range of the starter or transmitter. Refer to the Analog Data section under “Motor Current” for additional details.
Starter Type 0=ATL/1=VFD factory configured option, available if a compressor motor is equipped with both an
across-the-line starter and a VFD. This allows the operator to select the type of starter control, this parameter can
only be changed when the compressor motor is stopped.
This parameter can also be found in the ‘COMPRESSOR MOTOR’ group in the ‘ALARM PARAMETERS’ frame
of the OmniView display.
Motor Current Upper should be set to Full Load Amps X (0.99).
(484 Amps)(0.99)= 479.2 Amps

If motor current exceeds this parameter, the 'High Motor Current' alarm will be annunciated. This alarm is active
only when the compressor is running.
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Detail Displays
Power Parameters
This group displays all of the Power Monitoring Parameters.
Figure 34 Example Power Parameters window
These parameters can also be found in the ‘POWER FAIL RESET’ group in the ‘CONTROL/SHUTDOWN
Power Fail Reset Enable 0=No/1=Yes This entry determines whether the Power Fail Reset function is enabled.
Reset to Mode? 1=Local/2=Remote This entry determines whether the control panel will enter Local (1) or
Remote (2) mode when power is restored after a power failure.
Delay Before Power Fail Reset allows the operator to set a minimum amount of time (0-8000 seconds) that the
control panel will wait upon regaining acceptable line voltage before entering Local or Remote mode. This entry
should be set to allow a slight delay after regaining power to ensure that the power system has stabilized.
Additionally, this entry may be used to stagger compressor starts after a power failure in a multi-unit system.
Abort Power Fail Reset After allows the operator to set a maximum amount (0-8000 seconds) of time allowed
for a power fail reset sequence. If the power failure and/or Delay before Power Fail Reset lasts longer than this
entry, a power fail reset will not be attempted and a 'Aborted Power Fail Reset' Shutdown Annunciation will occur.
These parameters can also be found in the ‘POWER MONITORING’ group in the ‘CONTROL/SHUTDOWN
PARAMETERS’ frame of the OmniView window. The power usage displayed by a standard GForce control panel
is based solely on the motor current and a constant entered by the user (the ‘Demand Metering Ratio’ in the
‘Power Parameters’ group). This constant is calculated based on the formula described below.
Demand Metering Ratio should be set to the kW (see calculation below) that will be consumed by the motor at
the maximum current transformer output. This should take into account nominal line voltage and average power
factor. For example, consider a situation where a Maximum Motor Current setting of 500A is used, with a 485V
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nominal line voltage and a 0.7 average power factor. The kW consumed by the motor at the maximum current
transformer output would be calculated as follows.
((500 Amps)(485 Volts)(0.7 PF)( 1.732NOTE))/ 1000 Watts =294.0 kW

kilowatt hour Sampling Period establishes the time interval (5-30 minutes) used to approximate kilowatt Hours
from the measured kW Demand. Longer intervals provide more accurate results since instantaneous kW
Demand "spikes" become less significant when compared to the average kW used.
kilowatt hours Consumed is a digital kWh meter that accumulates energy used while the compressor motor
operates. This entry can be zeroed by the operator and examined later, yielding the energy consumed by this
compressor over the interval.
Please note that based on the formula, there is no adjustment made for the changes in line voltage or power
factor. Now that more accurate monitoring of power usage is required in most situations an alternative is
available.
If the motor starter/VFD is equipped with a 4-20mA output that can be configured to send the real-time kW
demand, the GForce™ Control panel can be configured(at the factory) to use this value. Both the kW demand
and the accumulated kWh are based on this input. When this option is used, the ‘Demand Metering Ratio’
parameter is not displayed. Please contact FES if this option is required.
NOTE : 1.732 = √3
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Detail Displays
PLC Sequencing Interface (Remote Sequence Slave)
Slide Valve Output Parameters

The GForce™ Control Panel is capable of providing up to four digital outputs that have operator adjustable on
and off points based on slide valve position. This example shows two of the four enabled. These two are typically
used with the Digital Remote Sequence Slave option to allow hard-wired control of compressor capacity by an
external PLC or other controller.
Figure 35 Example Slide Valve Output Parameters window
These parameters can also be found in the ‘SLIDE VALVE OUTPUT’ group in the ‘CONTROL/SHUTDOWN
Slide Valve Output #x On Position - determines the On position for the Slide Valve Output. If On > Off, then
the output will be de-energized until the actual slide valve position exceeds the On parameter, at which point it will
be energized. It will remain energized until the actual slide valve position falls below the Off parameter. If Off >
On, then the output will be energized until the actual slide valve position exceeds the Off parameter, at which
point it will be de-energized. It will remain de-energized until the actual slide valve position falls below the On
parameter.
Slide Valve Output #x Off Position - co-ordinates with the parameter above for the described operation.
As shown in the example Slide Valve Output #1 would be on below 20% slide valve and would be off above 25%
slide valve. Slide Valve Output #2 would be on above 75% slide valve and off below 70% slide valve. It is
recommended that the two setpoints for each output be at least a few tenths apart to prevent output chatter.
Digital Remote Sequence Slave Option

This group of I/O modules is used in combination with Slide Valve Outputs #1 and #2 to allow a remote PLC to
control the GForce™ compressor directly. Refer to the figures on the following page for two example connection
diagrams; Figure 36 using GForce™ power and Figure 37 using PLC power. The ‘Anti-Recycle Timing’ output is
energized if the compressor would be prevented from starting due to unexpired motor anti-recycle or oil drain
time. The ‘Remote Enabled’ is energized when the compressor is placed in ‘Remote’ mode and ‘External’ control.
Operation of the slide valve outputs is described above. Any pulses applied to the ‘Load’ and ‘Unload’ inputs is
relayed directly to the capacity control solenoids. If either input is constantly energized the related capacity control
solenoid will be constantly energized as well. Overloads are still functional and may limit the duration of any
capacity control pulses.
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Detail Displays
GFORCE POWER GFORCE POWER

GPIO ID 1
1199
RACK 2
PLC INPUTS
1200
ANTI-RECYCLE
1 TIMING 2
120
1201 1 OAC
ENERGIZED WHEN
LOCKED OUT
1202
REMOTE
3 ENABLED 4
120
1203 2 OAC
ENERGIZED WHEN
IN REMOTE MODE
1204
SLIDE
5 VALVE #1 6
120
1205 3 OAC
SEE TEXT
1206
SLIDE
7 VALVE #2 8
120
1207 4 OAC
SEE TEXT
1208
EXTERNAL
PLC OUTPUT 9 LOAD 10
120
1209 5 IAC
ENERGIZE TO LOAD
1210
EXTERNAL
PLC OUTPUT 11 UNLOAD 12
120
1211 6 IAC
ENERGIZE TO UNLOAD
1212
13 14
1213
Figure 36 PLC Connections using GForce™ Power
GFORCE POWER
GPIO ID 1
1199 PLC POWER PLC COMMON
RACK 2
PLC INPUTS
1200
ANTI-RECYCLE
1 TIMING 2
120
1201 1 OAC
ENERGIZED WHEN
LOCKED OUT
1202
REMOTE
3 ENABLED 4
120
1203 2 OAC
ENERGIZED WHEN
IN REMOTE MODE
1204
SLIDE
5 VALVE #1 6
120
1205 3 OAC
SEE TEXT
1206
SLIDE
7 VALVE #2 8
120
1207 4 OAC
SEE TEXT
1208
EXTERNAL
PLC OUTPUT 9 LOAD 10
120
1209 5 IAC
ENERGIZE TO LOAD
1210
EXTERNAL
PLC OUTPUT 11 UNLOAD 12
120
1211 6 IAC
ENERGIZE TO UNLOAD
1212
13 14
1213
Figure 37 PLC Connections using PLC Power
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Detail Displays
Economizer Control Parameters
ECONOMIZER
Economizer Solenoid On Above sets the slide valve position where the Economizer Solenoid
Output will be energized during compressor operation. The ‘On Above’ parameter must be slightly
greater than the ‘Off Below’ parameter to allow some hysteresis.
Economizer Solenoid Off Below sets the slide valve position where the economizer valve's solenoid
will be de-energized.
Hot Gas Bypass Control Parameters
HOT GAS BYPASS

Both start conditions must be met before the Hot Gas Bypass Output will be energized. The Hot Gas Bypass
output is de-energized if either of the Stop conditions are met.
Start Hot Gas below Slide Valve % - sets the Slide Valve Position above which Hot Gas Bypass is
enabled if the suction pressure is below the ‘Start Hot Gas below Suction’ setpoint.
Stop Hot Gas above Slide Valve % - sets the Slide Valve Position above which Hot Gas Bypass is
disabled.
Start Hot Gas below Suction - is the Suction Pressure below which Hot Gas Bypass is enabled if the
slide valve position is below the Start Hot Gas below Slide valve% setpoint.
Stop Hot Gas above Suction - is the Suction Pressure above which Hot Gas Bypass is disabled.
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Detail Displays
Alarms
This window displays all alarm annunciations with the time and date at which the alarm occurred. Up to two
hundred entries can be logged at any given time. Use the scrollbars to navigate through the list. The most recent
annunciation is displayed at the top of the list. Touch the [Alarm Off] button to silence the annunciation without
clearing it from the list. After correcting the problem, touch the [Clear] button to remove the annunciation from the
list.
Figure 38 Example Alarms window
If an alarm occurs while viewing a window other than the three main windows (Compressor View, OmniView,
Classic View), an ‘Alarm Notification Window’ pops up, touch this window to bring up the ‘Alarm Annunciations’
window. The [Alarm Off] button is used to clear the pop-up. On the OmniView the [Alarm Clear] button flashes
yellow to indicate the presence of an alarm. The [Alarm Off] button can be used to silence the alarm. Touch the
[Alarm Off] or [Clear] button to remove an alarm from the list after clearing the source of the problem.
Figure 39 Example Alarm Figure 40 Example Alarm Condition

Notification Window on OmniView
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Detail Displays
The GForce™ Control Panel will retain alarm annunciations until they are manually cleared, even through power
failures. If an attempt is made to clear an alarm it will re-appear if it has not been properly resolved. The
following is a list of possible alarms.
Hi Oil Separator Temp – Actual oil separator temperature exceeded the Oil Separator Upper Alarm
Parameter while the compressor was Stopped or in the process of Starting.
Lo Oil Separator Temp – Actual oil separator temperature fell below the Oil Separator Lower Alarm
Parameter while the compressor was in the process of Starting.
Auxiliary Alarm – The Auxiliary Alarm Input module was de-energized during Stop, Startup, Run, or
Shutdown. This input is typically connected to external warning devices for the compressor package.
High Motor Current – After a two minute delay at startup, the actual motor current exceeded the Motor
Current Upper Alarm Parameter while the compressor was operating in Run.
High Discharge Pressure – The actual discharge pressure exceeded the Discharge Pressure Maximum
Alarm Parameter during Stop, Startup, Run, or Shutdown.
High Discharge Temp – The actual discharge temperature exceeded the Discharge Temperature Upper
Alarm Parameter during Stop, Startup, Run, or Shutdown.
Hi Oil Filter Differential – After a two minute delay at startup, the pressure drop across the oil filter
exceeded the Oil Filter Pressure Drop Alarm Parameter during Run. For G Series and IntelliSOC or Liquid
Injection cooled X Series machines, this pressure drop is measured as the difference between the Oil
Filter Inlet Pressure (4TD) and the compressor Inlet Oil Pressure (3TD). For Thermosiphon or externally
cooled X Series machines, this pressure drop is measured as the difference between the Discharge
Pressure (2TD) and the Oil Filter Outlet Pressure (5TD) less the ‘Oil Filter Pressure Piping Loss
Adjustment Factor’ parameter.
Low Inlet Oil Temperature – For GM and GL/GLX series; after a two minute delay at Startup, the actual
inlet oil temperature fell below the Inlet Oil Temperature Lower Operating Parameter for five seconds
during Run. GS Series; from start up to four minutes after startup, no alarm. Four to six minutes after
start, Inlet Oil Temperature must be greater than 75.0°F/23.9°C. More than six minutes after start factory
configurable parameters or 90.0-115.0°F/32.2-46.1°C must be met.
High Inlet Oil Temperature – After a two minute delay at startup, the inlet oil temperature exceeded the
Inlet Oil Temperature Upper Alarm Parameter during Run.
Low Process Temperature – The compressor was operating in Process Temperature Control Mode.
After a two minute delay at startup, the process temperature fell below the Process Temperature Lower
Alarm Parameter for the active Control Point (1 or 2).
Low Suction Pressure – While operating in Process Temperature Control Mode during Run, the suction
pressure fell below the Process Temp Control Low Suction Alarm Parameter after a two minute delay at
Startup. While operating in Suction Pressure Control Mode during Run, the actual suction pressure fell
below the Suction Pressure Lower Alarm Parameter for the active Control Point (1 or 2) after a two minute
delay at Startup.
High Suction Pressure – While operating in Suction Pressure Control Mode, the suction pressure rose
above the Suction Pressure Upper Alarm Parameter for the active Control Point (1 or 2) after a two
minute delay at Startup.
High Panel Temperature – The panel interior temperature as measured on the GPIO board exceeded
135ºF(57ºC).
Low Line Voltage # – The line voltage powering the processor board dropped below the factory-
configured trip voltage. If the compressor was running, it was placed in Stop mode. The number
following the annunciation is the actual line voltage at the time of the annunciation. Note that this alarm is
active only when the Power Fail Reset option is enabled.
Analog Input Fault GPIO # Channel # – An analog input is outside the acceptable range. For 4-20mA
signals, anything below 3mA or above 20.5mA will generate the annunciation. For ICTD/Voltage inputs
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Detail Displays
anything below 0V or above 5V. Older GPIO boards 725-05045C-001 and 725-006200C-001 do not
detect faults on the high side.
Analog Output Fault GPIO # Channel # – The current flowing in an analog output control loop does not
match the value set by the controls. Check for an open, damaged or unconnected cable. Older GPIO
boards 725-05045C-001 and 725-006200C-001 do not detect output faults.
Loss Of Remote Start Signal – When a running compressor running in local mode is put into remote
mode, after 20 seconds the sequencer sent a stop command.
Additional Alarm Annunciations may be assigned for special applications, refer to the project specific
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Detail Displays
Shutdowns
This window displays all shutdown annunciations with the time and date at which the shutdown occurred. Up to
two hundred entries can be logged at any given time. Use the scrollbars to navigate through the list. The most
recent annunciation is displayed at the top of the list. Touch the [Alarm Off] button to silence the annunciation
without clearing it from the list. After correcting the problem, touch the [Clear] button to remove the annunciation
from the list. All shutdown annunciations must be cleared before the compressor can be restarted.
Figure 41 Example Shutdowns window
If a shutdown occurs while viewing a window other than the three main windows (Compressor View, OmniView,
Classic View), an ‘Shutdown Notification Window’ pops up, touch this window to bring up the ‘Shutdown
Annunciations’ window. The [Alarm Off] button is used to clear the pop-up. On the OmniView the [Shutdown
Clear] button flashes red to indicate the presence of an alarm. The [Alarm Off] button can be used to silence the
alarm. Touch the [Shutdown Clear] or [Clear] to remove a shutdown from the list after clearing the source of the
problem.
Figure 42 Example Shutdown Figure 43 Example Shutdown Condition

notification window on OmniView
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Detail Displays
The GForce™ Control Panel will retain shutdown annunciations until they are manually cleared, even through
power failures. If an attempt is made to clear a shutdown it will re-appear if it has not been properly resolved.
The following is a list of possible shutdowns.
High Oil Separator Temp – Oil separator temperature exceeded the Oil Separator Upper Operating
Parameter while the compressor was Stopped or in the process of Starting.
Low Oil Separator Temp – Oil separator temperature fell below the Oil Separator Lower Operating
Parameter while the compressor was in the process of Starting.
Auxiliary Shutdown – The appropriate Auxiliary Shutdown Input module was de-energized for 5
continuous seconds during Stop, Startup, Run, or Shutdown. This input is typically connected to external
safety devices for the compressor package.
Compressor Start – The Compressor Interlock Input module failed to be energized or actual motor
current greater than 10% of the Motor Current Lower Operating Parameter was not detected 8 seconds
after the Compressor Start Output module was energized at Startup.
Loss of Compressor Interlock – The Compressor Interlock Input module failed to be energized for at
least one half second while the compressor was operating in Run.
Loss of Compressor Motor Current – The motor current dropped below 10% of the Motor Current
Lower Operating Parameter while the compressor was operating in Run.
High Motor Current – The motor current exceeded the Motor Current Upper Operating Parameter for 30
continuous seconds while the compressor was operating in Run.
Motor Current Overload – The motor current exceeded the Motor Current Upper Operating Parameter,
then remained above (Motor Current Upper - Motor Current Deadband Operating Parameters) for 5
continuous minutes during Run.
Illegal Compressor Interlock – The Compressor Interlock Input module was energized for 5 seconds
while the compressor was Stopped, or remained energized 12 seconds after the compressor was
Shutdown.
Illegal Compressor Motor Current – Actual motor current greater than 5 amps was detected for 5
seconds while the compressor was Stopped, or 12 seconds after the compressor was Shutdown.
High Discharge Pressure – The actual discharge pressure exceeded the Discharge Pressure Maximum
Operating Parameter during Run, or was within 10 PSI of the Discharge Pressure Maximum Operating
Parameter at Startup.
High Discharge Temp – The actual discharge temperature exceeded the Discharge Temperature Upper
Operating Parameter during Stop, Startup, Run, or Shutdown.
Discharge Press Overload – The actual discharge pressure exceeded (Discharge Pressure Maximum -
Discharge Pressure Prop Band Operating Parameters) for 5 continuous minutes during Run.
High Oil Filter Differential – After a 90 second delay at Startup, the pressure drop across the oil filter
exceeded the Oil Filter Pressure Drop Operating Parameter for 30 seconds during Run For G Series and
IntelliSOC or Liquid Injection cooled X Series machines, this pressure drop is measured as the difference
between the Oil Filter Inlet Pressure (4TD) and the compressor Inlet Oil Pressure (3TD). For
Thermosiphon or externally cooled X Series machines, this pressure drop is measured as the difference
between the Discharge Pressure (2TD) and the Oil Filter Outlet Pressure (5TD) less the ‘Oil Filter
Pressure Piping Loss Adjustment Factor’ parameter.
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Detail Displays
Low Line Voltage # – The line voltage powering the processor board dropped below the factory-
configured trip voltage. The number following the annunciation is the actual line voltage at the time of the
annunciation. Note that this shutdown is active only when the Power Fail Reset option is disabled.
Analog Calibration # – The microprocessor detected an Analog Calibration outside its entry limits. The
number after the annunciation indicates which analog channel's calibration is in error. Refer to
Hardware's Table of Processor Board Analog Input Terminals and Configuration. Note that this
annunciation is active during Stop, Startup, Run, and Shutdown and cannot be cleared until the error is
corrected (channel re-calibrated).
Low Inlet Oil Temperature – For GM and GL/GLX series; after a two minute delay at Startup, the actual
inlet oil temperature fell below the Inlet Oil Temperature Lower Operating Parameter for five seconds
during Run. GS Series; from start up to four minutes after startup, no shutdown. Four to six minutes after
start, Inlet Oil Temperature must be greater than 75.0°F/23.9°C. More than six minutes after start factory
configurable parameters or 90.0-115.0°F/32.2-46.1°C must be met.
High Inlet Oil Temperature – After a two minute delay at Startup, the actual inlet oil temperature
exceeded the Inlet Oil Temperature Upper Operating Parameter for two minutes during Run.
Low Process Temperature – The compressor was operating in Process Temperature Control Mode with
the Low Process Temperature 0=Shutdn/1=Cycle Operating Parameter set to 0 (Shutdown). During Run,
the actual process temperature fell below the Process Temperature Lower Operating Parameter for the
active Control Point (1 or 2).
Low Suction Pressure – While operating in Process Temperature Control Mode, the actual suction
pressure fell below the Process Temp Control Low Suction Shutdown Operating Parameter for 10
continuous seconds during Run. Or while operating in Suction Pressure Control Mode with the Low
Suction Pressure Shutdown or Cycle Operating Parameter set to Shutdown, the actual suction pressure
fell below the Suction Pressure Lower Operating Parameter for the active Control Point (1 or 2) during
Run.
Low Suction Pressure Overload – While operating in Process Temperature Control Mode, the actual
suction pressure remained below the Process Temp Control Low Suction Prop Band Operating
Parameter for 5 continuous minutes during Run.
Loss of Auxiliary Oil Pump Interlock or Loss of Oil Pump Interlock # – The Oil Pump Interlock Input
module was not energized within 5 seconds of the microprocessor running the oil pump. This shutdown
will only include the oil pump number (#) if the compressor package is equipped with dual oil pumps. This
shutdown is only valid for compressors with external, auxiliary oil pumps.
Illegal Auxiliary Oil Pump Interlock or Illegal Oil Pump Interlock # – The Oil Pump Interlock Input
module remained energized for at least 5 seconds after the microprocessor stopped the oil pump. This
shutdown will only include the oil pump number (#) if the compressor package is equipped with dual oil
pumps. This shutdown is only valid for compressors with external, auxiliary oil pumps.
Low Auxiliary Oil Pump Pressure or Low Oil Pressure or Low Oil Pressure Pump # – The Oil
pressure failed to meet the minimum oil pressure requirements for five seconds. This shutdown becomes
active after the first 30 seconds of compressor operation. This shutdown will only include the oil pump
number (PMP #) if the compressor packages is equipped with dual oil pumps. The Low Auxiliary Oil
Pump Press shutdown will only occur with GM or GS compressors with external, auxiliary oil pumps.
High Oil Pressure – The actual compressor inlet oil pressure exceeded maximum oil pressure limit for
the compressor while it was running. Refer to the Control section of this manual for a detailed description
of these limits based upon the compressor model and Operating Parameter - Control settings. –OR– For
Grasso compressors with an external oil pump, an immediate shutdown is issued if the oil differential
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Detail Displays
pressure exceeds the existing high oil pressure limit {4 bar (58.0 psi) for GM/GS, 5 bar (72.5 psi) for
GL/GLX, and 6 bar (87 psi) for Variable Vi, Swing, Booster Mode GLX plus 2 bar (29.0 psi). For example,
if a High-Stage GL/GLX compressor's oil pressure exceeds 7 bar (101.5 psi) a shutdown will be issued
immediately. Prior to revision 10.6 there was a thirty second delay at startup. Beginning with revision 10.6
there is a factory configurable delay for high oil pressure shutdown on compressor startup. Default
startup delay is 6 seconds. This value can be factory configured for applications that require a longer
delay.
Compressor Slide Valve Unload – The slide valve reading remained above 5.0% for 5 minutes of
unload during an attempted Startup or when the compressor is stopping. This delay was 3 minutes on
revisions prior to 10.3.
Low Oil Level – The Oil Level Input module was de-energized for 5 seconds while Stopped, or for 3
minutes during Startup, Run or while Stopping.
Aborted Power Fail Reset – The power fail reset option was enabled. The microprocessor detected that
incoming line voltage dropped below the factory-configured limit and remained low longer than Abort
Power Fail Reset After Operating Parameter.
Oil Separator Temperature Probe Failure – The Oil Separator Temperature reading was below –76.0
°F/-60.0°C, indicating a Temperature Probe failure. While the temperature is below this value, the Oil
Heaters are de-energized. Refer to Analog Data section for information on the Oil Separator
Temperature.
Low Differential Pressure n – One of the following conditions existed:

1. Discharge – Suction < 2 bar (29.0 PSI) for 10 minutes after start or 1 minute after 10 minute start
delay expired.
2. Discharge – Suction < 4 bar (58.0 PSI) for 60 minutes after start or 1 minute after 60 minute start
delay expired.
3. Discharge – Suction < 4 bar (58.0 PSI) and Inlet Oil Temperature < 75.0°F/23.9°C for 60 seconds
after start or 5 seconds after start delay expired.
The “n” in the text of the shutdown will be 1, 2, or 3 to reflect which of the above conditions caused
the shutdown.
This shutdown is only valid for GM/GS compressors with only internal oil pumps.
rd
Low Oil Press - Startup – This shutdown is issued after the 3 start attempt of the oil pump to build valid
startup pressure.
Additional Shutdown Annunciations may be assigned for special applications, refer to the project specific
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Control
Control Descriptions
The following sections describe in detail the operation of the primary control systems of the GForce™
Compressor Control Panel. Some of these systems are factory configured options and may not be available on a
specific machine.
Compressor Start Sequence of Operation

1. The start sequence begins with an examination of the compressor motor's Anti-Recycle Timer and oil
drain timers. If sufficient time has not elapsed since the last start of the compressor motor, or oil drain
time still exists, the control panel will wait until both timers have expired.
2a. If Suction Pressure Control is enabled and the Low Suction Pres 0=Fail/1=Cycle Operating Parameter is
set 1(Cycle), the control panel will wait until the actual suction pressure exceeds the Suction Pressure (1
or 2) Upper Operating Parameter. The user can bypass this delay by pressing the [Local Start] button a
second time. If enabled in the factory configuration, an external device can bypass this delay by
energizing the Must Start Input module.
2b. If Process Temperature Control is enabled and the Low Process Temp 0=Shutdn/1=Cycle Operating
Parameter is set 1(Cycle), the control panel will wait until the actual process temperature exceeds the
Process Temperature (1 or 2) Upper Operating Parameter. The user can bypass this delay by pressing
the [Local Start] button a second time. If enabled in the factory configuration, an external device can
bypass this delay by energizing the Must Start Input module.
3. The Ready to Start Output module will be energized.
4. The Permissive Start Input module will be examined. If enabled in the factory-configuration, the control
panel will wait for it to be energized. While waiting on the Permissive Start, the [Local Start] or [Remote]
button will be flashing.
5. The external oil pump will be started for GL/GLX series compressors or GM/GS series compressors fitted
with an external oil pump.
6. The unload solenoids will be energized.
7. If equipped with a Discharge Check Valve it will be opened. It must open completely within 30 seconds,
or startup will be aborted.
8. The control panel will wait until the slide valve unloads to a position less than 5%. If it does not unload
within 3 minutes, startup will be aborted for all compressors equipped with an external oil pump and a
“Compressor Slide Valve Unload” shutdown will be issued. The GM and GS series compressors with an
internal pump (even if an external is also used) will be permitted to start if the slide valve position is less
than 70.0%. For GM and GS series compressors with or without an external pump proceed to step #11.
Note: The oil pressure built by the external oil pump is monitored while trying to unload the slide valve to
less than 5%. If valid oil pressure is not established as explained in the next section, a “Low Oil Press –
Startup” shutdown will be initiated. If this occurs, the Oil pump will still operate for up to 3 minutes to
unload the slide valve.
9. After verifying that the slide valve is less than 5%, the Inlet Oil pressure is tested. The Oil Pressure for
machines equipped with an external oil pump must exceed discharge pressure + 14.2 psi (1 bar) within 8
seconds of the oil pump being started. If this pressure is not achieved within 8 seconds, the oil pump will
be stopped for 10 seconds. The pump will be restarted 2 additional times for 8 seconds with 10 second
rd
pauses between. If the pressure is still not achieved after the last (3 ) pump start, a “Low Oil Press –
Startup” shutdown will be issued. Note: During the pump off cycles, the [Oil Pump] button will be flashing
at a 1.5 second on/off rate.
10. If the oil pump has been running longer than 20 seconds to unload the slide valve before the compressor
can be started, the startup will be delayed until the compressor has been given time to drain the oil
pumped into it during the startup process. Note: Any time the startup is delayed in this manner, the oil
drain timer will be set to 10 minutes and the compressor will remain in LOCAL or REMOTE mode. The
compressor will not be shutdown. The compressor will automatically attempt to restart when the oil drain
timer elapses. Oil drain time is displayed in the OPERATING DATA frame of the OmniView window.
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Control
11. The compressor motor starter will be energized to begin operation of the compressor.
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Control
Compressor Stop Sequence of Operation
1. The compressor motor starter will be de-energized to stop the compressor.
2. The compressor slide valve's unload solenoid will be energized.
3. The Ready to Start Output module will be de-energized.
4. The control panel will wait for the Compressor Interlock Input module to be de-energized, and actual
motor current to drop below 5 amps.
5. The external oil pump will continue to run until the compressor is unloaded for GL/GLX series
compressors or GM / GS series compressors fitted with an external oil pump. Stop sequence is
completed for GM / GS series compressors without an external oil pump or a combination of internal and
external oil pumps.
6. The control panel will wait until the slide valve unloads to a position less than 5%. If it does not unload
within 3 minutes, a “Compressor Slide Valve Unload” shutdown will be issued.
7. Once the compressor is shutdown, the compressor slide valve's unload solenoid will de-energize
8. If the oil pump has been running longer than 20 seconds after the compressor has been shutdown, the
compressor will be issued oil drain time to allow the compressor to drain the oil pumped into it during the
shutdown process. Note: Any time the shutdown sequence is extended such that the oil pump has been
running 20 seconds without the compressor, the oil drain timer will be set. The oil drain timer is set to 10
minutes and the compressor cannot be restarted until the timer has elapsed. Oil drain time is displayed in
the OPERATING DATA frame of the OmniView window.
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Control
Forward Capacity Control
Continuous Load
LD
Proportional Band
½ Dead Band
Setpoint
½ Dead Band
Proportional Band
UL
Continuous Unload
Figure 44 Suction Pressure / Process Temperature / Discharge Forward Capacity Control
Movement of the compressor slide valve and the resulting change in refrigeration capacity is done via a time-
proportioning scheme, as illustrated above.
The Control Mode Operating Parameter determines whether the compressor controls capacity based on suction
pressure, or process temperature (control variable). Additionally, the Control Point Operating Parameter allows
the operator to select between two setpoints, dead bands, and proportional bands.
The Capacity Control algorithms determine the proper load or unload pulse width based on the relationship shown
above. If the control variable is greater than (setpoint + 1/2 dead band + proportional band), then a continuous
load pulse will be used to move the slide valve. Conversely, a continuous unload pulse will be used if the control
variable is less than (setpoint - 1/2 dead band - proportional band).
Proportional loading takes place when control variable is greater than (setpoint + 1/2 dead band), but less than
(setpoint + 1/2 dead band + proportional band). Proportional unloading occurs when the control variable is less
than (setpoint - 1/2 dead band), but greater than (setpoint - 1/2 dead band - proportional band).
If the control variable is only slightly above or below the setpoint (within setpoint + 1/2 dead band), no load or
unload pulses will be issued.
In Suction Pressure Control Mode, the GForce™ monitors Discharge Pressure and Motor Current to make
adjustments to the basic capacity control scheme. In Process Temperature Control Mode a Low Suction Pressure
Overload is added. In Discharge Pressure Control Mode only the Motor Current Overload is active. These
overloads allow the machine to generate maximum capacity while continuing to operate safely. Detailed
descriptions of the overloads follow in this section.
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Control
Reversed Capacity Control
Continuous Unload
UL
Proportional Band
½ Dead Band
Setpoint
½ Dead Band
Proportional Band
LD
Figure 45 Suction Pressure / Process Temperature / Discharge Reversed Capacity Control
The Capacity control can be reversed using the ‘Capacity Control Direction’ Parameter. Reversing of the
Capacity Control is typically used with Discharge Pressure Control.
Movement of the compressor slide valve and the resulting change in refrigeration capacity is done via a time-
proportioning scheme, as illustrated above.
The Control Mode Operating Parameter determines whether the compressor controls capacity based on suction
pressure, or process temperature (control variable). Additionally, the Control Point Operating Parameter allows
the operator to select between two setpoints, dead bands, and proportional bands.
The Capacity Control algorithms determine the proper load or unload pulse width based on the relationship shown
above. If the control variable is greater than (setpoint + 1/2 dead band + proportional band), then a continuous
unload pulse will be used to move the slide valve. Conversely, a continuous load pulse will be used if the control
variable is less than (setpoint - 1/2 dead band - proportional band).
Proportional unloading takes place when control variable is greater than (setpoint + 1/2 dead band), but less than
(setpoint + 1/2 dead band + proportional band). Proportional loading occurs when the control variable is less than
(setpoint - 1/2 dead band), but greater than (setpoint - 1/2 dead band - proportional band).
If the control variable is only slightly above or below the setpoint (within setpoint + 1/2 dead band), no load or
unload pulses will be issued.
In Suction Pressure Control Mode, the GForce™ monitors Discharge Pressure and Motor Current to make
adjustments to the basic capacity control scheme. In Process Temperature Control Mode a Low Suction Pressure
Overload is added. In Discharge Pressure Control Mode only the Motor Current Overload is active. These
overloads allow the machine to generate maximum capacity while continuing to operate safely. Detailed
descriptions of the overloads follow in this section.
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Control
Low Suction Pressure Overload
Normal Loading
Suction Pressure
60.0 psig Load Adjust

Load Parameter
Limiting
55.0 psig Prop Setpoint
Proportional Parameter
Unloading
50.0 psig Low Suction
Parameter
Time
Figure 46 Example Low Suction Pressure Overload during Process Temperature Control
The Low Suction Pressure Overload is a mechanism to unload the compressor to avoid extremely low suction
pressures during Process Temperature Control Mode. When this overload is active, the message 'Ld Lim – Low
Suc' will appear in the upper left of the OPERATING DATA frame in the OmniView and the lower left corner of the
Classic View.
For an example, a compact water-chilling system will be analyzed. R-717(ammonia) will be used as the
refrigerant.
The Process Temperature Low Suction Operating Parameter is set to the minimum pressure that the system can
tolerate, which is typically the pressure equivalent of the process fluid's freezing point. Pressure drop between
the heat exchanger and the compressor package must be considered if relevant. If the suction pressure drops
below this parameter, the compressor will be shutdown. Since the example application's process fluid is water
and the system is compact, 50.0 PSIG was chosen as the pressure equivalent to the water's freezing point using
R-717.
The Process Temperature Prop Band Operating Parameter is typically set slightly above the process fluid's
freezing point, causing the compressor to unload as the suction pressure drops close to the pressure equivalent
of the freezing point. This unloading is proportional between the Process Temperature Prop Band and Low
Suction Operating Parameters. In the example, a 5.0 PSI proportional unload band was chosen so the Process
Temperature Prop Band Operating Parameter was set to 55.0 PSIG.
As the compressor's suction pressure nears the Process Temperature Prop Band Operating Parameter,
measures need be taken to slow loading of the compressor. Once the suction pressure drops below the Process
Temperature Load Adjust Operating Parameter, the intended load pulses will be proportionally reduced.
Typically, the load adjustment (load limiting) band should be equal to or greater than the proportional unload
band, which was chosen to be 5.0 PSI. For the example, the Process Temperature Load Adjust Operating
Parameter was set to 60.0 PSIG.
‘Load Adjust Parameter’ must be greater than ‘Prop Band Parameter’ and ‘Prop Band Parameter’ must be greater
than ‘Low Suction Parameter’. If these requires aren’t met than a Low Suction Overload will always be triggered.
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Control
Discharge Pressure Overload
Discharge Pressure
225 psig High Discharge

Longer Unload Pressure Shutdown
Pulses
Short Unload
Pulses Maximum – Discharge
215 psig Pressure Prop
Normal Loading Band Parameter
Time
Figure 47 Example Discharge Pressure Overload
The Discharge Pressure Overload is a mechanism to unload a compressor experiencing high discharge pressure,
in order to avoid a shutdown. When this overload is active, the message Overld – Hi Disch' will appear in the
upper left of the OPERATING DATA frame in the OmniView and the lower left corner of the Classic View.
At Startup, the compressor's discharge pressure must be at least 10.0 PSI lower than the High Discharge
Pressure Shutdown Parameter, or the 'High Discharge Pressure' shutdown will occur immediately.
When in Run mode, the control panel monitors the compressor's discharge pressure continuously. A proportional
unload band is established between the Discharge Pressure Maximum and Discharge Pressure Prop Band
Operating Parameters (225.0 PSI and 10.0 PSI respectively for this example). If actual discharge pressure rises
into the proportional unload band, the compressor will be unloaded in an attempt to avoid the 'High Discharge
Pressure' Shutdown.
‘Discharge Pressure Prop Band’ must be greater than 0. If ‘Discharge Pressure Prop Band’ is 0 then the
compressor won’t try to unload when approaching the High Discharge Pressure Shutdown.
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Control
Motor Current Overload, Fixed Speed Drive
Refer to MCP-171 if this compressor is equipped with a variable speed drive.
Continuous Unload Motor Current Upper

556 A
Motor Current Upper
No Loading
Deadband
545 A
Load Load
Motor Current
Limiting Limiting
484 A Motor Current Lower

Normal Capacity
Control Resumes
Normal
Capacity Control
Time
Figure 48 Example Motor Current Overload
The Motor Current Overload is designed to allow the compressor to utilize maximum motor horsepower, without
exceeding its thermal limitations. When this overload is active, the message Ld Lim – Mtr Cur' will appear in the
upper left of the OPERATING DATA frame in the OmniView or the lower left corner of the Classic View.
This example applies only to fixed speed drive, if the machine is equipped with a variable speed drive please refer
to MCP-171 Variable Speed Compressor for operation of the Motor Current Overload.
For an example, consider a motor with a Full Load Amps (FLA) rating of 484 Amps. The motor has a 1.15
Service Factor.
Typical settings:
Motor Current Upper is set to the nameplate FLA times Service Factor. Please note that the
control panel shutdown is in addition to the electromechanical overloads in the motor starter.
484 FLA X 1.15 = 556A
Motor Current Upper Deadband must be set to at least two percent of the nameplate FLA times
Service Factor.
484 FLA X 1.15 X 0.02 = 11A on the graph 556A – 11A = 545A
Motor Current Lower is set to the nameplate FLA. In this example 484A.
Operating scenario:
1. Motor current increases above the ‘Motor Current Lower’ parameter. The length of the load pulses will be
limited based upon how far the motor current is above the ‘Motor Current Lower’ parameter. This causes
the slide valve to load slowly in an effort to avoid a high motor current shutdown. ‘Ld Lim - Mtr Cur’ load
limiting message is shown on the display.
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2. If motor current drops back below the ‘Motor Current Lower’ parameter normal capacity control resumes.
Continue at step 9.
3. If motor current continues to rise above the ‘Motor Current Upper’ minus ‘Motor Current Upper Deadband’
parameters, loading of the compressor is stopped. ‘Overld - Mtr Cur’ overload message is shown on the
display.
4. If the motor current rises above the ‘Motor Current Upper’, the unload solenoid will be energized
continuously in an attempt to reduce the motor current.
5. If the motor current remains above the ‘Motor Current Upper’ for thirty continuous seconds, a ‘High Motor
Current’ shutdown occurs. Continue at step 9.
6. When the motor current is reduced below the ‘Motor Current Upper’, the unload pulses are terminated
and loading is not permitted. The ‘Ld Lim - Mtr Cur’ load limiting message replaces ‘Overld - Mtr Cur’
message on the display.
7. When the motor current drops below ‘Motor Current Upper’ minus ‘Motor Current Upper Deadband’
parameters and stays above the ‘Motor Current Lower’ parameter, limited loading is allowed to achieve
the required capacity.
8. When motor current drops back below the ‘Motor Current Lower’ parameter, normal capacity control
resumes.
9. The overload situation is terminated and ‘Overld - Mtr Cur’ overload message is removed from the
display.
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Control
Compressor Lubrication System Control
GL/GLX SERIES
The oil pump is started and pressure is established before the compressor is started. If at least 14.5 psi of oil
pressure is not established in eight seconds, the oil pump will be stopped for ten seconds. The pump will be
restarted two additional times for eight seconds with ten second pauses between. If the pressure is still not
rd
achieved after the last (3 ) pump start, a “Low Oil Press – Startup” shutdown will be issued. Note: During the
pump off cycles, the [Oil Pump] button will be flashing at a 1.5 second on/off rate. When the compressor has been
running for 15 seconds, the low oil pressure limit is lowered to discharge pressure + 7.3 psi. If the oil pressure
falls below Discharge Pressure + 7.3 psi for greater than six seconds, a ‘Low Oil Pressure’ shutdown will be
issued.
A ‘High Oil Pressure’ shutdown will be issued immediately if the oil pressure exceeds discharge pressure + 72.5
psi and the compressor has been running at least thirty seconds.
Note 1
After a ninety second delay on startup, the pressure drop across the Oil Filter must be less than 20 psi or a
‘Hi Oil Filter Differential’ shutdown will occur after thirty seconds. There is also an alarm for this condition that is
enabled two minutes after startup. The oil pump will continue to run as long as the compressor is running.
GM SERIES
The GM series can be configured with or without an external oil pump. The configuration of the oil pump is based
upon the “Oil Pump Selection” Operating Parameter located under the Control heading. Setting this parameter to
a ‘0’ configures the compressor without an external oil pump. Setting this parameter to a ‘1’ configures the
compressor with an external oil pump. Setting this parameter to a ‘3’ configures the compressor with both an
internal and an external oil pump. Setting the parameter to a ‘2’ configures the panel to examine the state of an
input module to determine the oil pump selection. The input module is an option that must be factory configured
and it is used to alter oil pump operation for swing applications without requiring the operator to have access to
change parameters to affect this selection. The input module is typically wired to a selector switch located on the
door of the panel to simplify the internal / external oil pump - high stage/booster modes respectively.
When the GM series compressor is equipped with an external oil pump, the oil pump is started and will continue
to run as long as the compressor is running. Valid oil pressure is established before the compressor is started. If
at least 14.5 psi of oil pressure is not established in eight seconds the oil pump will be stopped for ten seconds.
The pump will be restarted two additional times for eight seconds with ten second pauses between. If the
rd
pressure is still not achieved after the last (3 ) pump start, a “Low Oil Press – Startup” shutdown will occur. Note:
During the pump off cycles, the [Oil Pump] button will be flashing at a 1.5 second on/off rate. When the
compressor has been running for fifteen seconds, the low oil pressure limit is lowered to discharge + 7.3 psi. If
the oil pressure falls below discharge pressure + 7.3 psi for longer than six seconds a ‘Low Oil Pressure’
shutdown will be issued. If the Inlet Oil Pressure exceeds discharge pressure + 58.0 psi after a thirty second
delay at startup, a ‘High Oil Pressure’ shutdown will occur immediately.
When the GM series compressor is not equipped with an external oil pump, the compressor is permitted to start
without first establishing oil pressure. When the compressor has been running for thirty seconds, the inlet oil
pressure to the compressor must exceed discharge pressure - 36.75 psi. If the oil pressure falls below discharge
pressure – 36.75 psi for longer than six seconds, a ‘Low Oil Pressure’ shutdown will occur. There is no high inlet
oil pressure failure for GM series compressors without an external oil pump.
Note 1
After a ninety second delay on startup, the pressure drop across the Oil Filter must be less than 20 psi or a
‘Hi Oil Filter Differential’ shutdown is issued after thirty seconds. There is also an alarm for this condition that is
enabled two minutes after startup.
GS SERIES
The GS series can be configured with or without an external oil pump. The configuration of the oil pump is based
upon the “Oil Pump Selection” Operating Parameter located under the Control heading. Setting this parameter to
a ‘0’ configures the compressor without an external oil pump. Setting this parameter to a ‘1’ configures the
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compressor with an external oil pump. Setting the parameter to a ‘2’ configures the panel to examine the state of
an input module to determine the oil pump selection. The input module is an option that must be factory
configured and it is used to alter oil pump operation for swing applications without requiring the operator to have
access to change parameters to affect this selection. The input module is typically wired to a selector switch
located on the door of the panel to simplify the internal / external oil pump - high stage/booster modes
respectively.
When the GS series compressor is equipped with an oil pump, the oil pump is started and will continue to run as
long as the compressor is running. Valid oil pressure is established before the compressor is started. If at least
14.5 PSI of oil pressure is not established in eight seconds the oil pump will be stopped for ten seconds. The
pump will be restarted two additional times for eight seconds with ten second pauses between. If the pressure is
rd
still not achieved after the last (3 ) pump start, a “Low Oil Press – Startup” shutdown will occur. Note: During the
pump off cycles, the [Oil Pump] button will be flashing at a 1.5 second on/off rate.
When the compressor has been running for fifteen seconds, the low oil pressure limit is lowered to discharge
pressure + 7.3 psi. If the oil pressure falls below discharge pressure + 7.3 psi for longer than six seconds a ‘Low
Inlet Oil pressure’ shutdown will be issued. If the Inlet Oil Pressure exceeds discharge pressure + 50.8 psi a ‘High
Oil Pressure’ shutdown will occur immediately.
When the GS series compressor is not equipped with an oil pump, the compressor is permitted to start without
first establishing oil pressure. When the compressor has been running for fifteen seconds, the inlet oil pressure
sensed at the compressor must exceed discharge pressure – 43.5 psi. The 43.5 psi limit includes drops through
the strainer, oil filter and interconnecting piping. If the total pressure drop across these components exceeds 43.5
psi, the inlet oil pressure at the compressor will be less than discharge pressure – 43.5 psi. If the inlet oil
pressure fails to exceed this limit for six seconds, a ‘Low Inlet Oil Pressure’ shutdown will be issued. There is no
high inlet oil pressure failure for GS series compressors without at external oil pump.
Note
After a ninety second delay on startup, the pressure drop across the internal Oil Filter must be less than 30 psi
1
or a ‘Hi Oil Filter Differential’ shutdown is issued after thirty seconds. There is also an alarm for this condition
that is enabled two minutes after startup.
Note 1: If the GForce™ control panel is configured for an Oil Filter Outlet Transducer (5TD) instead of an Oil Filter
Inlet Transducer (4TD) the maximum allowable Oil Filter Differential for all models is increased by 5 psi.
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Control
Compressor Slide Valve Control
Both the Slide Valve Load and Slide Valve Unload outputs from the GForce™ control panel are connected to dual
solenoid valves. The Slide Valve Load output is connected to solenoids Y1 and Y4. The Slide Valve Unload
output is connected to solenoids Y2 and Y3. Two additional solenoids are added on variable Vi compressors to
control the Vi slide. The Vi slide of a variable Vi compressor is loaded by energizing solenoid Y5 and unloaded by
energizing solenoid Y6. De-energizing both Y5 and Y6 lock the Vi slide in its’ current position.
The operation of the slide valve outputs when the compressor is not running is dependent on the type of
compressor. If the compressor is a GL/GLX series, both primary and Vi slide valve outputs will be de-energized
whenever the compressor is not running. For a GM and GS series compressor, the presence or absence of the
external oil pump will determine how the slide valve outputs are controlled. If the GM or GS series compressor
has an external oil pump or a combination of internal and external oil pumps, the control of the slide valve outputs
is identical to that of the GL/GLX series machines. For GM and GS series not equipped with an external oil
pump, both slide valve outputs will be energized when the compressor is not running if the slide valve reading
exceeds 5%. Both outputs are energized to allow the pressure on either side of the slide valve piston to equalize
thus allowing the internal spring in the compressor to unload the machine.
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Control
Compressor Variable Vi Control
G and X Series compressors offer continuous variable Vi control that is designed specifically for the model of
compressor that is being controlled. The variable Vi mechanism is unique to each compressor family (GL, GLX,
GM or GS) so different control philosophies are required for each compressor family. The compressor family is
fixed during the factory configuration, the specific compressor model must be set using the Operating Parameter
‘VARIABLE Vi CONTROL, Compressor Model Selection’ .
GL/GLX Series Variable Vi Control

The optimum Vi for the compressor is calculated based on the refrigerant, economizer activity, and current
operating conditions using a proprietary algorithm. The optimum Vi setting produced by the algorithm is displayed
as “Vi Setting” on the Analog Data frame of the OmniView or on the Vi detail display.
The Vi control of the GL/GLX Series compressor is accomplished using two slides that operate in tandem with
one-another to simultaneously maintain the desired Vi and capacity of the compressor. To achieve the desired Vi
Setting, the primary slide is moved initially followed by the Vi slide. The Vi position is infinitely variable (not
stepped) using the two slides with the movement of the slides determined by the current “Vi Mode” of the
compressor. The Vi Mode (1, 2 or 3) determines which slide is being moved to control capacity and which slide is
being used to achieve the desired Vi setting. The Vi Mode and Current Vi are displayed on the bottom line of the
Operating Data frame of the OminView.
Vi Mode #1
The primary slide is moved to control the capacity of the machine and the Vi slide is kept unloaded. The
Vi of the compressor in Vi Mode #1 is therefore a function of the movement of the primary slide in order to
maintain the desired suction pressure / process temperature setpoint. The primary slide is used to control
the capacity of the machine from completely unloaded up to a position where the optimum Vi for the
operating conditions is located. This positon is displayed as “Vi SCALC” in the Operating Data Display.
Loading the primary slide beyond the value of Vi SCALC increases the Vi of the compressor beyond the
calculated Vi Setting. If the machine is attempting to load (increase capacity) and the primary slide
reading approaches the value of Vi SCALC, the primary slide will be locked at the value of Vi SCALC and
a 2 second transition timer is started. The 2 second timer will only time out when the load solenoid output
is energized, therefore; the actual duration of the transition timer is inversely proportional to the duration
of the load pulses. Continous load signals will transtion from Vi Mode #1 to Vi Mode #2 in 2 seconds.
Short load pulses will take significantly longer to transition because the time can only accumulate based
on the duration of the load pulses. When the requests to load the compressor accumulate 2 seconds of
load pulses, the timer will elapse and the Vi Mode will transition from Mode #1 to Vi Mode #2. If any type
of unload signal is generated interupting the 2 second time transition timer, the unload signals will be
issued and the 2 second timer will be reset.
Vi Mode #2
The primary slide is programmed to track the value of Vi SCALC and the Vi slide is adjusted to maintain
the suction pressure / process temperature setting. The value of Vi SCALC is constantly being
recalculated based on the current operating conditions. While in Vi mode #2, the primary slide will only
be moved to correct for changes in the value of Vi SCALC. There is no positional feedback from the Vi
slide, subsequently, there is no value for the Vi slide valve position for GL/GLX Series compressors. In Vi
Mode #2, the capacity of the compressor lies between the value of SCALC and 100% and will be a
calculated value based on the following formula:
Slide valve reading = SCALC + ((100% - SCALC) * (TIMER Value/30))
When the machine is attempting to load (increase capacity) and has initially entered Vi Mode #2 from Vi
mode #1, a 30 second timer is started. This 30 second timer will only time out while the load solenoid
output is energized, therefore; the actual duration of the transition timer is inversely proportional to the
duration of the load signals. Continous load signals will transtion from Vi Mode #2 to Vi Mode #3 in thirty
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Control
seconds. Short load pulses will take a proportionally longer time to transition because the timer is only
permitted to time for the duration of each load pulse. The slide valve reading will increase proportionally
as this thirty second transition timer accumulates. With this method, the accumulating load signals are
used to alter the displayed slide valve reading from the value of SCALC to 100%. The slide valve reading
will be approaching 99.9% just as the equivalent of thirty seconds of loading is accumulated. When the
timer has accumulated the full thirty seconds, the Vi Mode will transition from Mode #2 to Vi Mode #3
locking the machine at 100%.
An unload signal that interupts the thirty second Vi Mode #2 to Vi Mode #3 transition timer will
automatically set the Mode #2 to Mode #1 transition timer with the equivalent amount of time that the
compressor has been loading in Mode #2. This method allows the microprocessor to determine a relative
“position” for the Vi slide based on the duration of load/unload pulses. For example: If the compressor
has accumulated twelve seconds of Load pulses in Vi Mode #2, and begins unloading, twelve seconds of
unload pulses must accumulate prior to returning toVi Mode #1. In this example the slide valve reading
would be displayed as 40% of the difference between SCALC and 100% when the switch to unloading
occurred using the formula above.
Similarly, if the machine is attempting to unload (decrease capacity) and has initially entered Mode #2
from Mode #3, a thirty second unload timer is also started. This thirty second timer will only time out while
the unload solenoid output is energized, therefore; the actual duration of the transition timer is inversely
proportional to the duration of the unload signals. If a request to unload the compressor continues for
thirty continuous seconds, the Vi Mode will transition to Vi Mode #1. A load signal that interupts the thirty
second Vi Mode #2 to Vi Mode #1 transition timer will automatically set the Mode #2 to Mode #3 transition
timer with the equivalent amount of time that the compressor has been unloading. This method allows
the microprocessor to determine a relative “position” for the Vi slide based on the duration of load/unload
pulses. For example: If the compressor has accumulated 18 seconds of Unload pulses in Vi Mode #2,
and begins loading, 18 seconds of load pulses must accumulate prior to returning to Vi Mode #3. The
slide valve position that is displayed when transitioning from Mode #2 to Mode #1 is directly proportional
to the remaining time on the transition timer using the following formula.
Slide valve reading = 100 - ((100% - SCALC) * (TIMER Value/30))
This formula is different than the one used to transition between Modes #2 and Mode #3 because the
slide is operating in the opposite direction. The longer the Vi slide is loaded/unloaded in Vi Mode #2, the
equivalent time must elapse before the Vi mode can return to the previous Vi Mode. This sequence of
operation is used to approximate the operation of a conventional slide valve assembly for a GL/GLX
Series Variable Vi compressor.
Vi Mode #3
The primary slide continues to track the value of Vi SCALC and the Vi slide is placed in load to force the
compressor to maximum capacity. This arrangement ensures the maximum capacity from the
compressor while maintaining the optimum Vi setting for the current operating conditions. The capacity of
the compressor will always be displayed as 100% while operating in Vi Mode #3. In Vi Mode #3, a 1
second timer will be started when the capacity control generates an unload signal to decrease the
capacity of the compressor. When the unload signal accumulates the equivalent of 1 second of unload
pulsess, the Vi Mode will transition to Vi Mode #2. The Vi Mode will bypass the 1 second time delay and
transition to Mode #2 immediately if the capacity control is placed in Manual Unload mode.
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Control
GM Series Variable Vi Control
The optimum Vi for the compressor is calculated based on the refrigerant, economizer activity and current
as “Vi Setting” on the Analog Data frame.
The Vi control of the GM series compressor is accomplished using a series of two parallel slides that are operated
simultaneously maintain the desired Vi and capacity of the compressor. Each slide operates independently and
has its’own position indicator and proportional controller mechanism.
The primary slide is used to adjust the capacity of the compressor to maintain the desired suction pressure /
process temperature setpoint and is completely independent of the Vi slide.
The Vi Slide is used to maintain the optimum Vi for the current operating conditions. The optimum position of the
Vi Slide is a calculated value that is a function of the current optimum Vi setting and the current primary slide
valve reading. The optimum position for the Vi Slide is displayed as ‘Ideal Vi Slide Position’.The physical position
of the Vi slide is displayed as ‘Vi Slide Position’. ‘Ideal Vi Slide Position’ and ‘Vi Slide Position’ are both displayed
on the Analog Data Display frame as percentages (%). The GForce™ is programmed to proportionally load or
unload the Vi slide as needed until its’ percentage matches the calculated ‘Ideal Vi Slide Position’ percentage (+/-
1% deadband) when the compressor is running. When the ‘Vi Slide Position’ matches ‘Ideal Vi Slide Position’ +/-
the deadband, the compresor is operating at the optimum Vi Setting.
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Control
GS Series Variable Vi Control
The optimum Vi for the compressor is calculated based on the refrigerant, economizer activity and current
as “Vi Setting” on the Analog Data frame.
The Vi control of the GS series compressor is accomplished using a series of two parallel slides that are operated
independantly to maintain the desired Vi and capacity of the compressor.
The primary slide is used to adjust the capacity of the compressor to maintain the desired suction pressure /
process temperature setpoint and is completely independent of the Vi slide.
The Vi slide is used to maintain the optimum Vi for the current operating conditions. The Vi slide is loaded or
unloaded based upon a calculated value that is a function of the current optimum Vi setting and high / low Vi limits
of the compressor. This is displayed as ‘Optimum Vi’. If the ‘Optimum Vi’ for the compressor is below ‘Midpoint of
the Vi Range’ the Vi slide is loaded. If the ‘Optimum Vi’ setting is above the ‘Midpoint of the Vi Range’, the Vi
slide is unloaded. The Vi slide is loaded or unload in this manner when the compressor is running. There is no
positional feedback from the Vi slide, subsequently, there is no value displayed value for the Vi slide valve on GS
series compressors.
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Control
IntelliSOC™ Discharge Temperature Control
An electronic modulating valve is provided to control the Oil Cooling. The position of the valve is based on the
Discharge Temperature. The desired Discharge Temperature is an operator-adjustable parameter.
The valve is designed to recalibrate itself when it registers 4mA for one second. This calibration is necessary
on a periodic basis to provide accurate readout information. The program is configured to unload the valve to
4mA when the compressor shuts off. After a delay to assure the valve has reached the fully unloaded position,
the valve will resort to a new minimum position, allowing it to open slightly to avert trapping liquid between the
valve and the shutoff solenoid.
The modulating valve is held closed for 1.5 seconds after the shutoff solenoid is energized to allow pressure to
build against the control valve.
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Appendices
Appendix A: Table of Figures
Figure 1 GForce™ Touch Screen with Overlay ..........................................................................................................................1
Figure 2 Example Menu Bar ........................................................................................................................................................2
Figure 3 Panel Settings Icon ........................................................................................................................................................2
Figure 4 Compressor View Screen ..............................................................................................................................................3
Figure 5 OmniView .....................................................................................................................................................................5
Figure 6 Parameter Entry Keypad ................................................................................................................................................6
Figure 7 User Level Restriction ...................................................................................................................................................6
Figure 8 Operating Data Frame ...................................................................................................................................................7
Figure 9 GM Vi Slide Position ....................................................................................................................................................7
Figure 10 Slide Valve Maximum .................................................................................................................................................7
Figure 11 Keypad Frame .............................................................................................................................................................8
Figure 12 Classic View Window ............................................................................................................................................... 10
Figure 13 Detail Display Menu.................................................................................................................................................. 11
Figure 14 Analog Data Window ................................................................................................................................................ 12
Figure 15 Analog Data Frame .................................................................................................................................................... 12
Figure 16 Calibration Keypad .................................................................................................................................................... 14
Figure 17 Slide Valve Calibration ............................................................................................................................................. 15
Figure 18 Slide Valve Position Sensor....................................................................................................................................... 15
Figure 19 XXX:5 CT setting ...................................................................................................................................................... 20
Figure 20 XXX:1 CT setting ...................................................................................................................................................... 20
Figure 21 Motor Current Calibration ......................................................................................................................................... 21
Figure 22 Digital Detail Screen ................................................................................................................................................. 22
Figure 23 Digital Data Frame .................................................................................................................................................... 22
Figure 24 Panel Settings Window.............................................................................................................................................. 24
Figure 25 Example Suction Pressure Parameters window ......................................................................................................... 25
Figure 26 Example Process Temperature Parameters window .................................................................................................. 27
Figure 27 Example Discharge Parameters windows .................................................................................................................. 29
Figure 28 Example Remote Slide Valve Parameters window ................................................................................................... 31
Figure 29 Example Control Selection Parameters window........................................................................................................ 32
Figure 30 Example Lubrication System Parameters windows ................................................................................................... 36
Figure 31 Compressor Model Selection (prior to version 6.9)................................................................................................... 38
Figure 32 Compressor Model Selection (version 6.9 and above) .............................................................................................. 38
Figure 33 Example Compressor Motor Parameters window ..................................................................................................... 39
Figure 34 Example Power Parameters window ......................................................................................................................... 41
Figure 35 Example Slide Valve Output Parameters window ..................................................................................................... 43
Figure 36 PLC Connections using GForce™ Power ................................................................................................................. 44
Figure 37 PLC Connections using PLC Power .......................................................................................................................... 44
Figure 38 Example Alarms window .......................................................................................................................................... 46
Figure 39 Example Alarm Notification Window ....................................................................................................................... 46
Figure 40 Example Alarm Condition ......................................................................................................................................... 46
Figure 41 Example Shutdowns window .................................................................................................................................... 49
Figure 42 Example Shutdown notification window................................................................................................................... 49
Figure 43 Example Shutdown Condition ................................................................................................................................... 49
Figure 44 Suction Pressure / Process Temperature / Discharge Forward Capacity Control ...................................................... 56
Figure 45 Suction Pressure / Process Temperature / Discharge Reversed Capacity Control ..................................................... 57
Figure 46 Example Low Suction Pressure Overload during Process Temperature Control ...................................................... 58
Figure 47 Example Discharge Pressure Overload...................................................................................................................... 59
Figure 48 Example Motor Current Overload ............................................................................................................................. 60
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Appendices
Appendix B: Revisions
Revision A 5/1/07
Updated Remote Viewer operation.
Updated terminology on Variable Vi pages.
Added Intranet configuration screen.
Updated multiple screen shots.
Revision B 5/18/07
Eliminated unused Operating Parameter for Internal/External Oil Pump Selection, selection is made in configuration file.
Added CT to 4-20 mA converter configuration and revised motor current calibration section.
Fixed some errors in figure identification and table of figures.
Added note to description of [LOCAL START] to indicate that pressing it a second time when the compressor has cycled
off or has not started in cycling mode.
Added revision record.
Revision C 6/7/07
Added additional photos and text describing analog input connectors.
Added photo and text describing configuration jumpers.
Updated descriptions of some Variable Vi analog descriptions.
Corrected typographical errors.
Revision D 6/20/07
Clarified use of Model Selection parameter in Variable Vi section and added screen shot.
Maximum Inlet Oil Temp for GL, R-22, IntelliSOC machines was incorrectly listed at 155°F instead of 175°F.
Added detailed description of parameter entry procedures.
Corrected typographical errors and figure cross-references.
Revision E 9/25/07:
Updated description of ‘Motor Current’ in Analog Data and ‘Motor Current Maximum’ in Operating Parameter sections.
Added description of Emergency Stop Input.
Updated screen shot of ‘Classic View’ to show Anti-Recycle Time indicator.
Added two-point calibration for Motor Current.
Added description of Emergency Stop Input.
Revised description of Motor Thermal Shutdown Input.
Updated ‘Service Menu’ section and “Update Utility”, added some new utilities.
Revision F 5/14/08:
Updated touch screen calibration section to include the additional 2 methods.
Fixed typo “ADC” to “DAC” in Analog Out section.
Updated “Panel Settings” figure.
Removed “Update Update Utility” section.
Updated Intranet keyboard figure.
Updated Maintenance Log figure.
Updated Remote Viewer Setup figure.
Updated Update Utility figure.
Added “Auto Logoff” explanation in “Panel Settings” and ”User Level” sections.
Added “About” explanation and figure.
Updated System Restore description.
Added PDF loading bar figure and description.
Fixed figure listing in table of contents.
Added a note describing the change in slide position indicators on GS machines.
Updated RX-Trend Image.
Updated Model Figure in Variable VI section for versions after 6.9
Updated IntelliSOC ranges and default values
Revision G 9/17/08:
Updated File Manager section – removed [Check Drive] button and explanation
Added [SAVE SNAPSHOT] Button to the RX-Trend section and added explanation.
Added description of optional Oil Filter Outlet transducer and alternate Oil Filter Differential calculation.
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Appendices
Revision H 11/17/09:
Removed hardware, historical, documentation and service menu descriptions, this information common to all GForce™
Compressor Control Panels is now in MCP-209.
This document is no longer referred to as ‘Section 3’ of the compressor manual. Deleted references to ‘Section 3’ from
notes at the ends of analog, digital, alarm and shutdown sections. References to ‘contract’ changed to ‘project’.
Updated overlay image on introduction page.
Deleted reference to I/O diagnostic on introduction page, updated utilities description
Fixed image borders.
Fixed headings for Lubrication System and Slide Valve Control.
Changed brackets to parenthesis in control description section.
Corrected text case in keypad button references.
Added reference to Dual Oil Pump option addendum.
Added instructions to upload a new graphic image for the compressor data screen.
Updated motor current overload section.
Changed high panel temperature alarm point.
Updated slide valve calibration images and text.
Described cause of “???” being displayed for analog data values.
Refer to project specific addendum included with this document for description of Miscellaneous Parameters.
Add description of Remote Sequence Slave connections with figures.
Added description of DC module appearance on Digital Detail screen.
Added checkbox on panel settings screen to enable/disable anti-recycle timer when active.
Updated calibration procedure for GM secondary slide.
Added notes indicating that Oil Separator Heater control may be disabled in the factory configurations for certain
applications.
Fixed numbers of steps in ‘Slide Valve Calibration without an External Pump.
Revision J 08/04/10:
GForce application revision 10.2
Added note about custom buttons and/or indicators on keypad.
‘Digital Data’ was missing from table of contents.
Updated OmniView, Classic & Compressor view screen shots.
Fixed brackets in power calculation on page 35.
Cleaned up layout of Keypad page, updated graphic for new communications indicator.
Chinese characters were missing from Panel Settings screen shot.
Updated Panel Settings text.
Updated text describing power calculations.
Slide Valve Calibration without pump, second reference to ‘loaded’ was ‘unloaded’.
Added note regarding recommendation of the frequency of transducer calibration.
Added detailed description of ICTD and ICTD calibration.
Updated description of Low Oil Level Shutdown.
Updated description of Low Inlet Oil Temperature alarm and shutdown.
Added °C values for all temperatures.
Added optional parameter for Oil Filter Differential setting when using Oil Filter Outlet Transducer.
Revision K 03/24/11:
Revisions are now hyperlinked to the affected area of the document.
Changed title to include X Series. Added references to GLX where GL was referenced.
Added new slide valve position sensor calibration instructions. Updated slide valve calibration to better cover variable Vi
machines.
Removed reference to “Panel Purge Failure Input, Module 1-3” from digital data. Location is variable and is defined in the
special project addendum.
Corrected text for ‘Motor Current Maximum’ in calibration procedure and on detail screen.
Changed duration compressor slide valve unload shutdown delay.
Changed IntelliSOC parameter limits.
Removed red shutdown dot from Motor Current Maximum operating parameter on compressor motor detail screen since
there is no related shutdown.
Added X Series Suction Filter Combination Solenoid Output
Modified 'High Oil Pressure' Shutdown operation.
Document: MCP-169
Revision: Q
Effective: 07-23-12 72 of 74
Appendices
Revision L 05/04/11:
Updated slide valve position sensor calibration instructions.
Updated oil pressure limit in GM without external pump lubrication system control description, value was 36.3 psi, now
36.75 psi.
Revision M 05/24/11:
Updated Oil Filter Differential Pressure calculation, parameter and alarm/shutdown descriptions for X Series compressor
packages. Pages 12, 30, 40 & 43.
Revision N 08/29/11:
Added Slide Valve Position Maximum operating parameter and description.
Added description of the markers for slide valve position if it is limited in its minimum or maximum.
Added description for “Unload Slide Valve Before Stop’.
Updated ‘Compressor Slide Valve Unload’ shutdown to include the description for ‘Unload Slide Valve Before stopping’.
Changed Operating Parameter ‘Control Point’ to ‘Control Mode Point’.
Added Operating Parameter ‘Heat Pump’.
Added description of Suction Bypass Solenoid Output.
Added description of Fast Unload Solenoid Output.
Increased the time the oil pump must run for G Series compressors to initiate the Oil Drain 10 Minute Timer from 10
seconds to 20 seconds to allow enough time for building valid oil pressure. Pages 52 & 54.
Modified GL OmniView to display the secondary slide % as a red bar on the same linear gauge as the primary capacity
slide blue bar.
Added display of the GM secondary slide input % as a blue bar on the linear gauge directly below the primary capacity
slide on the OmniView.
The compressor slide valve's unload solenoid now is now de-energized when the compressor is not running.
Added Remote Mode Control Setpoint.
Revision P 01/04/12:
Changed “DX Chiller” reference to “Pump Down”.
Changed order of descriptions to match order of screens and parameters on GForce display, GForce was modified to
make list in Displays match order in Control/Shutdown Parameters.
Added new parameters for Discharge Pressure Control. Added screen shots with and without Discharge Pressure Control
enabled.
Modified Control Mode Parameter to include Discharge Pressure selection.
Added description for Reverse Capacity Control.
Changed ‘Heat Pump’ parameter to ‘Capacity Control Direction’.
Added descriptions of alarms generated when analog faults are detected.
Corrected page reference to Variable Vi section in Operating Data description.
Updated screen shot of Analog Data display.
Updated screen shot of Panel Settings window.
Fix minor inconsistency in Low Suction Cycling on Suction Pressure Detail screen.
Updated Control Parameters detail screen.
Updated Lubrication System parameters to show separate screens for Inlet Oil and Oil Separator.
IMPORTANT! Updated slide valve position sensor calibration procedure to incorporate latest changes to sensor
operation.
Added images and description of indicators for Vi slide position and limits for slide valve travel. Revised layout of
Operating Data section. Deleted an incorrect reference to slide stop.
Changed ‘Operating Parameters’ to ‘Control/Shutdown Parameters’
Moved references to external documents to end of table of contents.
Reduced size of most full-screen screen shots of the parameter displays.
Added description of Remote Slide Valve parameters.
Deleted reference to operating parameter out of range alarms.
Deleted reference to Alarm parameters out of range alarms
Deleted reference to MCP-176, Oil Return is described in project addendum.
Added cross-references to figures and page numbers when referenced in text.
Updated file name to match document title.
Changed Vi slide references from Secondary Slide to Vi Slide to match Grasso terminology.
Document: MCP-169
Revision: Q
73 of 74 Effective: 07-23-12
Appendices
Revision Q 03/27/12:
Added a note to suction overload stating the parameter values
Updated overload strings
Added a note to discharge overload stating the deadband cannot be 0 and changed some of the parameters to match
GForce’s name
Updated Panel settings screen shot and added description for gesturing and analog fault alarms generation
Updated Analog Data Screen and added description for analog faults display
Updated Analog Input/Output fault alarms to add notes about GPIO I not generating the fault alarms.
Added ‘Loss Of Remote Start Signal’ Alarm
Added a note to Remote Mode Control Setpoint
Document: MCP-169
Revision: Q
Effective: 07-23-12 74 of 74
GForce™
Communications Protocol
AB Modbus Description R/W Format Scale
Modbus Address is for Modbus Ethernet and Serial Modbus via FES Gateway and ComMENT unless noted.
Panel Information and Configuration

Panel ID for Sequencing and Panel-to-Panel
N10:0 400001 R 1-255 X1
Communications
N10:1 400002 Panel IP Address, first octet R 0-255 X1
N10:2 400003 Panel IP Address, second octet R 0-255 X1
N10:3 400004 Panel IP Address, third octet R 0-255 X1
N10:4 400005 Panel IP Address, fourth octet R 0-255 X1
37=GForce G Series Comp Panel

38=GForce S Series Comp Panel
39=GForce H-E Comp Panel
40=GForce R Series Comp Panel
41=GForce L-C Comp Panel
42=GForce L Series Comp Panel
43=GForce Mycom Step Variable Vi Comp
Panel
44=GForce Sullair Comp Panel
45=GForce Vilter Comp Panel
48=GForce Hall Comp Panel
49=GForce Frick RWB II/TDSH/RXF
50=GForce System Control Panel
52=GForce G Series w/ Recip Control
53=GForce S Series w/ Recip Control
54=GForce H-E w/ Recip Control
55=GForce R Series w/ Recip Control
N10:5 400006 Program Type Code R 56=GForce L-C w/ Recip Control X1
57=GForce L Series w/ Recip Control
58=GForce Mycom Step Variable Vi w/
Recip Control
59=GForce Sullair w/ Recip Control
60=GForce Vilter w/ Recip Control
61=GForce Hall w/ Recip Control
62=GForce Frick RWB II/TDSH/RXF w/
Recip Control
63=GForce System Control Panel w/ Recip
64=GForce Frick RDB w/ Recip Control
65=GForce Sabroe w/ Recip Control
66=GForce Stal w/ Recip Control
67=GForce Centrifugal w/ Recip Control
76=GForce Frick RDB Comp Panel
77=GForce Sabroe Comp Panel
78=GForce Stal Comp Panel
79=GForce Centrifugal Comp Panel
N10:6 400007 Program Revision Level R X10

N10:7 400008 Configuration Revison Level R X10
N10:8 400009 Compressor Control Enabled R 0=No/1=Yes X1
N10:9 400010 Custom Parameters Enabled R 0=No/1=Yes X1
N10:10 400011 Event Timers Enabled R 0=No/1=Yes X1
N10:11 400012 Compressor Sequencer Enabled Level 1 R 0=No/1=Yes X1
N10:15 400016 Saturated Liquid Temperature Calcs 1 R 0=No/1=Yes X1
N10:19 400020 Condenser Control Enabled R 0=No/1=Yes X1
N10:20 400021 Wet Bulb Discharge Pressure Control Enabled R 0=No/1=Yes X1
N10:21 400022 Water Pump Lockout Enabled R 0=No/1=Yes X1
N10:22 400023 E/M Recip Control Enabled R 0=No/1=Yes X1
N10:23 400024 Evaporator Control Enabled R 0=No/1=Yes X1
N10:24 400025 Pump Package Control Enabled R 0=No/1=Yes X1
N10:25 400026 kWh Monitor Enabled R 0=No/1=Yes X1
N10:26 400027 Low Line Voltage Trip Point R X10
400028 -
Document MCP-170
Revision: N
1 of 64 Effective 01/2012
GForce™
| Reserved for Configuration |
400050 -
Panel Settings
0=Eng/1=Españ/2=中文/3=Deustch/4=Franç
N10:50 400051 Language R/W X1
ais
N10:51 400052 Pressure Units R/W 0=kg/cm2/1=kPa/2=Psi/3=Bar X1
Note: Scaling for values with pressure units are dynamic, based on engineering units. (Address 400052)
kg/cm2 & mmHg - X100 & X10
kPa - X10
Psi & ""Hg - X10
bar - X100
N10:52 400053 Temperature Units R/W 0=°C/1=°F X1
N10:53 400054 Reserved X1
N10:54 400055 Real Time Clock Hours R/W 0 to 23 X1
N10:55 400056 RTC Minutes R/W 0 to 59 X1
N10:56 400057 RTC Seconds R/W 0 to 59 X1
N10:57 400058 RTC Day of Week R 0=Sunday…6=Saturday X1
N10:58 400059 RTC Month R/W 1=January…12=December X1
N10:59 400060 RTC Day of Month R/W 1 to 31 X1
N10:60 400061 RTC Year R/W X1
N10:61 400062 Historical Trending Interval R/W 1 to 120 Minutes X10
N10:62 400063 Unused
1=Compressor View
2=Recip Compressor View
3=OmniView
4=Startup Screen
N10:63 400064 Screen Picker W X1
101=Evap Zone #1 Detail
…
180=Evap Zone #80 Detail
0=Service
N10:64 400065 User Level R 1=User X1
2=Basic
400066 -
| Reserved for Panel Settings |
400070 -
Screw Compressor Configuration

N10:70 400071 Variable Speed Compressor Motor R 0=No/1=Yes X1
N10:71 400072 Variable Speed Oil Pump Motor R 0=No/1=Yes X1
1=Full Flow/2=Cycling/3=Startup/4=No
N10:72 400073 Oil Pump Type (Frick) R X1
Pump
N10:73 400074 Dual Oil Pumps R 0=No/1=Yes X1
N10:74 400075 Auxiliary Oil Pump R 0=No/1=Yes X1
N10:75 400076 Hot Gas Bypass R 0=No/1=Yes X1
N10:76 400077 IntelliSOC R 0=No/1=Yes X1
N10:77 400078 Vibration Monitoring R 0=No/1=Life Trac/2=Vtrac X1
N10:78 400079 Pump Down R 0=No/1=Manual/2=Automatic DX control X1
N10:79 400080 Variable Vi R 0=No/1=Continuous/2=Stepped X1
N10:80 400081 Engine or Turbine Drive R 0=No/1=Yes X1
N10:81 400082 Compressor Model R G Series Variable Vi Only X1
GS
Index GM Series GL Series
Series
1 C-51 H-51 P-50
2 C-52 L-51 P-51
3 C-53 M-51 P-52
4 D-51 N-51 R-50
5 D-52 R-51
6 D-53 R-52
7 E-51 S-50
8 E-52 S-51
9 E-53 S-52
10 G-51 V-50
11 G-52 V-51
12 G-53 V-52
Document MCP-170
Revision: N
GForce™
13 G-9 W-50
14 W-51
15 W-52
16 Y-50
17 Y-51
18 Y-52
19 Z-50
20 Z-51
21 Z-52
22 XA-50
23 XA-51
24 XA-52
25 XB-50
26 XB-51
27 XB-52
28 XC-50
29 XC-51
30 XC-52
31 XD-50
32 XD-51
33 XD-52
34 XE-50
35 XE-51
36 XE-52
37 XF-50
38 XF-51
39 XF-52
0=R22/1=R717/2=R134a/3=R12/4=R290
5=R404a/6=R507/7=R1270/8=R23
N10:82 400083 Refrigerant Selection R X1
9=R744/10=R600a/11=R170/12=Natural
Gas
N10:83 400084 Unused
0=No Transducer Required
N10:84 400085 Oil Filter Outlet Transducer R X1
1=Transducer Required
0=High-Stage / No Oil Pump

1=High-Stage / Startup Oil Pump
N10:85 400086 Hall Oil / Booster / High Stage Selection R X1
2=Booster / Full Flow Oil Pump
3=Booster / High-Stage / Cycling Oil Pump
N10:86 400087 Hall Oil Pump Return R 0=Disable/1=Enabled X1

N10:87 400088 Double Balance Piston (H-E) R 0=Disable/1=Enabled X1
N10:88 400089 Full Flow Cycling (XRV) R 0=Disable/1=Enabled X1
N10:89 400090 Oil Pump Selection R 0=Int/1=Ext/2=D.I./3=Int+Ext X1
N10:90 400091 Process Temperature Enabled R 0=No/1=Yes X1
N10:91 400092 Fast Unload Solenoid (Sabroe) R 0=Disable/1=Enabled X1
N10:92 400093 Startup Suction Bypass (Sabroe) R 0=Disable/1=Enabled X1
400094 -
| Reserved for Compressor Configuration |
400120 -
Screw Compressor Status

N11:20 400121 Compressor Start Mode R 0=Stop/1=Local/2=Remote X1
0=Hold/1=Unload/2=Load/3=Auto/4=Externa
N11:21 400122 Compressor Capacity Control Mode R X1
l
0=Stopped/1=Starting/2=Running/3=Stoppin
N11:22 400123 Compressor Operating Status R X1
g
N11:23 400124 Load Solenoid Status R 0=Off/1=On X1
N11:24 400125 Unload Solenoid Status R 0=Off/1=On X1
0=Suct/1=Proc/2=Pump Down/3=Remote
N11:25 400126 Current Control Mode R X1
SV
N11:26 400127 Current Control Point R 1=Setpint 1/2=Setpoint2 X1
N11:27 400128 Anti-Recycle Timing? R 0=No/1=Yes X1
N11:28 400129 Anti-Recycle Hours Remaining R X1
N11:29 400130 Anti-Recycle Minutes Remaining R X1
N11:30 400131 Anti-Recycle Seconds Remaining R X1
N11:31 400132 Power Fail Reset Timing? R 0=No/1=Yes X1
N11:32 400133 Power Fail Reset Hours Remaining R X1
Document MCP-170
Revision: N
GForce™
N11:33 400134 Power Fail Reset Minutes Remaining R X1
N11:34 400135 Power Fail Reset Seconds Remaining R X1
N11:35 400136 Oil Drain Timing? R 0=No/1=Yes X1
N11:36 400137 Oil Drain Hours Remaining R X1
N11:37 400138 Oil Drain Minutes Remaining R X1
N11:38 400139 Oil Drain Seconds Remaining R X1
GL Series 0=Vi Mode 1/1=Vi Mode 2/2=Vi
N11:39 400140 Vi Mode or Step R Mode 3 ; HE and Frick 0=Lo Vi/1=Medium X1
Vi/2=High Vi
N11:40 400141 Current Capacity Step R Frick RDB only X1
N11:41 400142 Current Capacity in Percent R Frick RDB only 0-100% X1
N11:42 400143 High Discharge Pressure Overload R 0=No/ELSE Yes X1
N11:43 400144 Low Suction Pressure Overload R 0=No/ELSE Yes X1
N11:44 400145 High Suction Pressure Overload R 0=No/ELSE Yes X1
N11:45 400146 Variable Vi Overload R 0=No/ELSE Yes X1
N11:46 400147 High Motor Current Overload R 0=No/ELSE Yes X1
N11:47 400148 Slide Valve Overload R 0=No/ELSE Yes X1
N11:48 400149 Load Limiting Mode Overload R 0=No/ELSE Yes X1
400150 -
| Reserved for additional Compressor Status |
400180 -
Screw Compressor Analog Data

N11:80 400181 Suction Pressure X10
N11:81 400182 Auxilliary Suction Safety Pressure X10
N11:82 400183 Discharge Pressure X10
N11:83 400184 Inlet Oil Pressure X10
N11:84 400185 Oil Filter Differential Pressure X10
N11:85 400186 Oil Filter Inlet Pressure X10
N11:86 400187 Oil Filter Outlet Pressure X10
N11:87 400188 Oil Differential Pressure X10
N11:88 400189 Oil Separator Temperature X10
N11:89 400190 Inlet Oil Temperature X10
N11:90 400191 Discharge Temperature X10
N11:91 400192 IntelliSOC Valve Position X10
N11:92 400193 Suction Temperature X10
N11:93 400194 Process Temperature X10
N11:94 400195 Slide Valve X10
N11:95 400196 Slide Valve based on Current VI X10
N11:96 400197 Slide Valve (Scalc) X10
N11:97 400198 Slide Valve Voltage X10
N11:98 400199 Motor Amps X10
N11:99 400200 kiloWatt Demand X10
N12:0 400201 kWh Average Usage X10
N12:1 400202 kWh Pulse Counter X10
N12:2 400203 Volume Index (Vi) X10
N12:3 400204 Compressor VFD Motor Speed (RPM) X1
N12:4 400205 Compressor VFD Motor PID % X10
N12:5 400206 Suction Superheat X10
N12:6 400207 Discharge Superheat X10
N12:7 400208 Current Capacity Step X10
N12:8 400209 Compressor Suction 1 Setpoint X10
N12:9 400210 Compressor Process 1 Setpoint X10
N12:10 400211 Compressor Suction 2 Setpoint X10
N12:11 400212 Compressor Process 2 Setpoint X10
N12:12 400213 Remote Slide Valve Position X10
N12:13 400214 Vi Stop Position X10
N12:14 400215 Slide Valve Voltage X10
N12:15 400216 Slide Valve Position mm X10
N12:16 400217 Double Balance Piston Pressure X10
GM Secondary Slide Position
N12:17 400218 X10
Frick Slide Stop Position
GM Secondary Slide Current Loop
N12:18 400219 X10
Frick Slide Stop Voltage
N12:19 400220 Miscellaneous Superheat #1 X10
Document MCP-170
Revision: N
GForce™
N12:31 400232 Not Used X10
N12:32 400233 Not Used X10
N12:33 400234 Pressure Ratio X10
N12:34 400235 Pre-Rotation Vane Output % X10
N12:35 400236 Centrifugal Hot Gas Output % X10
N12:36 400237 Oil Sump Pressure X10
N12:37 400238 Booster Compressor Suction Pressure X10
400239 -
| Reserved for additional Compressor Analog Data |
400250 -
System Panel Analog Data (Modbus Ethernet Only)

N12:50 400251 Sequence Suction Pressure Level 1 X10
N12:54 400255 Sequence Process Temperature Level 1 X10
N12:58 400259 Sequence Discharge Pressure Level 1 X10
N12:62 400263 System kW X10
N12:63 400264 Unused X10
N12:64 400265 Unused X10
N12:65 400266 Unused X10
N12:66 400267 Unused X10
N12:67 400268 Unused X10
N12:68 400269 Accumulated MWh 1 X1
N12:69 400270 Accumulated kWh 1 X10
400289 -
| Reserved for additional System Panel Analog Data |
400300 -
Analog Data (Modbus Ethernet required for Temps, Inputs, Math and PIDs above 50)
Document MCP-170
Revision: N
GForce™
N13:0 400301 Miscellaneous Temperatures 0-99 R based on configuration X10
| |
N13:99 400400 R
N14:0 400401 Miscellaneous Inputs 0-99 R based on configuration X10

| |
N14:99 400500 R
N15:0 400501 Miscellaneous Pressures 0-49 R based on configuration X10

| |
N15:49 400550 R
N15:50 400551 General Purpose Counters 0-49 R based on configuration -

| |
N15:99 400600 R
N16:0 400601 Math Blocks 0-199 R based on configuration -

| |
N17:99 400800 R
N18:0 400801 PID outputs 0-99 R based on configuration X10

| |
N18:99 400900 R
N19:0 400901 General Purpose Registers 0-49 R based on configuration -

| |
N19:49 400950 R
N19:50 400951 Condenser Discharge Pressure R X10

N19:51 400952 Ambient Temperature R X10
N19:52 400953 Relative Humidity R X10
N19:53 400954 Wet Bulb Temperature R X10
N19:54 400955 Superheat Temperature Input 1 R X10
N19:58 400959 Superheat Pressure Input 1 R X10
N19:62 400963 Saturated Liquid Temperature 1 R X10
N19:66 400967 Saturated Liquid Pressure 1 R X1
N19:70 400971 Reserved R X1
N19:76 400977 Panel Temperature Sensor 1-31 R X10

| |
N20:6 401007 R
N20:7 401008 Line Voltage 1-31 R X10

| |
N20:37 401038 R
N20:40 401041 Delay Block Timers 449-499 R Minutes X10

| |
N20:89 401090 R
N21:0 401101 Miscellaneous Temperatures 100-199 R based on configuration X10
Document MCP-170
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GForce™
| |
N13:99 401200 R

401217 -
| Reserved for additional Analog Data |
401300 -
Contract Information
N23:0 401301 Program Part Number if standard R Chara 1, 2=$A0 Chara 3-28 ASCII -
| Contract Number if special
N23:29 401330
N23:30 401331 ASCII spaces if standard program R Chara 1, 2=$A0 Chara 3-28 ASCII -
| Customer Name if special
N23:59 401360
| Info Text if special
N23:89 401390
| Location Text if special
N24:19 401420
401421 -
| Reserved for additional information |
401500 -
Digital I/O Rack Images

I/O Boards 1-4 are available on ComMENT, boards 5-31 require Modbus Ethernet
N25:0 401501 Board 1, Rack 1, Module 1 R Bit 0 bit
Board 1, Rack 1, Module 2 R Bit 1 bit
Document MCP-170
Revision: N
GForce™
N25:3 401504 Board 2, Rack 1, Modules 1-16 R Bit 0 bit
Board 2, Rack 1, Modules 17-24
N25:4 401505 R Bit 0 bit
N25:7 401508 R Bit 0 bit
N25:10 401511 R Bit 0 bit
N25:11 401512 Board 4, Rack 2, Module 9-24 R Bit 0 bit
N25:13 401514 R Bit 0 bit
N25:16 401517 R Bit 0 bit
N25:19 401520 R Bit 0 bit
N25:22 401523 R Bit 0 bit
N25:25 401526 R Bit 0 bit
N25:28 401529 R Bit 0 bit
401531 -
| Reserved for additional I/O Rack images |
401600 -
Document MCP-170
Revision: N
GForce™
Internal Custom Logic Points (Modbus Ethernet Only)
Enter block number in yellow cells to calculate modbus address
N26:0 401601 AND Blocks 0-399 R bit
| Block Number 399 401625 bit 14
N26:24 401625
N26:25 401626 NAND Blocks 0-99 R bit

N26:31 401632 bits 4-15 unused
N26:32 401633 OR Blocks 0-299 R bit

N26:50 401651 bits 12-15 unused
N26:51 401652 NOR Blocks 0-99 R bit

N26:57 401658 bits 4-15 unused
N26:58 401659 XOR Blocks 0-99 R bit

N26:64 401665 bits 4-15 unused
N26:65 401666 INVERT Blocks 0-499 R bit

N26:96 401697 bits 4-15 unused
N26:97 401698 DELAY Blocks 0-499 R bit

N27:28 401729 bits 4-15 unused
N27:29 401730 FLIP-FLOP Blocks 0-499 R bit

N27:60 401761 bits 4-15 unused
N27:61 401762 COMPARE Blocks 0-499 R bit

N27:92 401793 bits 4-15 unused
N27:93 401794 SELECT Blocks 0-99 Outputs 0-9 R bit

N28:55 401856 Output 9 bits 8-15 unused
N28:56 401857 ALARM SEARCH Blocks 0-499 R bit

N28:87 401888 bits 4-15 unused
N28:88 401889 EVENT TIMER Blocks 0-99 R bit

N28:94 401895 bits 4-15 unused
N28:95 401896 SOFTKEY Blocks 0-49 R bit

N28:98 401899 bits 2-15 unused
N29:-1 401900 MISCELLANEOUS INPUT Blocks 0-499 R bit

N29:30 401931 bits 4-15 unused
401932 -
| Reserved |
402000 -
Blocks 0-19 available on ComMENT, blocks 20-99 require Modbus Ethernet

N30:0 402001 NETWORK OUTPUT Blocks 0-99 R/W 0=Off/1=On/2=Toggle/3=Momentary X1
|
402100
Screw Compressor Standard Logic Points
Document MCP-170
Revision: N
GForce™
N31:0 402101 Shutdown StatusOutput R Bit 0 bit
Alarm Status Output R Bit 1 bit
Compressor Starter Output R Bit 2 bit
Oil Separator Heater Output R Bit 3 bit
Close Disch Check Valve Output R Bit 4 bit
Open Disch Check Valve Output R Bit 5 bit
Disch Check Valve Closed Input R Bit 6 bit
Disch Check Valve Open Input R Bit 7 bit
Oil Pump #1 Starter Output R Bit 8 bit
Oil Pump #2 Starter Output R Bit 9 bit
Oil Pump #1 Interlock Input R Bit 10 bit
Oil Pump #2 Interlock Input R Bit 11 bit
Compressor Interlock Input R Bit 12 bit
External Load Input R Bit 13 bit
External Unload Input R Bit 14 bit
Load Solenoid Output R Bit 15 bit
N31:1 402102 Unload Solenoid Output R Bit 0 bit
Control Status Output R Bit 1 bit
Anti-Recycle Timing Output R Bit 2 bit
Slide Valve Output #1 R Bit 3 bit
Remote Start/Stop Input R Bit 7 bit
Remote & External Output R Bit 8 bit
Pushbutton Stop Input R Bit 9 bit
Pushbutton Remote Input R Bit 10 bit
Pushbutton Local Input R Bit 11 bit
Compressor Pressure/Temperature Select Input R Bit 12 bit
Compressor Point 1/Point 2 Select Input R Bit 13 bit
Oil Cooling/IntelliSOC Output R Bit 14 bit
Pump Down Input R Bit 15 bit
N31:2 402103 Hot Gas Bypass Output R Bit 0 bit
Low Oil Level Input R Bit 1 bit
Economizer Solenoid Output R Bit 2 bit
Compressor Permissive Input R Bit 3 bit
Compressor Ready to Start Output R Bit 4 bit
Compressor Must Start Input R Bit 5 bit
Compressor in Stop Mode Output R Bit 6 bit
Compressor in Up Mode Output R Bit 7 bit
Compressor in Run Mode Output R Bit 8 bit
Compressor in Down Mode Output R Bit 9 bit
Compressor in Hold Mode Output R Bit 10 bit
Compressor in Unload Mode Output R Bit 11 bit
Compressor in Load Mode R Bit 12 bit
Compressor in Auto Mode R Bit 13 bit
Compressor in External Mode R Bit 14 bit
Compressor in Hold Mode R Bit 15 bit
N31:3 402104 Compressor in Unload Mode R Bit 0 bit
Compressor in Load Mode R Bit 1 bit
Compressor in Auto Mode R Bit 2 bit
Compressor in External Mode R Bit 3 bit
Alarm Off Input R Bit 4 bit
kWh Pulse Input R Bit 5 bit
kWh Clear Input R Bit 6 bit
Saturated Liquid Temperature #1 Output R Bit 7 bit
Saturated Liquid Temperature #1 Output R Bit 8 bit
Compressor Suction Setpoint Low Output R Bit 9 bit
Compressor Process Setpoint Low Output R Bit 10 bit
Compressor in Stop Mode Output R Bit 11 bit
Compressor in Local Mode Output R Bit 12 bit
Compressor in Remote Mode Output R Bit 13 bit
Remotely Start via Seqencing Output R Bit 14 bit
Oil Still Heater Input R Bit 15 bit
N31:4 402105 Oil Still Level Switch Input R Bit 0 bit
Oil Still Heater Output R Bit 1 bit
Oil Return Equalizer Solenoid Output R Bit 2 bit
Oil Return Oil Drain Solenoid Output R Bit 3 bit
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GForce™
Oil Return Transfer Solenoid Output R Bit 4 bit
Oil Return Transfer Pending Output R Bit 5 bit
Oil Return Check Pending Output R Bit 6 bit
Oil Return Ready to Check Output R Bit 7 bit
Oil Return Check Lamp Output R Bit 8 bit
Oil Return Transfer Lamp Output R Bit 9 bit
Watchdog Output R Bit 10 bit
Compressor Illegally Started Output R Bit 11 bit
Secondary Slide Load Solenoid R Bit 12 bit
Secondary Slide Unload Solenoid R Bit 13 bit
Oil Pump Selection Input R Bit 14 bit
Booster/High Stage Mode Input R Bit 15 bit
N31:5 402106 Stop Indication Softkey Output R Bit 0 bit
Oil pump Softkey Output R Bit 1 bit
Oil pump flash Softkey Output R Bit 2 bit
Remote start Softkey Output R Bit 3 bit
Remote start flash Softkey Output R Bit 4 bit
Local start Softkey Output R Bit 5 bit
Local start flash Softkey Output R Bit 6 bit
Shutdowns Softkey Output R Bit 7 bit
Alarms Softkey Output R Bit 8 bit
Anti-recycle Softkey Output R Bit 9 bit
Oil sep heater Softkey Output R Bit 10 bit
Auto Softkey Output R Bit 11 bit
Hold Softkey Output R Bit 12 bit
Load Softkey Output R Bit 13 bit
Alarm Off Softkey Output R Bit 14 bit
Unload Softkey Output R Bit 15 bit
N31:6 402107 Anti-recycle flash Softkey Output R Bit 0 bit
External key Softkey Output R Bit 1 bit
Power fail reset Softkey Output R Bit 2 bit
Oil Return Initiate Softkey Output R Bit 3 bit
Oil Return Check Softkey Output R Bit 4 bit
VTrac/LifeTrac Vibration Alarm R Bit 5 bit
VTrac/LifeTrac Vibration Shutdown R Bit 6 bit
DX Chiller Liquid Feed Solenoid #1 R Bit 7 bit
DX Chiller Liquid Feed Solenoid #2 R Bit 8 bit
Auto Pump Down Softkey Output R Bit 9 bit
In Pump Down R Bit 10 bit
Booster/High Stage Solenoid Output R Bit 11 bit
High Vi Solenoid Output R Bit 12 bit
Medium Vi Solenoid Output R Bit 13 bit
Low Vi Solenoid Output R Bit 14 bit
Double Balance Piston Output R Bit 15 bit
N31:7 402108 Slide Stop Increase Solenoid Output R Bit 0 bit
Slide Stop Decrease Solenoid Output R Bit 1 bit
Sump Oil Heater R Bit 2 bit
Lubricator Pump R Bit 3 bit
Lubricator Pump Intlk R Bit 4 bit
Jacket Cooling Output R Bit 5 bit
Jacket Coolant Flow Switch R Bit 6 bit
Capacity Solenoid 1 Output R Bit 7 bit
N31:8 402109 Capacity Solenoid 10 Output R Bit 0 bit
Startup Oil Return R Bit 7 bit
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GForce™
Unloaded Start Solenoid R Bit 8 bit
Lube oil pump Softkey Output R Bit 9 bit
Lube oil pump flash Softkey Output R Bit 10 bit
Oil Drain Line Clear Input R Bit 11 bit
Fast Unload Solenoid Output R Bit 12 bit
Suction Bypass Solenoid Output R Bit 13 bit
Bits 14-15 are not used
402110 -
| Reserved for Compressor Digital Logic Points |
402120 -
System Panel Logic Points (Modbus Ethernet Only)

N31:20 402121 Unused
N31:21 402122 Recip Comp #1 Stop Softkey Output R Bit 0 bit
Recip Comp #1 Remote Softkey Output R Bit 1 bit
Recip Comp #1 Remote Flash Softkey Output R Bit 2 bit
Recip Comp #1 Local Softkey Output R Bit 3 bit
Recip Comp #1 Local Flash Softkey Output R Bit 4 bit
Recip Comp #1 Auto Softkey Output R Bit 5 bit
Recip Comp #1 Hold Softkey Output R Bit 6 bit
Recip Comp #1 Load Softkey Output R Bit 7 bit
Recip Comp #1 Unload Softkey Output R Bit 8 bit
Recip Comp #1 Power Fail Reset Softkey Output R Bit 9 bit
Recip Comp #1 Anti-Recycle Softkey Output R Bit 10 bit

Unused R Bit 11-15 bit



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GForce™





Document MCP-170
Revision: N
GForce™

N31:31 402132 Evap Zone Defrost Softkey Output R Bit 0-15 = Evap Zone #1-16 bit
N31:36 402137 Evap Zone Defrost Flash Softkey Output R Bit 0-15 = Evap Zone #1-16 bit
N31:41 402142 Compressor Sequencing Auto Softkey Output R Bit 0 bit
Compressor Sequencing Hold Softkey Output R Bit 1 bit
Compressor Sequencing Previous Step Softkey
R Bit 2 bit
Output
Compressor Sequencing Next Step Softkey Output R Bit 3 bit
Condenser Sequencing Auto Softkey Output R Bit 4 bit

Condenser Sequencing Hold Softkey Output R Bit 5 bit
Condenser Sequencing Previous Step Softkey
R Bit 6 bit
Output
Condenser Sequencing Next Step Softkey Output R Bit 7 bit
402143 -
| Reserved for System Panel Digital Logic Points |
402200 -
Screw Compressor Commands

N32:0 402201 Compressor Start Mode R/W 0=Stop/1=Local/2=Remote X1
N32:1 402202 Remote Start/Stop R/W 0=Stop/1=Start X1
N32:2 402203 Compressor Capacity Control Mode R/W X1
l
N32:3 402204 Clear Remaining Anti-Recycle Time W Any non-zero write executes command -
N32:4 402205 Clear Remaining Power Fail Reset Time W Any non-zero write executes command -
N32:5 402206 Acknowledge Shutdown W Any non-zero write executes command -
N32:6 402207 Acknowledge Alarm W Any non-zero write executes command -
N32:7 402208 Load Pulse W 0.1 to 10.0 seconds X10
N32:8 402209 Unload Pulse W 0.1 to 10.0 seconds X10
Note: Capacity Control Mode must be External (Modbus Register 2203, Value=4) to accept
Load/Unload pulses via Modbus Registers 2208 and 2209.
N32:9 402210 Abort Computer Sequencing W ASCII 'AB' or 16706 -
N32:10 402211 Register Computer Sequencing - 5 Minutes W ASCII 'CS' or 17235 -
N32:11 402212 Register Computer Sequencing - 1 Minute W ASCII 'CS' or 17235 -
Note: Registering Computer Sequencing is not required, but can be used to check for communication
loss.
To utilize this control, you must write to Modbus Register 2211 or 2212 at least every 5 minutes or 1
minute respectively, otherwise a 'Loss of Sequencer Communication' Alarm is issued and if the
Compressor is running it will automatically revert to Local Start Mode and Auto Capacity Control Mode.
Writing to Modbus Register 2210 will cancel these timers and will avoid checking for 'Loss of Sequencer
Communication.'
N32:12 402213 Remote Slide Valve Control % W 0.0 to 100.0 % X10
Note: Control Mode must be set to Remote Slide Valve (Modbus Register 2351, Value=3).
Capacity Control Mode will control the slide valve to this value when Compressor Capacity Control
Mode is set to Auto (Modbus Register 2203, Value=3). There is a fixed 2.0% deadband and fixed
10.0% proportional band in this control. If an overload condition is present, the control will force unload
the slide valve.
N32:13 402214 Remote VFD Control % W 0.0 to 100.0 % X10
Note: VFD Control Mode must be set to Remote (Modbus Register 2397, Value=3).
VFD will control VFD PID output to this value. If an overload condition is present, the control will force
unload the VFD.
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GForce™
N32:14 402215 Remote Total Capacity W 0.0 to 200.0 X10
Note: This value is a combination of Modbus Registers 2213 and 2214. A value 0 to 1000 will set the
Remote Slide Valve Control % to the value written, and a value from 1000 to 2000 will set the Remote
Slide Valve Control % to 100.0% and the Remote VFD Control % to (written value - 1000) %.
402216 -
| Reserved for Compressor Commands |
402300 -
Screw Compressor Operating Parameters

SUCTION
N33:0 402301 Suction 1 Pressure Setpoint R/W X10
N33:1 402302 Suction 1 Pressure Upper R/W X10
N33:2 402303 Suction 1 Pressure Lower R/W X10
N33:3 402304 Suction 1 Pressure Prop Band R/W X10
N33:4 402305 Suction 1 Pressure Dead Band R/W X10
N33:8 402309 Suction 2 Pressure Prop Band R/W X10
N33:10 402311 Low Suction Pressure Shutdn or Cycle? R/W 0=Shutdown/1=Cycle X1
N33:11 402312 Low Auxiliary Suction Setpoint R/W X10
PROCESS
N33:12 402313 Process 1 Temperature Setpoint R/W X10
N33:13 402314 Process 1 Temperature Upper R/W X10
N33:14 402315 Process 1 Temperature Lower R/W X10
N33:15 402316 Process 1 Temperature Prop Band R/W X10
N33:16 402317 Process 1 Temperature Dead Band R/W X10
N33:20 402321 Process 2 Temperature Prop Band R/W X10
N33:22 402323 Low Process Temperature Shutdn or Cycle? R/W 0=Shutdown/1=Cycle X1
N33:23 402324 Process Temp Cntl Low Suction Shutdown R/W X10
N33:24 402325 Process Temp Cntl Low Suction Prop Band R/W X10
N33:25 402326 Process Temp Cntl Low Suction Load Adjust R/W X10
PUMP DOWN X10
N33:26 402327 Pump Down Cycle On Setpoint R/W X10
N33:27 402328 Pump Down Cycle Off Setpoint R/W X10
N33:28 402329 Pump Down Cycle Once or Cycle On & Off? R/W 0=Cycle Once/1=Cycle On & Off X1
REMOTE SLIDE VALVE
N33:29 402330 Remote SV Cntl Low Suction Shutdown R/W X10
N33:30 402331 Remote SV Cntl Low Suction Prop Band R/W X10
N33:31 402332 Remote SV Cntl Low Suction Load Adjust R/W X10
COMPRESSOR MOTOR
N33:32 402333 Motor Current Upper R/W X10
N33:33 402334 Motor Current Lower R/W X10
N33:34 402335 Motor Current Dead Band R/W X10
N33:35 402336 Anti-Recycle Period R/W 20-240 Minutes X1
N33:36 402337 Accumulated Compressor Runtime (khours) R/W 0 to 32767 khours X1
N33:37 402338 Accumulated Compressor Runtime (hours) R/W 0 to 999.9 hours X10
N33:38 402339 Motor Current Maximum R/W 50-2500 X1
N33:39 402340 Operating Mode Selection R 0=ATL/1=VFD X1
INLET OIL
N33:40 402341 Oil Filter Pressure Drop R/W X10
N33:41 402342 Inlet Oil Temperature Upper R/W X10
N33:42 402343 Inlet Oil Temperature Lower R/W X10
N33:43 402344 Lead Oil Pump Select (1/2) R/W 1 or 2 X1
OIL SEPARATOR
N33:44 402345 Oil Separator Heater Setpoint R/W X10
N33:45 402346 Oil Separator Heater Upper R/W X10
N33:46 402347 Oil Separator Heater Lower R/W X10
DISCHARGE
N33:47 402348 Discharge Pressure Maximum R/W X10
N33:48 402349 Discharge Pressure Prop Band R/W X10
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GForce™
N33:49 402350 Discharge Temperature Upper R/W X10
CONTROL
N33:50 402351 Control Mode Select R/W 0=Suct/1=Proc/2=DI/3=Rmt SV/4=Discharge X1
N33:51 402352 Not Used

N33:52 402353 Control Point Select R/W 0=DI/1=PNT1/2=PNT2 X1
N33:53 402354 Capacity Load-Unload Period R/W 1.0 -10.0 sec X10
N33:54 402355 Slide Valve Position Minimum R/W 0-100% X10
N33:55 402356 Max Load Pulse During Pulldown R/W 1.0 -10.0 sec X10
N33:56 402357 Allow Normal Loading R/W 0=No/1=Yes X1
N33:57 402358 Allow Normal Loading After %SV R/W 0-100% X10
N33:58 402359 Load Limit R/W 0=None/1=Pulse/2=SP/3=SV X1
N33:59 402360 Ramp to Suct Setpt per Min, PSI R/W 0 to 75.0 Psi X10
N33:60 402361 Ramp to Max Slide Valve Over, Min R/W 1 to 120 min X10
N33:61 402362 Booster/High Stage Mode R/W 0=Booster/1=High Stage/2=D.I. X1
N33:62 402363 Unload Slide Valve Before Compressor Stop R/W 0=No/1=Yes X1
ECONOMIZER
N33:63 402364 Economizer Solenoid ON Above % R/W X10
N33:64 402365 Economizer Solenoid OFF Below % R/W X10
HOT GAS
N33:65 402366 Start Hot Gas Below SV% R/W X10
N33:66 402367 Stop Hot Gas Above SV% R/W X10
N33:67 402368 Start Hot Gas Below Suction R/W X10
N33:68 402369 Stop Hot Gas Above Suction R/W X10
SLIDE VALVE OUTPUT
N33:69 402370 Slide Valve Output #1 On R/W X10
N33:70 402371 Slide Valve Output #1 Off R/W X10
POWER FAIL RESET
N33:77 402378 Power Fail Reset to Mode? R/W 1=Local/2=Remote X1
N33:78 402379 Delay Before Pwr Fail Reset R/W 0-8000 seconds X1
N33:79 402380 Abort Pwr Fail Reset After R/W 0-8000 seconds X1
POWER MONITORING
N33:80 402381 Demand Metering Ratio R/W X10
N33:81 402382 kiloWatt Hour Sampling Period R/W X10
N33:82 402383 kWh Input Pulse Weight R/W X10
N33:83 402384 MegaWatt Hours Consumed R/W 0-32767 X1
N33:84 402385 KiloWatt Hours Consumed x 10 R/W 0-999.9 X10
HISTORICAL DATA
N33:85 402386 Reserved
N33:86 402387 Long-Term Sampling Period R/W X10
SUPERHEAT
N33:87 402388 Suction Superheat Maximum R/W X10
N33:88 402389 Suction Superheat Minimum R/W X10
N33:89 402390 Suction Superheat Shutdown Delay R/W 0=Disable Shutdown/Alarm X10
N33:90 402391 Discharge Superheat Maximum R/W X10
N33:91 402392 Discharge Superheat Minimum R/W X10
N33:92 402393 Discharge Superheat Shutdown Delay R/W 0=Disable Shutdown/Alarm X10
VAR SPEED COMP MOTOR
N33:93 402394 Proportional Constant R/W 0.0 to 10.0 X10
N33:94 402395 Integral Constant R/W 0.0 to 300.0 X10
N33:95 402396 Derivative Constant R/W 0.0 to 10.0 X10
N33:96 402397 Manual Control 0=No/1=Yes R/W X1
N33:97 402398 Manual Control Percent R/W 0.0 to 100.0% X10
N33:98 402399 VFD Speed at 4 mA R/W 0 to 5000 rpm X1
N33:99 402400 VFD Speed at 20 mA R/W 0 to 5000 rpm X1
OIL RETURN
N34:0 402401 Length of Oil Return Cycle R/W 0 to 600.0 Sec X10
N34:1 402402 Enable Initiate Timer R/W 0=Disabled/1=Enabled X1
N34:2 402403 Initiate Transfer Day of Week R/W 0=Daily/1=Sunday/7=Saturday X1
N34:3 402404 Initiate Transfer Hour R/W 0-23 X1
N34:4 402405 Initiate Transfer Minute R/W 0-59 X1
VARIABLE Vi CONTROL
Document MCP-170
Revision: N
GForce™
N34:5 402406 Vi Operating Mode R/W 0 = Auto/1= Manual X1
N34:6 402407 Manual Vi Setting R/W 2.2 to 5.5 Vi X10
DX CHILLER CONTROL
N34:7 402408 Compressor Start Pressure R/W X10
N34:8 402409 Second Liquid Feed On Above SV% R/W 0.0 to 100.0% X10
N34:9 402410 Second Liquid Feed Off Below SV% R/W 0.0 to 100.0% X10
INTELLISOC CONTROL
90.0 to 150.0°F
N34:10 402411 Discharge Temperature Setpoint R/W X10
150.0 to 175.0°F(GL, R-22, IntelliSOC)
N34:11 402412 Minimum Valve Position R/W 0.0 to 100.0% X10
N34:12 402413 Proportional Constant R/W 0.0 to 60.0 X10
N34:13 402414 Integral Constant R/W 0.0 to 200.0 X10
N34:14 402415 Derivative Constant R/W 0.0 to 10.0 X10
N34:15 402416 Manual Control 0=No/1=Yes R/W 0 or 1 X1
N34:16 402417 Manual Control Percent R/W 0.0 to 100.0% X10
N34:17 402418 Calibrate Time Before Valve Bleed R/W 5.0 to 90.0 sec X10
COMPRESSOR (SULLAIR, H-E RETROFITS)
(SULLAIR) Model # 0=A Series/1=B Series
N34:18 402419 2=C Series R/W X1
(H-E) Model # 0=19/1=23/2=28/3=32
N34:19 402420 Vi Fixed at 0=2.20/1=3.65/2=5.00 R/W X1
(L SERIES RETROFIT)
N34:20 402421 Slide Valve Sensor Type 0=Pot/1=ESP R/W X1
INLET OIL
(S SERIES, MYCOM, FRICK RETROFITS)
N34:21 402422 Lag Oil Pump Start Pressure R/W X10
N34:22 402423 Oil Pressure Start Upper R/W X10
N34:23 402424 Oil Pressure Start Lower R/W X10
N34:24 402425 Oil Pressure Run Upper R/W X10
N34:25 402426 Oil Pressure Run Lower R/W X10
Not Used
N34:26 402427 Not Used
N34:27 402428 Not Used
VARIABLE Vi CONTROL
(HE, MYCOM, FRICK STEPPED Vi)
N34:28 402429 0=Auto/1=Low/2=Med/3=High Vi R/W X1
N34:29 402430 Low/Medium Vi Transfer Setpoint R/W X10
N34:30 402431 Low/Medium Vi Transfer Dead Band R/W X10
N34:31 402432 Medium/High Vi Transfer Setpoint R/W X10
N34:32 402433 Medium/High Vi Transfer Dead Band R/W X10
N34:33 402434 0=Booster/1=High-Stage R/W X1
N34:34 402435 Booster Mode Discharge Pressure Maximum R/W X10
VARIABLE Vi CONTROL
(FRICK CONTINOUS Vi)
Vi Operating Mode 0=Auto/1=Manual/
N34:35 402436 R/W X1
2=Increment/3=Decrement
N34:36 402437 Manual Vi Control Setting R/W X10
N34:37 402438 Vi Slide Stop Proportional Band R/W X10
N34:38 402439 Vi Slide Stop Dead Band R/W X10
N34:39 402440 Vi Slide Increment/Decrement Period R/W X10
CAPACITY STEP CONTROL
(FRICK RDB)
N34:40 402441 Suction Pressure Step Up Delay R/W 5.0 to 300 Seconds X10
N34:41 402442 Suction Pressure Step Down Delay R/W 5.0 to 300 Seconds X10
N34:42 402443 Process Temp Step Up Delay R/W 5.0 to 300 Seconds X10
N34:43 402444 Process Temp Step Down Delay R/W 5.0 to 300 Seconds X10
N34:44 402445 Digital Input Step Up Delay R/W 5.0 to 300 Seconds X10
N34:45 402446 Digital Input Step Down Delay R/W 5.0 to 300 Seconds X10
N34:46 402447 Minimum Capacity Step R/W 0=Min/16=Max X1
N34:47 402448 Enable Max Time at Minimum Step R/W 0=No/1=Yes X1
N34:48 402449 Max Time at Minimum Step R/W 0 to 90 Minutes X10
INLET OIL
(VILTER RETROFIT)
N34:49 402450 Oil Pump Cycle On Setpoint R/W X10
N34:50 402451 Oil Pump Cycle Off Setpoint R/W X10
N34:51 402452 Oil Pressure Start Upper R/W X10
N34:52 402453 Oil Pressure Start Lower R/W X10
Document MCP-170
Revision: N
GForce™
VARIABLE Vi CONTROL
(VILTER RETROFIT)
Vi Operating Mode 0=Auto/1=Manual/
N34:55 402456 R/W X1
2=Increase/3=Decrease
N34:56 402457 Manual Volume Slide Setting R/W X10
N34:57 402458 Volume Slide Increase/Decrease Period R/W X10
N34:58 402459 Volume Slide Adjustment Factor R/W X10
CONTROL
(SABROE, STAL RETROFIT)
Unload Solenoid Control 0=Energize to
N34:59 402460 R/W X1
Unload/1=De-Energize to Unload
N34:60 402461 High Slide Valve Fast Unload Time R/W 0 to 60 seconds X10
N34:61 402462 Suction Bypass Delay Time R/W 0 to 60 seconds X10
N34:62 402463 Oil Filter Pressure Piping Loss Adjustment R/W X10
CONTROL (SULLAIR RETROFIT)
N34:63 402464 External Oil Pump Enable 0=No/1=Yes/2=DI R/W X1
TWO-STAGE CONTROL
N34:64 402465 Booster Start Permissive Pressure Setpoint R/W X10
High-Stage Suction Pressure Offset Setpoint
N34:65 402466 R/W X10
(0=Disabled/Single-Stage Mode)
PRE-ROTATION VANE CONTROL
N34:66 402467 Stop Mode Minimum Valve Position R/W X10
N34:67 402468 Startup Mode Minimum Valve Position R/W X10
N34:68 402469 Run Mode Minimum Valve Position R/W X10
N34:69 402470 Proportional Constant R/W X10
N34:70 402471 Integral Constant R/W X10
N34:71 402472 Derivative Constant R/W X10
N34:73 402474 Manual Control Percent R/W X10
N34:74 402475 Capacity Control Startup Delay R/W X10
Hot Gas Bypass % Before Starting Capacity
N34:75 402476 R/W X10
Control
HOT GAS BYPASS CONTROL
N34:76 402477 Suction Pressure Capacity Control Dead Band R/W X10
N34:77 402478 Stop Mode Minimum Valve Position R/W X10
N34:78 402479 Startup Mode Minimum Valve Position R/W X10
N34:79 402480 Run Mode Minimum Valve Position R/W X10
INLET OIL CON'T
N34:85 402486 Pre-Lube Time Period R/W X10
N34:86 402487 Post-Lube Time Period R/W X10
N34:87 402488 Startup Oil Pressure Required R/W X10
VTrac™
N34:88 402489 VTrac™ Damage Input Type 0=Shutdown/1=Alarm R/W X1
N34:89 402490 Enable Vibration Alarms Above SV % R/W X10

INLET OIL CON'T
N34:90 402491 Oil Pump Minimum Run Time Period R/W X10
VAR SPEED COMP MOTOR CON'T
N34:91 402492 VFD Control Mode 0=Local/1=Remote/2=DI R/W X1
HOT GAS BYPASS CON'T
N34:92 402493 Process Temperature Capacity Control Dead Band R/W X10
N34:93 402494 Stop Hot Gas Above PRV Valve Position R/W X10
CONTROL CON'T
Remote Mode Control Setpoint 0=Control
N34:94 402495 R/W X1
Parameter / 1=Communications
N34:95 402496 Capacity Control Direction 0=Forward/1=Reverse R/W X1
N34:96 402497 Slide Valve Position Maximum R/W X10

N34:97 402498 Pump Down Max Cycle Attemps Before Alarm R/W X1
N34:98 402499 Pump Down Max Cycle Period Before Alarm R/W 0 = Disable Alarm X10
Document MCP-170
Revision: N
GForce™
402500 -
| Reserved for Compressor Operating Parameters |
402500 -
Screw Compressor Alarm Parameters

SUCTION
N35:4 402505 Low Auxiliary Suction Setpoint R/W X10
PROCESS
N35:9 402510 Process Temp Cntl Low Suction Alarm R/W X10
REMOTE SV
N35:10 402511 Remote SV Cntl Low Suction Alarm R/W X10
COMPRESSOR MOTOR
N35:11 402512 Motor Current Upper R/W X10
INLET OIL
N35:12 402513 Oil Filter Pressure Drop R/W X10
N35:13 402514 Inlet Oil Temperature Upper R/W X10
N35:14 402515 Inlet Oil Temperature Lower R/W X10
OIL SEPARATOR
N35:15 402516 Oil Separator Heater Upper R/W X10
N35:16 402517 Oil Separator Heater Lower R/W X10
DISCHARGE
N35:17 402518 Discharge Pressure Maximum R/W X10
N35:18 402519 Discharge Temperature Upper R/W X10
SUPERHEAT
N35:19 402520 Suction Superheat Maximum R/W X10
N35:20 402521 Suction Superheat Minimum R/W X10
N35:21 402522 Discharge Superheat Maximum R/W X10
N35:22 402523 Discharge Superheat Minimum R/W X10
INLET OIL
(S SERIES, MYCOM, FRICK RETROFITS)
(SULLAIR RETROFITS)
N35:25 402526 Oil Pressure Max R/W X10
402527 -
| Reserved for Compressor Alarm Parameters |
402600 -
Custom Parameters
N36:0 402601 Custom Parameter 0-199 R/W Range and scaling are configurable
| (Parameters 100-199 available on Modbus Ethernet Only)
402800
Event Timers (Timers 10-99 are available on Modbus Ethernet Only)

The following parameters are repeated for each Event Timer 0-99
EVENT TIMER 0
N38:0 402801 ON Timing Event Day of Week R/W 0=Daily/1=Sunday/7=Saturday X1
N38:1 402802 ON Timing Event Hour R/W 0-23 X1
N38:2 402803 ON Timing Event Minute R/W 0-59 X1
N38:3 402804 OFF Timing Event Day of Week R/W 0=Daily/1=Sunday/7=Saturday X1
N38:4 402805 OFF Timing Event Hour R/W 0-23 X1
N38:5 402806 OFF Timing Event Minute R/W 0-59 X1
N38:6 402807 EVENT TIMER 1

N38:12 402813 EVENT TIMER 2
|
|
|
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Revision: N
GForce™
N43:88 403389 EVENT TIMER 98
N43:94 403395 EVENT TIMER 99
|
403400
Condenser Status (Modbus Ethernet Only)

N44:0 403401 Control Mode R 0=Setpoint/1=Wet Bulb X1
N44:1 403402 Control Point R 1=PNT1 / 2=PNT2 X1
N44:2 403403 Sequence Step R/W 0=Shutdown / 1-50 X1
N44:3 403404 Sequence Mode R/W 0=Auto / 1=Hold X1
0=No Message/1=Soak/2=Next
Step/3=Previous Step/4=@ Maximum
N44:4 403405 Timer Message R X1
Capacity/5=@ Minimum
Capacity/6=Shutdown
N44:5 403406 Timer Value R Seconds (Messages 1, 2, 3) X1
N44:6 403407 Active Schedule R 1=SCH1 / 2=SCH2 X1
403408 -
| Reserved for Condenser Status |
403420 -
Condenser Device Status (Modbus Ethernet Only)

The following group of items is repeated for each device 1-50
0=Stop/1=Run/2=Low/3=High/4=Auto
N44:20 403421 Current Mode R X1
%/5=Hold %
Current Mode=0/Non-zero for
N44:21 403422 Current Mode Info R Lockout/Current Mode=4 Minimum X1
%/Current Mode=5 Hold %
N44:22 403423 Current PID Output % R For Current Mode=4,5 X1
N44:23 403424 Number of Cnd Device Starts R/W 0-32767 X1
N44:24 403425 Runtime kHours R/W 0-32767 khours X1
N44:25 403426 Runtime Hours X 10 R/W 0-999.9 hours X10
N44:26 403427 Device 2

N44:32 403433 Device 3
|
|
|
N47:8 403709 Device 49
N47:14 403715 Device 50
|
403720
Condenser Parameters (Modbus Ethernet Only)

DISCHARGE PRESSURE
N47:20 403721 Discharge 1 Pressure Setpoint R/W X10
N47:21 403722 Discharge 1 Pressure Upper R/W X10
N47:22 403723 Discharge 1 Pressure Lower R/W X10
N47:23 403724 Discharge 1 Pressure Next Step R/W X10
N47:24 403725 Discharge 1 Pressure Previous Step R/W X10
SATURATED LIQUID
N47:30 403731 Saturated Liquid 1 Pressure Differential R/W 0.0 - 100.0 PSI X10
N47:31 403732 Saturated Liquid 2 Pressure Differential R/W " X10
CONTROL
N47:34 403735 Control Mode Select R/W 0=Setpoint / 1=Wet Bulb X1
N47:35 403736 Control Point Select R/W 0=DI / 1=PNT1 / 2=PNT2 X1
N47:36 403737 Schedule Select R/W 0=DI / 1=SCH1 / 2=SCH2 X1
N47:37 403738 Wet Bulb Setpoint Split R/W 0.0 - 30.0 PSI X10
PUMP LOCKOUT
N47:38 403739 Enable Water Pump Lockout R/W 0=Disabled/1=Enabled/2=Digital Input X1
N47:39 403740 Disable Pumps Below Ambient Temp R/W 20-50 ºF X10
Document MCP-170
Revision: N
GForce™
N47:40 403741 Enable Pumps Above Ambient Temp R/W " X10
N47:41 403742 Delay between Cnd Pump Starts R/W 1-30 Minutes X10
N47:42 403743 Delay between Cnd Pump Stops R/W 1-30 Minutes X10
COND STEP CONTROL
N47:43 403744 Maximum Condenser Step for Schedule 1 R/W 1-50 X1
N47:44 403745 Maximum Condenser Step for Schedule 2 R/W 1-50 X1
PUMP LOCKOUT CON'T
Disable Discharge Pressure Override Below
N47:45 403746 R/W X10
Pressure
Enable Discharge Pressure Override Above
N47:46 403747 R/W X10
Pressure
403748
| Reserved for Condenser Parameters
403800
Condenser Setup Viewport

8 devices, 16 capacity steps
(Modbus Ethernet Only)
N48:0 403801 1st Condenser Device in Viewport (CND) R/W 1-50 X1
N48:1 403802 1st Step in Viewport (Stp) R/W 1-50 X1
N48:2 403803 View / Edit Schedule R/W 1=SCH1 / 2=SCH2 X1
N48:4 403805 Current Step for Level in Viewport R Bit0=Stp+0, Bit9=Stp+9 X1
The following group is repeated for each step 1-10

N48:5 403806 Soak Timer for Active Level R/W 0-3600 seconds X1
N48:6 403807 Next Step for Active Level R/W 0-3600 seconds X1
N48:7 403808 Previous Step for Active Level R/W 0-3600 seconds X1
N48:10 403811 Step 2

N48:15 403816 Step 3
N48:20 403821 Step 4
N48:25 403826 Step 5
N48:30 403831 Step 6
N48:35 403836 Step 7
N48:40 403841 Step 8
N48:45 403846 Step 9
N48:50 403851 Step 10
|
N48:54 403855
403856 -
| Reserved |
403885 -
N48:85 403886 Actual Step Number 1-50 R If Stp+X > 50, then entry is zero.
The following group of items is repeated for each device 1-8

N48:86 403887 Internal Condener Device # R 0=Don't Display, 1-50 X1
0=Unused/1=Single Speed Fan/2=Single
Speed Fan with Interlock/3=Double Speed
Fan/4=Double Speed Fan with
N48:87 403888 Condenser Device Type R X1
Interlock/5=Variable Speed Fan/6=Variable
Speed Fan with Interlock/7=Pump/8=Pump
with Interlock
N48:88 403889 Number of Starts R/W 0-32767 X1
N48:89 403890 Runtime kHours R/W 32767 X1
N48:90 403891 Runtime Hours X 10 R/W 0-999.9 X10
N48:91 403892 Delay High->Low in Seconds R/W Dbl Spd Fan only (Type=3,4) X1
N48:92 403893 Proportional Constant R/W Var Spd Fan only (Type=5,6) X1
N48:93 403894 Integral Constant R/W Var Spd Fan only (Type=5,6) X1
N48:94 403895 Derivative Constant R/W Var Spd Fan only (Type=5,6) X1
N48:95 403896 PID Output % R Var Spd Fan only (Type=5,6) X1
Bit0=Output A / Bit1=Output B /Bit2=Input A /
N48:96 403897 Module Status (0=Off / 1=On) R X1
Bit3=Input B
N48:97 403898 Condenser Device Status R X1
Document MCP-170
Revision: N
GForce™
Show *** Lockout *** Message? Bit0 0=No/1=Yes
Show Delay High->Low? Bit1 0=No/1=Yes
Show PID Parameters? Bit2 0=No/1=Yes
Show Control Module Message? Bit3 0=No/1=Yes
Show Interlock Message? Bit4 0=No/1=Yes
Show Low Speed High Speed Message? Bit5 0=No/1=Yes
Show Interlock Interlock Message? Bit6 0=No/1=Yes
Condenser Device Enabled? Bit7 0=No/1=Yes
N48:98 403899 Condenser Device Enable R/W 0=No/1=Yes/2=External DI X1
403900 Reserved
403901 Reserved
403902 Reserved
0=Stop/1=Run(SSF/PMP)/2=Low(DSF)/3=Hi
N49:2 403903 Stp+0 Step Mode R/W X1
gh(DSF)/4=Auto(VSF)/5=Hold(VSF)
Mode=4, Minimum 0-99%, Mode=5,
N49:3 403904 Stp+0 Step Parameter R/W X1
Hold 0-99%
N49:4 403905 Stp+1 Step Mode R/W
N49:5 403906 Stp+1 Step Parameter R/W
403923 Reserved -
403924 Reserved -
403925 Reserved -
N49:25 403926 Device 2

N49:64 403965 Device 3
N50:3 404004 Device 4
N50:42 404043 Device 5
N50:81 404082 Device 6
N51:20 404121 Device 7
N51:59 404160 Device 8
|
404198
404199 -
| Reserved |
404200 -
Condenser Logic Points (Modbus Ethernet Only)

N52:0 404201 Condenser Permissive Input R Bit 0 bit
Control Point 1/2 Select Input R Bit 1 bit
Schedule 1/2 Select Input R Bit 2 bit
Discharge Setpoint Low Output R Bit 3 bit
Water Pump Lockout Input R Bit 4 bit
Condenser Device Output A 1 R Bit 5 bit
Document MCP-170
Revision: N
GForce™
N52:1 404202 Condenser Device Output A 12 R Bit 0 bit
Condenser Device Output B 1 R Bit 7 bit
N52:4 404205 Condenser Device Output B 10 R Bit 0 bit
Document MCP-170
Revision: N
GForce™
Condenser Device Input A 1 R Bit 9 bit
N52:7 404208 Condenser Device Input A 8 R Bit 0 bit
Document MCP-170
Revision: N
GForce™
Condenser Device Input B 1 R Bit 11 bit
N52:10 404211 Condenser Device Input B 6 R Bit 0 bit
Condenser Device Enable Input 1 R Bit 13 bit
N52:13 404214 Condenser Device Enable Input 4 R Bit 0 bit
Document MCP-170
Revision: N
GForce™
Condenser I/O Enable Input R Bit 15 bit
N52:16 404217 Condenser Auto Input R Bit 0 bit
Condenser Hold Input R Bit 1 bit
Condenser Load Input R Bit 2 bit
Condenser Unload Input R Bit 3 bit
Bits 4-15 are unused
404218 -
| Reserved for Condenser I/O |
404300 -
Sequence Status (Modbus Ethernet Only)

Level 1
N53:0 404301 Control Mode R 0=Suct / 1=Proc X1
Capacity/6=Shutdown
N53:6 404307 Reserved -
N53:7 404308 Reserved -
Level 2
Document MCP-170
Revision: N
GForce™
Capacity/6=Shutdown
N53:14 404315 Reserved -
N53:15 404316 Reserved -
Level 3
Capacity/6=Shutdown
N53:22 404323 Reserved -
N53:23 404324 Reserved -
Level 4
Capacity/6=Shutdown
N53:30 404331 Reserved -
N53:31 404332 Reserved -
Sequenced Compressor Information (Modbus Ethernet Only)

N53:32 404333 Sequenced Compressor #1 Level R 1-4, 0 = No compressor ID entered X1
N53:33 404334 Sequenced Compressor #2 Level R X1
Document MCP-170
Revision: N
GForce™
404383 -
| Reserved for Sequencer expansion |
404400 -
Sequence Parameters (Modbus Ethernet Only)

LEVEL 1 SUCTION
N54:3 404404 Suction 1 Pressure Next Step R/W X10
N54:4 404405 Suction 1 Pressure Previous Step R/W X10
N54:10 404411 Low Suction Pressure Shutdown or Cycle? R/W 0=Shutdown / 1=Cycle X1
LEVEL 1 PROCESS
N54:14 404415 Process 1 Temperature Next Step R/W X10
N54:15 404416 Process 1 Temperature Previous Step R/W X10
N54:21 404422 Low Process Temperature Shutdown or Cycle? R/W 0=Shutdown / 1=Cycle X1
L1 CONTROL
N54:22 404423 Control Mode Select R/W 0=Suction / 1=Process / 2=DI/ 3=Discharge X1
LEVEL 2 SUCTION
LEVEL 2 PROCESS
Document MCP-170
Revision: N
GForce™
LEVEL 2 CONTROL
LEVEL 3 SUCTION
LEVEL 3 PROCESS
LEVEL 3 CONTROL
LEVEL 4 SUCTION
LEVEL 4 PROCESS
Document MCP-170
Revision: N
GForce™
LEVEL 4 CONTROL
404497 -
| Reserved for Sequence Parameters |
404500 -
Sequence Setup Viewport

8 compressors, 16 capacity steps
(Modbus Ethernet Only)
N55:0 404501 1st Compressor in Viewport (Cmp) R/W 1-50 X1
N55:1 404502 1st Step in Viewport (Stp) R/W 1-50 X1
N55:2 404503 Active Level in Viewport (Lvl) R/W 1-4 X1
N55:4 404505 Current Step for Level in Viewport R Bit0=Stp+0, Bit9=Stp+9 X1
The following group is repeated for each step 1-9

N55:7 404508 Soak Timer for Active Level R/W 0 - 3600 Seconds X1
N55:8 404509 Next Step for Active Level R/W " X1
N55:9 404510 Previous Step for Active Level R/W " X1
N55:12 404513 Step 2

N55:17 404518 Step 3
N55:22 404523 Step 4
N55:27 404528 Step 5
N55:32 404533 Step 6
N55:37 404538 Step 7
N55:42 404543 Step 8
N55:47 404548 Step 9
N55:52 404553 Step 10
|
404557
N55:57 404558 Actual Step Number 1-50 R If Stp+X > 50, then entry is zero X1
The following group is repeated for each compressor 1-8

N55:58 404559 Internal Compressor ID R 0=Don't Display / 1 - 32 X1
N55:59 404560 Panel ID R 001 - 255 X1
N55:60 404561 Node ID R/W 0=Remove/1-255 X1
N55:61 404562 IP Address, first octet R/W 0-255 X1
N55:62 404563 IP Address, second octet R/W " X1
N55:63 404564 IP Address, third octet R/W " X1
N55:64 404565 IP Address, fourth octet R/W " X1
N55:65 404566 Level Assignment R/W 0=Invalid / 1-4 X1
N55:66 404567 Cmp Sequence Status R X1
Communication Status Bit0 0=Ok / 1=Error
Compressor Available for Seq? Bit1 0=No / 1=Yes
Compressor Type Bit2 0=Screw / 1=Recip or Rotary
Anti-Recycle Timing? Bit3 0=No / 1=Yes
Control Point Bit4 0=Suction / 1=Process
Two-Stage Flag? Bit5 0=No / 1=Yes
Dual or Recip Flag? (CP: present on screen) Bit6 0=No / 1=Yes
Drive Type Bit7 0=Electric / 1=Engine
Node ID & Level Information Valid? Bit8 0=Invalid / 1=Valid
Recip Flag Bit9 0=No / 1=Yes
Dual Flag Bit10 0=No / 1 = Yes
N55:67 404568 ComMENT Panel Type R Same as ComMENT Database X1
N55:68 404569 Operating Mode (OPMODE) R 0=Stop/1=Remote/2=Local/3=Shutdown X1
N55:69 404570 Operating Status (OPSTAT) R 0=AR/1=Ready/2=Run/3=Shutdown X1
N55:70 404571 Capacity Mode (CAPMODE) R 0=Hold/1=Unload/2=Load/ X1
3=Auto/4=External
Document MCP-170
Revision: N
GForce™
N55:71 404572 Suction Pressure R X10
N55:72 404573 Process Temperature R X10
N55:73 404574 Capacity Control Position R X10
N55:74 404575 Motor Current / Engine Speed R X1
N55:75 404576 Compressor Enabled? R/W 0=No / 1=Yes / 2=External X1
Compressor Number for Duals and E/M

Recips (1 or 2 for duals, 1-10 for Recips)
N55:76 404577 CP (Internal Compressor) Number? R/W X1
(0 = Screw Compressor and 1 - 10 for
Recips for GForce)
0=Stop/1=Unload/2=Load/3=Auto/4=Hold/5=
N55:77 404578 Stp+0 Step Mode R/W X1
Backup
Mode=0, 0=Ignore A-R / else Stop after A-
R;
N55:78 404579 Stp+0 Step Parameter R/W X1
Mode=3, Minimum Cap Pos;
Mode=4, Maintain Capacity Step
N55:97 404598 Compressor 2

|
N58:69 404870
404871 -
| Reserved for Sequencing |
404880 -
Compressor Sequencing Logic Points (Modbus Ethernet Only)

N58:80 404881 Safety Input Level 1 R Bit 0 bit
Safety Input Level 2 R Bit 1 bit
Permissive Input Level 1 R Bit 4 bit
Compressor Running Output Level 1 R Bit 8 bit
Must Start Compressor Input Level 1 R Bit 12 bit
N58:81 404882 Ready to Start Compressor Output Level 1 R Bit 0 bit
Ready to Start Compressor Output Level 2 R Bit 1 bit
Document MCP-170
Revision: N
GForce™
Suction Setpoint Low Output Level 1 R Bit 4 bit
Process Setpoint Low Output Level 1 R Bit 8 bit
Pressure/Temperature Select Input Level 1 R Bit 12 bit
N58:82 404883 Setpoint 1/Setpoint 2 Select Input Level 1 R Bit 0 bit
Setpoint 1/Setpoint 2 Select Input Level 2 R Bit 1 bit
Compressor Enable Input 1 R Bit 4 bit
N58:83 404884 Compressor Enable Input 13 R Bit 0 bit
Document MCP-170
Revision: N
GForce™
Compressor Permissive Input 1 R Bit 6 bit
N58:86 404887 Compressor Permissive Input 11 R Bit 0 bit
Auto Input Level 1 R Bit 8 bit
Hold Input Level 1 R Bit 12 bit
N58:89 404890 Load Input Level 1 R Bit 0 bit
Load Input Level 2 R Bit 1 bit
Unload Input Level 1 R Bit 4 bit
Saturated Liquid Temp Output 1 R Bit 8 bit
Document MCP-170
Revision: N
GForce™
Compressor Ready Output Level 1 R Bit 12 bit
N58:90 404891 Compressor in Anti-Recycle Output Level 1 R Bit 0 bit
Compressor in Anti-Recycle Output Level 2 R Bit 1 bit
Compressor in Stop Mode Output Level 1 R Bit 4 bit
Compressor in Local Mode Output Level 1 R Bit 8 bit
Compressor in Remote Mode Output Level 1 R Bit 12 bit
N58:91 404892 Compressor in Shutdown Output Level 1 R Bit 0 bit
Compressor in Shutdown Output Level 2 R Bit 1 bit
Bits 4-15 are not used
404893 -
| Reserved for Sequencing I/O |
405000 -
Alarm Codes (Codes 21-50 available on Modbus Ethernet Only)

N60:0 405001 Alarm Array #1 (Alarm) Code# R 0=No Alarms X1
1=High Oil Separator Temp
2=Low Oil Separator Temp
3=Aborted Power Fail Reset
4=High Motor Current
5=High Discharge Pressure
6=High Discharge Temp
7=High Oil Filter Differential
8=Low Inlet Oil Temperature
9=High Inlet Oil Temperature
10=Low Process Temperature
11=High Process Temperature
12=Low Suction Pressure
13=High Suction Pressure
14=Loss Oil Pmp Interlock #
15=Illegal Oil Pmp Interlock #
16=Low Oil Pressure
17=High Oil Pressure
18=Low Oil Pressure Pump #
19=Low Suction Superheat
20=High Suction Superheat
21=Low Discharge Superheat
22=High Discharge Superheat
23=Low Line Voltage #
24=Annunciate Block #
25=Loss of Condenser Interlock #
26=Illegal Condenser Interlock #
27=High Condenser Discharge Pressure
28=Low Condenser Discharge Pressure
29=Sequence Safety
30=Low Sequence Suction Pressure
31=Low Sequence Process Temperature
32=Units Error Math Block #

33=Illegal Oil Filter Differential
Document MCP-170
Revision: N
GForce™
34=Not Used
35=Not Used
36=Sequencer Communications Error
38=Watchdog
39=High Seq Discharge Pressure
40=Max Pump Down Cycles
41=Not used
42=Low Auxiliary Suction Pressure
43=Not Used
44=LifeTrac High Vibration
45=Loss of Communications
46=High Panel Temperature
47=Low Panel Temperature
48=Analog Sensor Power Fault
49=Panel Purge Failure
50=Analog Output Fault Channel #
51=High Oil Sump Temperature
52=Low Oil Sump Temperature
53=High Vibration Warning Sensor #
54=High Vibration Damage Sensor #
55=Analog Input Fault Channel #
56=Loss of Motor Starter
Communication #
RECIP COMPRESSOR ALARMS
1001=High Discharge Pressure #
1002=Low Suction Pressure #
1003=High Suction Pressure #
1004=High Oil Differential #
1005=Low Oil Differential #
1006=High Motor Current #
1007=Low Temperature #
1008=High Temperature #
1009=High Discharge Temperature #
1010=Low Process Temperature #
1011=High Process Temperature #
1012=High Discharge Pressure #1 #
1014=High Discharge Temperature #1 #
1016=High Intermediate Pressure #
1017=High Intermediate Discharge
Temperature #
1018=Low Auxilliary Suction Pressure #
1019=Aborted Power Fail Reset #
1020=Low Discharge Pressure #1
1021=Low Discharge Pressure #2
1022=Low Discharge Pressure
EVAPORATOR ALARMS
N60:1 405002 Auxiliary Info R "#" for Alarm Codes X1
N60:2 405003 Priority Level (Reserved for Future Use) R X1
N60:3 405004 Hour R X1
N60:4 405005 Minute R X1
N60:5 405006 Second R X1
N60:6 405007 Month R X1
N60:7 405008 Day R X1
N60:8 405009 Year R X1
N60:9 405010 Clear Alarm W Any write clears alarm -
N60:10 405011 Alarm Code #2 R

N60:20 405021 Alarm Code #3 R
N60:30 405031 Alarm Code #4 R
| R
|
|
N64:80 405481 Alarm Code #49 R
Document MCP-170
Revision: N
GForce™
N64:90 405491 Alarm Code #50 R
|
405500
Notification Codes available on Modbus Ethernet Only

N65:0 405501 Alarm Array #2 (Notification)
|
406000
Shutdown Codes (Codes 21-50 available on Modbus Ethernet Only)

N70:0 406001 Alarm Array #3 (Shutdown) Code# R 0=No Alarm/Shutdown X1
1=High Oil Separator Temperature
2=Low Oil Separator Temperature
3=Discharge Check Valve not Open
4=Discharge Check Valve not Closed
5=Illegal Oil Injection Setpoints
6=Compressor Start
7=Loss of Compressor Interlock
8=Loss of Compressor Motor Current
9=High Motor Current
10=Motor Current Overload
11=Illegal Compressor Interlock
12=Illegal Compressor Motor Current
13=High Discharge Pressure
14=High Discharge Temperature
15=Not Used
16=Discharge Pressure Overload
17=High Oil Filter Differential
18=Low Line Voltage #
19=Not Used
20=Low Inlet Oil Temperature
21=High Inlet Oil Temperature
22=Low Process Temperature
23=Low Suction Pressure
24=Low Suction Prs Overload
25=Loss of Oil Pmp Interlock
26=Illegal Oil Pmp Interlock
27=Low Oil Pressure
29=Compressor Slide Valve Unload
30=Low Oil Pressure Pump #
31=Low Suction Superheat
32=High Suction Superheat
33=Low Discharge Superheat
34=High Discharge Superheat
35=Low Oil Level
36=Not Used
37=Not Used
38=Not Used
39=Not Used
40=Annunciate Block #
41=Not Used
42=Not Used
43=Not Used
44=Not Used
45=Not Used
46=Not Used
47=Loss of Aux Oil Pump Interlock
48=Illegal Aux Oil Pump Interlock
49=Low Aux Oil Pump Pressure
50=Low Oil Differential
51=Oil Separator Temp Probe Failure
52=Max Unload Run Time Expired
53=Balance Piston not Open
54=Compressor Oil Drain
55=Low Oil Press - Startup
56=Low Differential Pressure
57=Low Auxiliary Suction Pressure
Document MCP-170
Revision: N
GForce™
58=Life Trac High Vibration
59=Loss of Communications
60=Emergency Stop
61=WatchDog
62=High Oil Sump Temperature
63=Low Oil Sump Temperature
64=Oil Sump Temp Probe Failure
65=High Vibration Damage Sensor #
66=Loss of Motor Starter
Communication #
67=Motor Starter Fault #
68=VFD Motor Starter Fault #
69=Motor Starter Lockout #
RECIP COMPRESSOR SHUTDOWNS
1001=Loss of Comp Motor Current #
1002=Illegal Comp Motor Current #
1003=Loss of Comp Interlock #
1004=Illegal Comp Interlock #
1005=High Motor Current #
1006=High Discharge Pressure #
1007=Compressor Failure #
1008=Low Suction Pressure #
1009=High Suction Pressure #
1010=Low Oil Differential #
1011=High Oil Differential #
1014=High Discharge Temperature #
1015=High Process Temperature #

1020=High Intermediate Pressure #
1021=High Pressure Ratio #
1022=High Intermediate Discharge
Temperature #
1023=Low Auxiliary Suction Pressure #
1024=Motor Current Overload
1025=Discharge Pressure Overload
1026=Illegal Process Control Low Suction
Setpoints
1027=Low Suction Pressure Overload
N70:1 406002 Auxiliary Info R "#" for Alarm/Shutdown Codes X1
N70:2 406003 Priority Level (Reserved for Future Use) R X1
N70:3 406004 Hour R X1
N70:4 406005 Minute R X1
N70:5 406006 Second R X1
N70:6 406007 Month R X1
N70:7 406008 Day R X1
N70:8 406009 Year R X1
N70:9 406010 Clear Shutdown W Any write clears shutdown -
N70:10 406011 Shutdown Code #2 R

| R
|
|
|
406500
Annunciate Block Flags 100-499 available on Modbus Ethernet Only
Document MCP-170
Revision: N
GForce™
0 = inactive,
1 = Shutdown (General),
2 = Alarm (General),
3 = Alarm (No Output),
N75:0 406501 Annunciate Block Flags 0-499 R X1
4 = Shutdown (Group #1 - Recip),
5 = Alarm (Group #1 - Recip),
6 = Shutdown (Group #2 - System),
7 = Alarm (Group #2 - System)
|
407000
Alarm Array #1 (Alarm) Flags

N80:0 407001 Alarm Status R 0=normal, 1=alarm present X1
N80:1 407002 High Oil Separator Temperature R X1
N80:2 407003 Low Oil Separator Temperature R X1
N80:3 407004 Aborted Power Fail Reset R X1
N80:4 407005 High Motor Current R X1
N80:5 407006 High Discharge Pressure R X1
N80:6 407007 High Discharge Temp R X1
N80:7 407008 High Oil Filter Differential R X1
N80:8 407009 Low Inlet Oil Temperature R X1
N80:9 407010 High Inlet Oil Temperature R X1
N80:10 407011 Low Process Temperature R X1
N80:11 407012 High Process Temperature R X1
N80:12 407013 Low Suction Pressure R X1
N80:13 407014 High Suction Pressure R X1
N80:14 407015 Loss of Oil Pump Interlock R X1
N80:15 407016 Illegal Oil Pump Interlock R X1
N80:16 407017 Low Oil Pressure R X1
N80:17 407018 High Oil Pressure R X1
N80:18 407019 Low Oil Pressure Pump R X1
N80:19 407020 Low Suction Superheat R X1
N80:20 407021 High Suction Superheat R X1
N80:21 407022 Low Discharge Superheat R X1
N80:22 407023 High Discharge Superheat R X1
N80:23 407024 Low Line Voltage R X1
N80:24 407025 Annunciate Block # R X1
N80:25 407026 Loss of Condenser Interlock # R X1
N80:26 407027 Illegal Condenser Interlock # R X1
N80:27 407028 High Condenser Discharge Pressure R X1
N80:28 407029 Low Condenser Discharge Pressure R X1
N80:29 407030 Sequence Safety R X1
N80:30 407031 Low Sequence Suction Pressure R X1
N80:31 407032 Low Sequence Process Temperature R X1
N80:32 407033 Units Error Math Block # R X1
N80:33 407034 Illegal Oil Filter Differential R X1
N80:34 407035 Not Used R X1
N80:35 407036 Not Used R X1
N80:36 407037 Sequencer Communications Error R X1
N80:38 407039 Watch Dog R X1
N80:39 407040 High Sequencer Discharge Pressure R X1
N80:40 407041 Max Pump Down Cycles R X1
N80:41 407042 Not Used R X1
N80:42 407043 Low Auxiliary Suction Pressure R X1
N80:43 407044 Not Used R X1
N80:44 407045 Life Trac High Vibration R X1
N80:45 407046 Loss of Communications R X1
N80:46 407047 High Panel Temperature R X1
N80:47 407048 Low Panel Temperature R X1
N80:48 407049 Analog Sensor Power Fault R X1
N80:49 407050 Panel Purge Failure R X1
N80:50 407051 Analog Output Fault Channel # R X1
N80:51 407052 High Oil Sump Temperature R X1
N80:52 407053 Low Oil Sump Temperature R X1
N80:53 407054 High Vibration Warning Sensor # R X1
N80:54 407055 High Vibration Damage Sensor # R X1
N80:55 407056 Analog Input Fault Channel # R X1
Document MCP-170
Revision: N
GForce™
N80:56 407057 Loss of Motor Starter Communication R X1
RECIP COMPRESSOR ALARMS
N81:3 407104 High Oil Differential R X1
N81:4 407105 Low Oil Differential R X1
N81:6 407107 Low Temperature R X1
N81:7 407108 High Temperature R X1
N81:8 407109 High Discharge Temperature R X1
N81:10 407111 High Process Temperature R X1
N81:11 407112 High Discharge Pressure #1 R X1
N81:13 407114 High Discharge Temperature #1 R X1
N81:15 407116 High Intermediate Pressure R X1
N81:16 407117 High Intermediate Discharge Temperature R X1
N81:18 407119 Aborted Power Fail Reset R X1
N81:19 407120 Low Discharge Pressure #1 R X1
N81:20 407121 Low Discharge Pressure #2 R X1
N81:21 407122 Low Discharge Pressure R X1
EVAPORATOR ALARMS
407153 -
| Reserved for additional Alarm Annunciations |
407200 -
Alarm Array #2 (Notification) Flags available on Modbus Ethernet Only

N82:0 407201 Alarm Array #2 Flags -
| Reserved | 0=normal, 1=alarm present X1
407400 -
Alarm Array #3 (Shutdown) Flags

N84:0 407401 Shutdown Status R 0=normal, 1=alarm present X1
N84:1 407402 High Oil Separator Temperature R X1
N84:2 407403 Low Oil Separator Temperature R X1
N84:3 407404 Discharge Check Valve not Open R X1
N84:4 407405 Discharge Check Valve not Closed R X1
N84:5 407406 Illegal Oil Injection Setpoints R X1
N84:6 407407 Compressor Start R X1
N84:7 407408 Loss of Compr Interlock R X1
N84:8 407409 Loss of Compr Motor Current R X1
N84:10 407411 Motor Current Overload R X1
N84:11 407412 Illegal Cmp Interlock R X1
N84:12 407413 Illegal Cmp Mtr Current R X1
N84:15 407416 Not Used R X1
N84:16 407417 Discharge Pressure Overload R X1
N84:17 407418 High Oil Filter Differential R X1
N84:18 407419 Low Line Voltage # R X1
N84:19 407420 Not Used R X1
N84:20 407421 Low Inlet Oil Temperature R X1
N84:21 407422 High Inlet Oil Temperature R X1
N84:24 407425 Low Suction Pressure Overload R X1
N84:25 407426 Loss of Oil Pmp Interlock R X1
N84:26 407427 Illegal Oil Pmp Interlock R X1
N84:27 407428 Low Oil Pressure R X1
N84:29 407430 Compressor Slide Valve Unload R X1
Document MCP-170
Revision: N
GForce™
N84:30 407431 Low Oil Pressure Pump R X1
N84:31 407432 Low Suction Superheat R X1
N84:32 407433 High Suction Superheat R X1
N84:33 407434 Low Discharge Superheat R X1
N84:34 407435 High Discharge Superheat R X1
N84:35 407436 Low Oil Level R X1
N84:36 407437 Not Used R X1
N84:37 407438 Not Used R X1
N84:38 407439 Not Used R X1
N84:39 407440 Not Used R X1
N84:40 407441 Annunciate Block # R X1
N84:41 407442 Not Used R X1
N84:42 407443 Not Used R X1
N84:43 407444 Not Used R X1
N84:44 407445 Not Used R X1
N84:45 407446 Not Used R X1
N84:46 407447 Not Used R X1
N84:47 407448 Loss of Aux Oil Pump Intlk R X1
N84:48 407449 Illegal Aux Oil Pump Intlk R X1
N84:49 407450 Low Aux Oil Pump Pressure R X1
N84:51 407452 Oil Separator Temperature Probe Failure R X1
N84:52 407453 Max Unload Run Time Expired R X1
N84:53 407454 Balance Piston not Open R X1
N84:54 407455 Compressor Oil Drain R X1
N84:55 407456 Low Oil Press - Startup R X1
N84:56 407457 Low Differential Pressure R X1
N84:58 407459 LifeTrac High Vibration R X1
N84:59 407460 Loss of Communications R X1
N84:60 407461 Emergency Stop R X1
N84:61 407462 WatchDog R X1
N84:62 407463 High Oil Sump Temperature R X1
N84:63 407464 Low Oil Sump Temperature R X1
N84:64 407465 Oil Sump Temp Probe Failure R X1
N84:65 407466 High Vibration Damage Sensor # R X1
N84:66 407467 Loss of Motor Starter Communication # R X1
N84:67 407468 Motor Starter Fault # R X1
N84:68 407469 VFD Motor Starter Fault # R X1
N84:69 407470 Motor Starter Lockout # R X1
RECIP COMPRESSOR SHUTDOWNS
N85:0 407501 Loss of Compressor Motor Current R X1
N85:1 407502 Illegal Compressor Motor Current R X1
N85:2 407503 Loss of Compressor Interlock R X1
N85:3 407504 Illegal Compressor Interlock R X1
N85:6 407507 Compressor Failure R X1
N85:10 407511 High Oil Differential R X1
N85:19 407520 Hight Intermediate Pressure R X1
N85:20 407521 High Pressure Ratio R X1
N85:21 407522 High Intermediate Discharge Temperature R X1
N85:23 407524 Motor Current Overload R X1
N85:24 407525 Discharge Pressure Overload R X1
N85:25 407526 Illegal Process Control Low Suction Setpoints R X1
N85:26 407527 Low Suction Pressure Overload R X1
Document MCP-170
Revision: N
GForce™
407529 -
| Reserved for additional Shutdown Annunciations |
407600 -
FES Compressor Sequencing Area

407601
| Reserved for FES Sequencer to Compressor Communications
408100
Recip Compressor Control (Modbus Ethernet Only)

Recip Compressor Viewport Setup
0=No Entries
N92:0 408201 Entry in Viewport R/W X1
Else = Compressor #1-10
Recip Compressor Status (Viewport)
N92:1 408202 Number of Solenoids R 1 to 10 X1
N92:2 408203 Number of Steps R 1 to 11 X1
N92:3 408204 Suction Pressure Control Enabled? R 0=No / Else=Yes X1
N92:4 408205 Process Temperature Control Enabled? R 0=No / Else=Yes X1
N92:5 408206 Discharge Pressure Monitoring Enabled? R 0=No / Else=Yes X1
N92:6 408207 Discharge Temperature Monitoring Enabled? R 0=No / Else=Yes X1
N92:7 408208 Oil Pressure Monitoring Enabled? R 0=No / Else=Yes X1
N92:8 408209 Motor Current Monitoring Enabled? R 0=No / Else=Yes X1
N92:9 408210 Temperature Monitoring Enabled? R 0=No / Else=Yes X1
N92:10 408211 VFD Control Enabled? R 0=No / Else=Yes X1
N92:11 408212 Startup Oil Return Enabled? R 0=No / Else=Yes X1
N92:12 408213 Recip Enabled? R 0=No / Else=Yes X1
N92:13 408214 Anti-Recycle Timing? R 0=No / Else=Yes X1
N92:14 408215 Anti-Recycle Hours R 0 to 23 X1
N92:15 408216 Anti-Recycle Minutes R 0 to 59 X1
N92:16 408217 Anti-Recycle Seconds R 0 to 59 X1
N92:17 408218 Delay Power Fail Reset Timing? R 0=No, 1 to 8000 sec Delay Time Remaining X1
N92:18 408219 Abort Power Fail Reset Hours Remaining R 0 to 23 X1

N92:19 408220 Abort Power Fail Reset Minutes Remaining R 0 to 59 X1
N92:20 408221 Abort Power Fail Reset Seconds Remaining R 0 to 59 X1
N92:21 408222 Two-Stage R 0=No / Else=Yes X1
0 = No InterCooler
1 = Injection Interstage Gas Cooling
2 = Combined Interstage Gas &
Economizer Cooling
N92:22 408223 InterCooler Type R X1
3 = Open Flash Interstage Cooling
4 = Closed Flash Interstage Cooling
5 = 2 x (1 = Combined Interstage Gas &
Economizer Cooling)
Recip Compressor Parameters (Viewport)

SUCTION
N93:3 408304 Suction 1 Pressure High Alarm R/W X10
N93:5 408306 Suction 1 Pressure Low Alarm R/W X10
N93:9 408310 Suction 2 Pressure High Alarm R/W X10
N93:11 408312 Suction 2 Pressure Low Alarm R/W X10
N93:12 408313 Low Suction Pressure, 0=Fail/1=Cycle R/W X1
PROCESS
N93:16 408317 Process 1 Temperature High Alarm R/W X10
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Revision: N
GForce™
N93:18 408319 Process 1 Temperature Low Alarm R/W X10
N93:22 408323 Process 1 Temperature High Alarm R/W X10
N93:24 408325 Process 1 Temperature Low Alarm R/W X10
N93:25 408326 Low Process Temperature, 0=Fail/1=Cycle R/W X1
N93:26 408327 Process Temp Control Low Suction R/W X10
CONTROL
N93:27 408328 Control Mode 0=P/1=T/2=DI R/W X1
N93:28 408329 Control Mode Point 0=DI/1=PNT1/2=PNT2 R/W X1
N93:29 408330 Capacity Control Up Timer R/W 1 to 1800 Seconds X1
N93:30 408331 Capacity Control Down Timer R/W 1 to 1800 Seconds X1
N93:31 408332 Minimum Capacity Step R/W X1
N93:32 408333 Invert Solenoids R/W 0=Factory Default/1=Reverse X1
OIL PRESSURE
N93:33 408334 High Oil Pressure Shutdown R/W X10
N93:34 408335 High Oil Pressure Alarm R/W X10
N93:35 408336 Low Oil Pressure Shutdown R/W X10
N93:36 408337 Low Oil Pressure Alarm R/W X10
DISCHARGE
N93:37 408338 High Discharge Pressure Shutdown R/W X10
N93:38 408339 High Discharge Pressure Alarm R/W X10
N93:39 408340 High Discharge Temperature Shutdown R/W X10
N93:40 408341 High Discharge Temperature Alarm R/W X10
TEMPERATURE
N93:41 408342 High Temperature Shutdown R/W X10
N93:42 408343 Low Temperature Shutdown R/W X10
N93:43 408344 High Temperature Alarm R/W X10
N93:44 408345 Low Temperature Alarm R/W X10
COMPRESSOR MOTOR
N93:45 408346 Compressor Start Interlock Shutdown Delay R/W 5 to 900 Seconds X1
N93:46 408347 High Motor Current Shutdown R/W X10
N93:47 408348 High Motor Current Alarm R/W X10
N93:48 408349 Motor Current Lower R/W X10
N93:49 408350 Motor Current Dead Band R/W X10
N93:50 408351 Anti-Recycle Period Min R/W 10-900 Minutes X1
N93:51 408352 Accum Compressor Runtime (khours) R/W 0 to 32767 khours X1
N93:52 408353 Accum Compressor Runtime (hours) R/W 0 to 999.9 hours X10
N93:53 408354 Motor Current Maximum R/W 50-2500 X1
STARTUP OIL RETURN
N93:54 408355 Oil Return Time Setpoint R/W X10
VARIABLE SPEED DRIVE SETPOINTS
N93:55 408356 VFD Motor Proportional Constant R/W X10
N93:56 408357 VFD Motor Integral Constant R/W X10
N93:57 408358 VFD Motor Derivative Constant R/W X10
N93:60 408361 VFD Motor Speed at 4mA R/W X10
N93:61 408362 VFD Motor Speed at 20mA R/W X10
POWER FAIL RESET
N93:62 408363 Power Fail Reset Enable 0=No/1=Yes R/W X1
N93:63 408364 Reset to Mode? 1=Local/2=Remote R/W X1
N93:64 408365 Delay Before Power Fail Reset (Sec) R/W X10
N93:65 408366 Abort Power Fail Reset After (Min) R/W X10
POWER MONITORING
N93:66 408367 Demand Metering Ratio kW R/W X10
N93:67 408368 KiloWatt Hour Sampling Period Min R/W X10
N93:68 408369 MegaWatt Hours Consumed R/W 0-32767 X1
N93:69 408370 KiloWatt Hours Consumed R/W 0-999.9 X10
INTERMEDIATE
N93:70 408371 High Intermediate Discharge Pressure Shutdown R/W X10
N93:71 408372 High Intermediate Discharge Pressure Alarm R/W X10

High Intermediate Discharge Temperature
N93:72 408373 R/W X10
Shutdown
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Revision: N
GForce™
N93:73 408374 High Intermediate Discharge Temperature Alarm R/W X10
N93:74 408375 High Pressure Ratio Shutdown R/W X10

SUCTION CON'T
N93:75 408376 Low Suction Auxiliary Safety Shutdown R/W X10
N93:76 408377 Low Suction Auxiliary Safety Alarm R/W X10
CONTROL CON'T
N93:77 408378 Load Limit 0=None/1=SP R/W X1

N93:78 408379 Ramp to Suction R/W X10
VARIABLE SPEED DRIVE SETPOINTS CON'T
N93:79 408380 VFD Control Mode 0=Local/1=Remote/2=DI R/W X1
CONTROL CON'T
N93:81 408382 Capacity Control Direction 0=Forward/1=Reverse R/W X1
DISCHARGE CON'T
N93:82 408383 Discharge Pressure Prop Band R/W X10
PROCESS CON'T
N93:83 408384 Process Temp Control, Unload Band R/W X10
Process Temperature Control, Low Suction
N93:84 408385 R/W X10
Pressure Alarm
DISCHARGE CON'T
N93:86 408387 Discharge 1 Pressure DeadBand R/W X10
N93:88 408389 Discharge 1 Pressure Low Alarm R/W X10
N93:90 408391 Discharge 2 Pressure DeadBand R/W X10
N93:92 408393 Discharge 2 Pressure High Alarm R/W X10
N93:94 408395 Discharge 2 Pressure Low Alarm R/W X10
N93:95 408396 Low Discharge Pressure R/W 0=Shutdown/1=Cycle X10
Discharge Pressure Control, Low Suction Pressure
N93:96 408397 R/W X10
Setpoint
Discharge Pressure Control, Low Suction Pressure
N93:97 408398 R/W X10
Alarm
N93:98 408399 High Discharge Pressure Max R/W X10
Recip Compressor Commands

Recip Compressor #1 Commands
N94:0 408401 Start Mode R/W 0=Stop / 1=Local / 2=Remote X1
N94:1 408402 Remote Start Mode R/W 0=Stop / 1=Start X1
0=Auto (If Applicable)
1=Hold at Present Step
2=Load
3=Unload
4=Hold at Step #1 (Start)
5=Hold at Step #2
6=Hold at Step #3
N94:2 408403 Capacity Control Mode R/W 7=Hold at Step #4 X1
8=Hold at Step #5
9=Hold at Step #6
10=Hold at Step #7
11=Hold at Step #8
12=Hold at Step #9
13=Hold at Step #10
14=Hold at Step #11
Document MCP-170
Revision: N
GForce™
0=Stopped
1=Step #1 (Start)
2=Step #2 of n
3=Step #3 of n
4=Step #4 of n
5=Step #5 of n
N94:3 408404 Current Capacity Step R X1
6=Step #6 of n
7=Step #7 of n
8=Step #8 of n
9=Step #9 of n
10=Step #10 of n
11=Step #11 of n
N94:4 408405 Clear Remaining Anti-Recycle Time W Any non-zero write executes command -
N94:5 408406 Clear Remaining Power Failure Reset Time W Any non-zero write executes command -
N94:6 408407 Remote VFD Control % W 0.0 to 100.0 % X10
Note: VFD Control Mode must be set to Remote or DI (Modbus Register 8380, Value=1 or 2).
N94:7 408408 Abort Computer Sequencing W ASCII 'AB' or 16706 -
0=Recip not Enabled
1=Start Only
2=Start and 1 Step
2=Start and 2 Steps
4=Start and 3 Steps
5=Start and 4 Steps
N94:10 408411 Maximum Capacity Steps R X1
6=Start and 5 Steps
7=Start and 6 Steps
8=Start and 7 Steps
9=Start and 8 Steps
10=Start and 9 Steps
11=Start and 10 Steps
Current Capacity in Percent 0 to 100%
N94:11 408412 This address returns ON/OFF codes if Compressor R 253=OFF X1

is configured as a Rotary or as a Screw with no 254=ON
slide valve output
N94:12 408413 Anti-Recycle Timing? R 0=No,1=Yes X1
N94:13 408414 Delay Power Fail Reset Timing? R 0=No, 1 to 8000 sec Delay Time Remaining X1
N94:14 408415 Recip Compressor #2 Commands

|
N94:27 408428

|
N94:41 408442

|
N94:55 408456

|
N94:69 408470

|
N94:83 408484

|
N94:97 408498

|
N95:11 408512
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GForce™

|
N95:25 408526

|
N95:39 408540
Recip Compressor Analog/Setpoint Data

N96:0 408601 Compressor #1 Suction Pressure #1 R X10
|
|
N96:20 408621 Compressor #1 Suction Pressure Average R X10
|
N96:29 408630 Compressor #10 Suction Pressure Average R X10
N96:30 408631 Compressor #1 Discharge Pressure #1 R X10
|
|
N96:50 408651 Compressor #1 Discharge Pressure Average R X10
|
N96:59 408660 Compressor #10 Discharge Pressure Average R X10
N96:60 408661 Compressor #1 Oil Pressure R X10
|
N96:69 408670 Compressor #10 Oil Pressure R X10
N96:70 408671 Compressor #1 Oil Differential Pressure R X10
|
N96:79 408680 Compressor #10 Oil Differential Pressure R X10
N96:80 408681 Compressor #1 Process Temperature R X10
|
N96:89 408690 Compressor #10 Process Temperature R X10
N96:90 408691 Compressor #1Discharge Temperature #1 R X10
|
N96:99 408700 Compressor #10 Discharge Temperature #1 R X10
|
N97:10 408711 Compressor #1 Discharge Temperature Average R X10
N97:19 408720 Compressor #10 Discharge Temperature Average R X10
N97:20 408721 Compressor #1kiloWatt Demand R X10

|
N97:29 408730 Compressor #10 kiloWatt Demand R X10
N97:30 408731 Compressor #1 VFD Motor Speed (RPM) R X1
|
N97:39 408740 Compressor #10 VFD Motor Speed (RPM) R X1
N97:40 408741 Compressor #1 Capacity Input R X10
|
N97:49 408750 Compressor #10 Capacity Input R X10
N97:50 408751 Compressor #1 Temperature R X10
|
N97:59 408760 Compressor #10 Temperature R X10
N97:60 408761 Compressor #1 Motor Current R X10
|
N97:69 408770 Compressor #10 Motor Current R X10
N97:70 408771 Compressor #1 Intermediate Pressure R X10
|
N97:79 408780 Compressor #10 Intermediate Pressure R X10
Compressor #1 Intermediate LP Discharge
N97:80 408781 R X10
Temperature
Document MCP-170
Revision: N
GForce™
|
Compressor #10 Intermediate LP Discharge
N97:89 408790 R X10
Temperature
Compressor #1 Intermediate HP Suction
N97:90 408791 R X10
Temperature
|
Compressor #10 Intermediate HP Suction
N87:99 408800 R X10
Temperature
N98:0 408801 Compressor #1 Pressure Ratio R X10
|
N98:9 408810 Compressor #10 Pressure Ratio R X10
N98:10 408811 Compressor #1 Suction Pressure 1 Setpoint R/W X10
|
|
N98:30 408831 Compressor #1 Process Temperature 1 Setpoint R/W X10
N98:50 408851 Compressor #1 Control Mode 0=P/1=T/2=DI R/W X1

|
N98:59 408860 Compressor #10 Control Mode 0=P/1=T/2=DI R/W X1
Compressor #1 Control Mode Point
N98:60 408861 R/W X1
0=DI/1=PNT1/2=PNT2
|
Compressor #10 Control Mode Point
N98:69 408870 R/W X1
0=DI/1=PNT1/2=PNT2
N98:70 408871 Compressor #1 Minimum Capacity Step R/W X1
|
N98:79 408880 Compressor #10 Minimum Capacity Step R/W X1
N98:80 408881 Compressor #1 VFD Motor PID % R/W X10
|
N98:89 408890 Compressor #10 VFD Motor PID % R/W X10
N98:90 408891 Compressor #1 Suction Temperature R/W X10
|
N99:-1 408900 Compressor #10 Suction Temperature R/W X10
Recip Compressor Digital Data

N99:0 408901 Compressor #1 Starter Output R Bit 0 bit
Compressor #2 Starter Output R Bit 1 bit
N99:1 408902 Compressor #1 Motor Interlock R Bit 0 bit
Compressor #2 Motor Interlock R Bit 1 bit
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GForce™
N99:2 408903 Compressor #1 Ready to Start Output R Bit 0 bit
Compressor #2 Ready to Start Output R Bit 1 bit
N99:3 408904 Compressor #1 Permissive Input R Bit 0 bit
Compressor #2 Permissive Input R Bit 1 bit
N99:4 408905 Compressor #1 Illegal Start Output R Bit 0 bit
Compressor #2 Illegal Start Output R Bit 1 bit
N99:5 408906 Compressor #1 Capacity Step #1 R Bit 0 bit
Compressor #2 Capacity Step #1 R Bit 1 bit
Document MCP-170
Revision: N
GForce™
N99:14 408915 Compressor #1 Shutdown Status Output R Bit 0 bit
Compressor #2 Shutdown Status Output R Bit 1 bit
Document MCP-170
Revision: N
GForce™
N99:15 408916 Compressor #1 Compressor Fail Input R Bit 0 bit
Compressor #2 Compressor Fail Input R Bit 1 bit
N99:16 408917 Compressor #1 Unloaded Start Output R Bit 0 bit
Compressor #2 Unloaded Start Output R Bit 1 bit
N99:17 408918 Compressor #1 Anti-Recycle Timer Output R Bit 0 bit
Compressor #2 Anti-Recycle Timer Output R Bit 1 bit
N99:18 408919 Compressor #1 Pressure/Temperature Select Input R Bit 0 bit
Compressor #2 Pressure/Temperature Select Input R Bit 1 bit
Compressor #10 Pressure/Temperature Select

R Bit 9 bit
Input
N99:19 408920 Compressor #1 Point 1/Point 2 Select Input R Bit 0 bit
Compressor #2 Point 1/Point 2 Select Input R Bit 1 bit
Document MCP-170
Revision: N
GForce™
N99:20 408921 Compressor #1 In Stop Mode Output R Bit 0 bit
Compressor #2 In Stop Mode Output R Bit 1 bit
N99:21 408922 Compressor #1 In Local Mode Output R Bit 0 bit
Compressor #2 In Local Mode Output R Bit 1 bit
N99:22 408923 Compressor #1 In Remote Mode Output R Bit 0 bit
Compressor #2 In Remote Mode Output R Bit 1 bit
N99:23 408924 Compressor #1 In Stop State Output R Bit 0 bit
Compressor #2 In Stop State Output R Bit 1 bit
N99:24 408925 Compressor #1 In Up State Output R Bit 0 bit
Compressor #2 In Up State Output R Bit 1 bit
N99:25 408926 Compressor #1 In Run State Output R Bit 0 bit
Compressor #2 In Run State Output R Bit 1 bit
Document MCP-170
Revision: N
GForce™
N99:26 408927 Compressor #1 In Down State Output R Bit 0 bit
Compressor #2 In Down State Output R Bit 1 bit
N99:27 408928 Compressor #1 In Auto Mode Output R Bit 0 bit
Compressor #2 In Auto Mode Output R Bit 1 bit
N99:28 408929 Compressor #1 In Hold Mode Output R Bit 0 bit
Compressor #2 In Hold Mode Output R Bit 1 bit
N99:29 408930 Compressor #1 In Load Mode Output R Bit 0 bit
Compressor #2 In Load Mode Output R Bit 1 bit
N99:30 408931 Compressor #1 In Unload Mode Output R Bit 0 bit
Compressor #2 In Unload Mode Output R Bit 1 bit
408932
| Unused, reserved
409000
Event Scheduler (Modbus Ethernet Only)

Schedule Viewport Setup
0=No Entries
N100:0 409001 Entry in Viewport R/W X1
1-First Available Entry (409005)
N100:1 409002 Unused
N100:2 409003 Unused
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GForce™
N100:3 409004 Insert Scratchpad Entry W Any write updates schedule -
N100:4 409005 Maximum Available R X1
N100:5 409006 First Available in Schedule R X1
N100:6 409007 Unused
Schedule Entry Scratchpad
(cleared after insertion)
0=Disabled
N100:7 409008 Type R/W 1=Evap Temperature Entry X1
2=Evap Defrost Entry
0=One Time
1=Continuous
2=Daily/Weekly
N100:8 409009 Mode R/W X1
3=Monthly
4=Event Trigger
5=Date Range
N100:9 409010 Enabled? R/W 0=No, 1=Yes X1
N100:10 409011 Device # (0=Evap #1…79=Evap #80) R/W X1
N100:11 409012 Start Time Month R/W 1 to 12 X1
N100:12 409013 Start Time Day of Month R/W 1 to 31 X1
N100:13 409014 Start Time Year R/W i.e. 2008 X1
N100:14 409015 Start Time Hour R/W 0 to 23 X1
N100:15 409016 Start Time Minute R/W 0 to 59 X1
N100:16 409017 End Time Month R/W 1 to 12 X1
N100:17 409018 End Time Day of Month R/W 1 to 31 X1
N100:18 409019 End Time Year R/W i.e. 2008 X1
N100:19 409020 End Time Hour R/W 0 to 23 X1
N100:20 409021 End Time Minute R/W 0 to 59 X1
Interval/End Time Enabled?
N100:21 409022 R/W 0=No, 1=Yes X1
- Used in Daily/Weekly or Monthly modes
N100:22 409023 Interval Hour R/W 0 to 23 X1
N100:23 409024 Interval Minute R/W 0 to 59 X1
Days
N100:24 409025 R/W Bit 0 = Sun… Bit 6 = Sat X1
-used for Daily/Weekly Mode
Week Interval
N100:25 409026 R/W 1 to 52 X1
Day of Month
N100:26 409027 R/W 1 to 31 X1
-used for Monthly Mode
0=First
1=Second
Week Frequency
N100:27 409028 R/W 2=Third X1
3=Fourth
4=Last
0=Sunday
1=Monday
2=Tuesday
Day of Week
N100:28 409029 R/W 3=Wednesday X1
4=Thursday
5=Friday
6=Saturday
Months
N100:29 409030 R/W Bit 0 = January... Bit 11 = December X1
N100:30 409031 Value (i.e. Temperature Setpoint) R/W X10
N100:31 409032 Unused
N100:32 409033 Unused
N100:33 409034 Unused
N100:34 409035 Unused
N100:35 409036 Unused
Schedule Entry (Viewport)
0=Disabled (Delete Entry)
N100:36 409037 Type R/W 1=Evap Temperature Entry X1
2=Evap Defrost Entry
N100:37 409038 Mode R/W 0=One Time X1
N100:38 409039 Enabled? R/W 0=No, 1=Yes X1
N100:39 409040 Device # (0=Evap #1…79=Evap #80) R/W X1
N100:40 409041 Start Time Month R/W 1 to 12 X1
N100:41 409042 Start Time Day of Month R/W 1 to 31 X1
N100:42 409043 Start Time Year R/W i.e. 2008 X1
N100:43 409044 Start Time Hour R/W 0 to 23 X1
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GForce™
N100:44 409045 Start Time Minute R/W 0 to 59 X1
N100:45 409046 End Time Month R/W 1 to 12 X1
N100:46 409047 End Time Day of Month R/W 1 to 31 X1
N100:47 409048 End Time Year R/W i.e. 2008 X1
N100:48 409049 End Time Hour R/W 0 to 23 X1
N100:49 409050 End Time Minute R/W 0 to 59 X1
Interval/End Time Enabled?
N100:50 409051 R/W 0=No, 1=Yes X1
- Used in Daily/Weekly or Monthly modes
N100:51 409052 Interval Hour R/W 0 to 23 X1
N100:52 409053 Interval Minute R/W 0 to 59 X1
Days
N100:53 409054 R/W Bit 0 = Sun… Bit 6 = Sat X1
Week Interval
N100:54 409055 R/W 1 to 52 X1
Day of Month
N100:55 409056 R/W 1 to 31 X1
0=First
1=Second
Week Frequency
N100:56 409057 R/W 2=Third X1
3=Fourth
4=Last
0=Sunday
1=Monday
2=Tuesday
Day of Week
N100:57 409058 R/W 3=Wednesday X1
4=Thursday
5=Friday
6=Saturday
Months
N100:58 409059 R/W Bit 0 = January... Bit 11 = December X1
N100:59 409060 Value (i.e. Temperature Setpoint) R/W X10
N100:60 409061 Unused
N100:61 409062 Unused
N100:62 409063 Unused
N100:63 409064 Unused
N100:64 409065 Unused
408966
| Unused, reserved
409500
Evaporator Control (Modbus Ethernet Only)

Evaporator Zone Data
0=Not Applicable
1=Disabled
2=Misc Mode #1 (NH3 Shutdown)
3=Misc Mode #2
4=Satisfied Fans Off
5=Satisfied Fans On
6=Satisfied
7=Cooling
8=Heating - Pump Down
9=Heating
10=Standby
11=Defrost Stage 1
N105:0 409501 Zone #1 Status R 12=Defrost Stage 2 X1
13=Defrost Stage 3
14=Defrost Stage 4
15=Defrost Stage 5
16=Defrost Stage 6
17=Defrost Stage 7
18=Defrost Stage 8
19=Defrost Stage 9
20=Defrost Stage 10
21=Defrost Stage 11
22=Defrost Stage 12
23=Override
24=Reset Delay
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GForce™
N105:1 409502 Zone #2 Status R X1
|
N105:79 409580 Zone #80 Status R X1
Bit 0 = Parameter Shutdown
N106:0 409601 Zone #1 Alarm Status R Bit 1 = High Temp Alarm X1
Bit 2 = Low Temp Alarm
N106:1 409602 Zone #2 Alarm Status R X1
|
N106:79 409680 Zone #80 Alarm Status R X1
Bit 0 = Output #1
Bit 1 = Output #2
Bit 2 = Output #3
Bit 3 = Output #4
Bit 4 = Output #5
Bit 5 = Output #6
Bit 6 = Output #7
Bit 7 = Output #8
N107:0 409701 Zone #1 Feedback Word R X1
Bit 8 = Output #9
Bit 9 = Output #10
Bit 10 = Output #11
Bit 11 = Output #12
Bit 12 = Output #13
Bit 13 = Output #14
Bit 14 = Output #15
Bit 15 = Unused
|
N108:0 409801 Zone #1 Temperature R X10
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N109:0 409901 Zone #1 Temperature Setpoint R/W X10
|
N110:0 410001 Zone #1 Humidity R X10
|
N111:0 410101 Zone #1 High Temperature Alarm Offset R/W X10
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N112:0 410201 Zone #1 Low Temperature Alarm Offset R/W X10
|
N113:0 410301 Zone #1 Fan Status R 0=Off / 1=On(Forward) / 2=On(Reverse) X1
N113:1 410302 Zone #2 Fan Status R X1

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N113:79 410380 Zone #80 Fan Status R X1
Evaporator Zone (Viewport)

N115:0 410501 Zone to Display in Viewport R/W 1-80, 0 = No Zone Information in Viewport X1
N115:1 410502 Unused
N115:2 410503 Unused
N115:3 410504 Zone Enabled R/W 0 = No / 1 = Yes / 2 = External X1
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GForce™
0=Not Applicable
1=Disabled
2=Misc Mode #1 (NH3 Shutdown)
3=Misc Mode #2
4=Satisfied Fans Off
5=Satisfied Fans On
6=Satisfied
7=Cooling
8=Heating - Pump Down
9=Heating
10=Standby
11=Defrost Stage 1
N115:4 410505 Zone Status R 12=Defrost Stage 2 X1
13=Defrost Stage 3
14=Defrost Stage 4
15=Defrost Stage 5
16=Defrost Stage 6
17=Defrost Stage 7
18=Defrost Stage 8
19=Defrost Stage 9
20=Defrost Stage 10
21=Defrost Stage 11
22=Defrost Stage 12
23=Override
24=Reset Delay
Bit 0 = Parameter Shutdown

N115:5 410506 Zone Alarm Status R Bit 1 = High Temp Alarm X1
Bit 2 = Low Temp Alarm
Bit 0 = Output #1
Bit 1 = Output #2
Bit 2 = Output #3
Bit 3 = Output #4
Bit 4 = Output #5
Bit 5 = Output #6
Bit 6 = Output #7
Bit 7 = Output #8
N115:6 410507 Zone Feedback Word R X1
Bit 8 = Output #9
Bit 9 = Output #10
Bit 10 = Output #11
Bit 11 = Output #12
Bit 12 = Output #13
Bit 13 = Output #14
Bit 14 = Output #15
Bit 15 = Unused
0=Not Started
1=Fans turning off in XX min (off delay)
2=Fans turning on in XX min (on delay)
N115:7 410508 Zone Fan Cycling Status R 3=Fans on for XX min (Agitation) - No S.P. X1
check
4=Fans on for XX min (Agitation) - Yes S.P.
check
0=Not Started
N115:8 410509 Heat Status R 1=Pumping Down for XX min X1
2=Heating
N115:9 410510 Heat Enabled? R 0=No, 1=Yes X1
0=Not Started
N115:10 410511 Dehumidification Status R X1
1=Dehumidifying
N115:11 410512 Dehumidification Enabled? R 0=No, 1=Yes X1
0=Not Started
1=Fan running in Forward for XX min
N115:12 410513 Reversing Fan Status R X1
2=Fan running in Reverse for XX min
3=Spinning Down for XX min
Reversing Fan Enabled? (Factory Config)

N115:13 410514 If Enabled, reference address N115:62 (4010563) R 0=No, 1=Yes X1
to see if disabled by parameter value.
N115:14 410515 Defrosting? R 0=No, 1=Yes X1

N115:15 410516 Pending Defrost? R 0=No, 1=Yes X1
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Revision: N
GForce™
Initiate Defrost
- If not defrosting will be placed into Defrost or

Pending
N115:16 410517 - If pending will be placed into Defrost immediately W Any write initiates
- If Defrosting and not at Soft Hot Gas stage will
cancel
- If Defrosting and at Soft Hot Gas or Hot Gas stage
will skip to next stage past Soft Hot Gas or Hot Gas
Time for Event (Fan Cycling, Defrost, Heat)

N115:17 410518 R Hours X1
All 0 = Not Timing
N115:18 410519 R Minutes X1
N115:19 410520 R Seconds X1
N115:20 410521 Liquid Solenoid Valve Run Time R Hours X1
N115:21 410522 R Minutes X1
N115:22 410523 R Seconds X1
Time for Pending Defrost
N115:23 410524 R Hours X1
All 0 = Not Timing
N115:24 410525 R Minutes X1
N115:25 410526 R Seconds X1
Time for Reversing Fans
N115:26 410527 R Hours X1
All 0 = Not Timing
N115:27 410528 R Minutes X1
N115:28 410529 R Seconds X1
N115:29 410530 VFD Fan Enabled? R 0=No, 1=Yes X1
0=Hold
1=Unload
N115:30 410531 VFD Fan Mode R X1
2=Load
6=Auto with Minimum
N115:31 410532 VFD Fan Output % R 0.0 to 100.0 % X10
N115:32 410533 Modulating Valve Enabled? R 0=No, 1=Yes X1
0=Hold
1=Unload
N115:33 410534 Modulating Valve Mode R X1
2=Load
6=Auto with Minimum
N115:34 410535 Modulating Valve Output % R 0.0 to 100.0 % X10
N115:35 410536 Zone Temperature R X10
N115:36 410537 Zone Setpoint (Parameter/Schedule) R X10
N115:37 410538 Zone Humidity R X10
Evaporator Parameters (Viewport)

TEMPERATURE SETTINGS
N115:40 410541 Temperature Setpoint R/W X10
N115:41 410542 High Temperature Alarm Offset R/W X10
N115:42 410543 Low Temperature Alarm Offset R/W X10
N115:43 410544 Temperature Setpoint Deadband R/W X10
N115:44 410545 Temperature Setpoint Delay R/W Seconds X10
HEAT SETTINGS
N115:45 410546 Heat Temperature Setpoint R/W X10
N115:46 410547 Heat Time Delay R/W Seconds X10
N115:47 410548 Pump Down before Heat? R/W 0=No, 1=Yes X1
N115:48 410549 Pump Down Time R/W Minutes X10
DEHUMIDIFICATION SETTINGS
N115:49 410550 Dehumidification Temperature Setpoint R/W X10
N115:50 410551 Temperature Time Delay R/W Seconds X10
N115:51 410552 Dehumidification Humidity Setpoint R/W X10
N115:52 410553 Humidity Time Delay R/W Seconds X10
N115:53 410554 Control Point R/W 0=Temperature/1=Humidity X1
VFD FAN SETTINGS
N115:54 410555 Minimum Speed Setting R/W 0-100% X10
N115:58 410559 Enable Test/Manual Control R/W 0=No/1=Yes X1
N115:59 410560 Test/Manual Mode Setpoint R/W 0-100% X10
N115:60 410561 Maximum Time at Minimum Speed R/W Minutes X10
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GForce™
N115:61 410562 Air Temperature Agitation Time R/W Minutes X10
FAN CYCLING SETTINGS
N115:62 410563 Enable Fan Cycling 0=No/1=Yes R/W X1
N115:63 410564 Fan Cycle Off Delay R/W X10
N115:64 410565 Fan Cycle On Delay R/W X10
N115:65 410566 Air Temperature Agitation Time R/W X10
N115:66 410567 Setpoint Delay While Agitating R/W X10
DEFROST SETTINGS
N115:67 410568 Liquid Solenoid Valve Runtime (0=Disable) R/W Minutes X1
N115:68 410569 Reset Liquid Solenoid Valve Runtime W Any write Clears
N115:69 410570 Defrost Stage 1 Timer R/W Minutes X10
N115:81 410582 Post Defrost Alarm Delay R/W Minutes X10
N115:82 410583 Defrost Loop Number R/W 1 to 80 X1
MODULATING VALVE SETTINGS
N115:83 410584 Minimum Position R/W 0-100% X10
N115:87 410588 Enable Test/Manual Control R/W 0=No/1=Yes X1
N115:88 410589 Test/Manual Mode Setpoint R/W 0-100% X10
REVERSING FAN SETTINGS
N115:89 410590 Forward/Reverse Cycling Period (0=Disabled) R/W Minutes X10
N115:90 410591 Fan Spin-Down Delay R/W Seconds X10
SUCTION VALVE OUTPUT SETTINGS
N115:91 410592 All Stages 0=Factory/1=Reverse R/W X1
N115:92 410593 Satisfied Stages 0=Energize/1=De-Energize R/W X1
HEAT SETTINGS CON'T
N115:93 410594 Post Pump Down Time Delay R/W X10
410595
| Unused, reserved
410700
Evaporator Digital Data

N117:0 410701 Evap Zone Enable Input R Bit 0-15 = Evap Zone #1-#16 bit
N117:5 410706 Evap Zone Shutdown #1 Input R Bit 0-15 = Evap Zone #1-#16 bit
N117:15 410716 Evap Zone Defrost Initiate Input R Bit 0-15 = Evap Zone #1-#16 bit
N117:20 410721 Evap Zone Defrost Terminate Input R Bit 0-15 = Evap Zone #1-#16 bit
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GForce™
N117:25 410726 Evap Zone Output #1 R Bit 0-15 = Evap Zone #1-#16 bit
Document MCP-170
Revision: N
GForce™
Custom Parameters Con't (Modbus Ethernet Only)

N118:0 410801 Custom Parameter 200-599 R/W Range and scaling are configurable
|
N129:99 412000
Screw Compressor Operating Parameters Cont.

N130:3 412004 Discharge 1 Pressure Prop Band R/W X10
N130:4 412005 Discharge 1 Pressure Dead Band R/W X10
N130:10 412011 High Discharge Pressure R/W 0=Shutdown/1=Cycle X1
Discharge Pressure Control,
N130:11 412012 R/W X10
Low Suction Pressure Setpoint
Sequence Parameters (Modbus Ethernet Only) Cont.

LEVEL 1 DISCHARGE
LEVEL 2 DISCHARGE
LEVEL 3 DISCHARGE
Document MCP-170
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GForce™
LEVEL 4 DISCHARGE
Allen-Bradley ControlLogix Remote I/O Definition

[Module]:I.Data[Index]
Index Input to PLC Instance #1 -- Screw/Recip Compressor(s)
Screw Compressor #1
0 Suction Pressure R X10
1 Process Temperature R X10

2 Slide Valve R X10
3 Motor Amps R X10
4 Compressor VFD Motor PID % R X10
5 Suction 1 Pressure Setpoint R X10
6 Process 1 Temperature Setpoint R X10
7 Control Mode Select R 0=Suct/1=Proc/2=DI/3=Rmt SV/4=Discharge X1
8 Control Point Select R 0=DI/1=PNT1/2=PNT2 X1
9 Slide Valve Position Minimum R 0-100% X10
10 Minimum Capacity Step R 0=Min/16=Max X1
11 Compressor Start Mode R 0=Stop/1=Local/2=Remote X1

12 Remote Start/Stop R 0=Stop/1=Start X1
13 Compressor Capacity Control Mode R X1
l
14 Anti-Recycle Timing? R 0=No/1=Yes X1
15 Power Fail Reset Timing? R 0=No/1=Yes X1
16 Shutdown Status R 0=normal, 1=alarm present X1
17 Alarm Status R 0=normal, 1=alarm present X1
20 Reserved for future use

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37
Recip Compressor #1
40 Suction Pressure R X10
41 Process Temperature R X10
42 Current Capacity Step R X10
43 Current Capacity % R X10
44 Max Capacity Step R X10
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GForce™
45 Motor Amps R X10
46 Compressor VFD Motor PID % R X10
47 Suction 1 Pressure Setpoint R X10
48 Process 1 Temperature Setpoint R X10
49 Control Mode 0=P/1=T/2=DI R X1
50 Control Mode Point 0=DI/1=PNT1/2=PNT2 R X1
51 Minimum Capacity Step R 0=Min/16=Max X1
52 Compressor Start Mode R 0=Stop/1=Local/2=Remote X1
53 Remote Start/Stop R 0=Stop/1=Start X1
2=Load
3=Unload
5=Hold at Step #2
6=Hold at Step #3
54 Compressor Capacity Control Mode R 7=Hold at Step #4 X1
8=Hold at Step #5
9=Hold at Step #6
10=Hold at Step #7
11=Hold at Step #8
12=Hold at Step #9
13=Hold at Step #10
14=Hold at Step #11
55 Anti-Recycle Timing? R 0=No/1=Yes X1
56 Power Fail Reset Timing? R 0=No/1=Yes X1
57 Shutdown Status R 0=normal, 1=alarm present X1
58 Alarm Status R 0=normal, 1=alarm present X1
60 Recip Compressor #2
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78
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98

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118

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138

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158

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178

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198

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218

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238
Index Output to PLC Instance #2 -- Screw/Recip Compressor(s)

Screw Compressor #1
0 Suction 1 Pressure Setpoint W X10
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GForce™
1 Process 1 Temperature Setpoint W X10
0=Suct/1=Proc/2=DI/3=Rmt SV/
2 Control Mode Select W X1
4=Discharge
3 Control Point Select W 0=DI/1=PNT1/2=PNT2 X1
4 Slide Valve Position Minimum W 0-100% X10
5 Minimum Capacity Step W 0=Min/16=Max X1
6 Compressor Start Mode W 0=Stop/1=Local/2=Remote X1
7 Remote Start/Stop W 0=Stop/1=Start X1
8 Compressor Capacity Control Mode W X1
l
9 Clear Remaining Anti-Recycle Time W Any non-zero write executes command -
10 Clear Remaining Power Fail Reset Time W Any non-zero write executes command -
11 Acknowledge Shutdown W Any non-zero write executes command -
12 Acknowledge Alarm W Any non-zero write executes command -
13 Load Pulse W 0.1 to 10.0 seconds X10
14 Unload Pulse W 0.1 to 10.0 seconds X10
Note: Capacity Control Mode must be External (Modbus Register 2203, Value=4) to accept
15 Abort Computer Sequencing W ASCII 'AB' or 16706 -
16 Register Computer Sequencing - 5 Minutes W ASCII 'CS' or 17235 -
17 Register Computer Sequencing - 1 Minute W ASCII 'CS' or 17235 -
18 Remote Slide Valve Control % W 0.0 to 100.0 % X10
Note: Control Mode must be set to Remote Slide Valve (Modbus Register 2351, Value=3).
19 Remote VFD Control % W 0.0 to 100.0 % X10
Note: VFD Control Mode must be set to Remote (Modbus Register 2397, Value=3).
20 Remote Total Capacity W 0.0 to 200.0 X10
Note: This value is a combination of Modbus Registers 2213 and 2214. A value 0 to 1000 will set the
25 Reserved for future use

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45
Recip Compressor #1
50 Suction 1 Pressure Setpoint W X10
51 Process 1 Temperature Setpoint W X10
52 Control Mode Select W 0=Suct/1=Proc/2=DI/3=Rmt SV/4=Discharge X1
53 Control Point Select W 0=DI/1=PNT1/2=PNT2 X1

54 Minimum Capacity Step W 0=Min/16=Max X1
55 Start Mode W 0=Stop / 1=Local / 2=Remote X1
56 Remote Start Mode W 0=Stop / 1=Start X1
2=Load
3=Unload
5=Hold at Step #2
6=Hold at Step #3
57 Capacity Control Mode W 7=Hold at Step #4 X1
8=Hold at Step #5
9=Hold at Step #6
10=Hold at Step #7
11=Hold at Step #8
12=Hold at Step #9
13=Hold at Step #10
14=Hold at Step #11
58 Clear Remaining Anti-Recycle Time W Any non-zero write executes command -
59 Clear Remaining Power Failure Reset Time W Any non-zero write executes command -
60 Remote VFD Control % W 0.0 to 100.0 % X10
Note: VFD Control Mode must be set to Remote or DI (Modbus Register 8380, Value=1 or 2).
61 Abort Computer Sequencing W ASCII 'AB' or 16706 -
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83
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GForce™
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103

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123

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143

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163

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183

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203

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223

|
243
Screw Compressor Operating Parameters Cont.

Discharge Pressure Control,
N130:11 412012 R/W X10
Low Suction Pressure Setpoint
Sequence Parameters (Modbus Ethernet Only) Cont.

LEVEL 1 DISCHARGE
LEVEL 2 DISCHARGE
Document MCP-170
Revision: N
GForce™
LEVEL 3 DISCHARGE
LEVEL 4 DISCHARGE
Document MCP-170
Revision: N
CONTROL PANEL
GForce™ COMPRESSOR
CONTROL PANEL DESCRIPTION & OPERATION
TABLE OF CONTENTS
Introduction ..................................................................................................................................... 1
Hardware Overview ........................................................................................................................ 2
Touch Screen........................................................................................................................... 2
Emergency Stop ...................................................................................................................... 2
Processor Assembly ................................................................................................................ 2
General Purpose I/O Board ..................................................................................................... 2
Analog Inputs ........................................................................................................................... 4
Analog Overcurrent Reset ....................................................................................................... 6
Digital I/O Racks ...................................................................................................................... 6
Analog Outputs ........................................................................................................................ 6
Line Voltage Monitor ................................................................................................................ 7
Panel Temperature Monitor ..................................................................................................... 7
Power Supply ........................................................................................................................... 8
Optional Hardware ................................................................................................................... 9
CT/4-20 mA Converter..................................................................................................... 9
4-20mA Loop Isolator ...................................................................................................... 9
Motor Thermal Monitor .................................................................................................... 9
Slide Valve Potentiometer Interface Board ................................................................... 10
ESP Board ..................................................................................................................... 10
Historical Data .............................................................................................................................. 11
Historical Table ...................................................................................................................... 12
Historical Graph ..................................................................................................................... 13
RX-Trends .............................................................................................................................. 14
Alarm/Shutdown History ........................................................................................................ 15
Documentation ............................................................................................................................. 16
Intranet ......................................................................................................................................... 17
Service Menu ............................................................................................................................... 18
File Manager .......................................................................................................................... 18
Parameter Backup/Restore ................................................................................................... 18
Export Panel Data Report to USB ......................................................................................... 19
Export Panel Data Report to USB ......................................................................................... 19
Copy GForce Historian to USB .............................................................................................. 19
Maintenance .......................................................................................................................... 19
Setup Network ....................................................................................................................... 20
Email Setup ............................................................................................................................ 20
Viewer Configuration ............................................................................................................. 24
Copy Remote Viewer to USB ........................................................................................ 24
Start/Restart Viewer Server ........................................................................................... 24
Washdown ............................................................................................................................. 24
Calibrate Touch Screen ......................................................................................................... 25
Update Software .................................................................................................................... 28
Factory Reset......................................................................................................................... 31
About Screen ......................................................................................................................... 32
User Level .................................................................................................................................... 33
Document: MCP-209
Revision: F
Effective: 07-2012
Boot Sequence ............................................................................................................................. 34
Appendix A: Table of Figures ....................................................................................................... 35
Appendix B: Compressor Operations Manuals ............................................................................ 37
Appendix C: Revisions ................................................................................................................. 38
Document: MCP-209
Revision: F
Effective: 07-2012
General Information
Introduction
This section provides detailed information on the FES GForce™ compressor control panel hardware, historical
data logging, on-line documentation and service features. Refer to the ‘GForce™ Operations Manual’ section for
the operation of specific compressor models.
The front of the control panel features a fifteen inch full color LCD with a resistive touch screen as the user
interface. The Emergency Stop switch is wired directly to the Compressor Motor starter as well as to an input on
the controller. The Emergency Stop switch should not be used during normal operation to stop the compressor.
Power for the panel computer can only be turned off at a breaker inside the panel.
Figure 1 GForce™ Screen with Overlay
The panel operates in two tabular display modes. This screen displays all of the current instrument readings,
digital I/O states, operating and alarm parameters, alarms, shutdowns and operating modes all on one screen.
Historical Data can be displayed in either tabular or graphical formats. System manuals and drawings are
available on-screen using an embedded PDF viewer.
Operating parameter settings can be saved to and recalled from a removable USB memory device to allow
greater operating flexibility. Software update utilities are included on the panel, program updates are handled
through the USB port.
All of the features and functions of the control panel are available remotely via an Ethernet connection. The
display on the remote computer is an exact duplicate of the local screen.
Document: MCP-209
Revision: F
1 of 38 Effective: 07-2012
Hardware
Hardware Overview
Touch Screen
The touch screen is the user interface to the control panel. It is protected with a hard-coated polyester overlay for
abrasion and chemical resistance. It may be cleaned with a cloth or towel and most commercial glass and surface
cleaners.
Emergency Stop
The Emergency Stop switch is a push to stop, twist to release switch. When activated it interrupts power to the
compressor motor starter output. A shutdown annunciation is also generated.
Processor Assembly
The processor assembly is mounted on the inside of the
enclosure door. USB and Ethernet ports are available at
the top of the assembly. Components inside this assembly
are not serviceable in the field. The entire assembly may
be removed by disconnecting the power and
communications cables and removing the six nuts holding
it in place. Slots are provided on the mounting bracket that
allow the top two nuts to be loosened but left in place. The
polyester overlay is not attached to the processor assembly
so the environmental seal of the enclosure is not affected if
changing out the processor assembly is ever required.
Figure 2 Processor Assembly
General Purpose I/O Board

Mounted on the back plate, this board provides analog input signal
conditioning, interface to the digital I/O racks, analog outputs and line
voltage and panel temperature monitoring. The Processor Assembly
communicates with the General Purpose I/O Board through P3 on a
proprietary RS485 network. Transient protection is provided and
termination is jumper selectable via J4. For a single General Purpose I/O
Board installed in a Compressor Control Panel all of the termination
jumpers should be in the ‘OFF’ position. The board slave address is set
using J3; for a compressor control panel this is usually ‘1’, only the ‘1’
jumper should be in the ‘ON’ position.
Jumper J1 is used for firmware updates to the General Purpose I/O Board,
when the connector is not in use the right two pins must be jumpered to
enable digital I/O rack function.
Switch SW1 will reset the microcontroller on the General Purpose I/O
board, all outputs will be turned off and communications to the Processor
Assembly will be interrupted.
Status LED’s are provided to give indication of various functions.
Figure 3 GP I/O Board II
Document: MCP- 209

Revision: F
Effective: 07-2012 2 of 38
Hardware
LED1 ♥ – green, flashes for processor activity indication.
LED2 COMM ERR – red, on when a communications error or timeout occurs.
LED3 TX – amber, flashes on when a data packet is being transmitted to the
processor assembly.
LED4 RX – amber, flashes on when a data packet is being received from the
processor assembly.
LED5 – green, on when analog transducer power is OK.
LED6 – red, on when analog over current protection has tripped.
LED7 – blue(725-06319C-001 only), flashes to indicate USB activity.
Figure 4 GP I/O Board Status LEDs
Test Points
Test points are provided to aid in troubleshooting. Most of these are DC voltages and can be used to narrow
down the source of a problem.
Point Description Nominal Reading Range

TP1 Incoming Power 24.0V 22.8V to 25.2V
TP2 Logic Supply 5.00V 4.85V to 5.15V
TP4 ADC Reference 2.500V 2.475V to 2.525V
TP5 Sensor Supply If LED5 (green) is on 24.0V 22.8V to 25.2V
If LED6 (red) is on 0.0V 0.0V to 0.1V
TP6 Conditioned Low Line 1.31VDC with 115VAC applied to low 1.22VDC to 1.40VDC
Input line voltage transformer input
TP8 Processor clock output 0.0 to 5.0V square wave pulse, 250 -
nsec wide
TP9 Ground reference - -
TP10 ADC oscillator 15.7MHz 0.0 to 5.0V square wave -
CH1 Analog input test points, 0.0 to 5.0V based on the input value, -0.3V to +5.30V
thru voltage at the input pin of for current loops, multiply the reading (below 0.0V and
CH16 the ADC in mA * 250 ohms above 5.0V are fault
conditions)
Figure 5 GP I/O Board 725-06319C-001 Test Points
Point Description Nominal Reading Range

TP1 Incoming Power 24.0V 22.8V to 25.2V
TP2 Logic Supply 5.00V 4.85V to 5.15V
TP3 ICTD Reference 2.232V 2.199V to 2.265V
TP4 ADC Reference 2.500V 2.475V to 2.525V
TP5 Sensor Supply If LED5 (green) is on 24.0V 22.8V to 25.2V
If LED6 (red) is on 0.0V 0.0V to 0.1V
TP6 Conditioned Low Line 1.31VDC with 115VAC applied to low 1.22VDC to 1.40VDC
Input line voltage transformer input
TP7 DAC Logic Supply nominal 5.00V 4.85V to 5.15V
TP8 Processor clock output 0.0 to 5.0V square wave pulse, 200 -
nsec wide
TP9 Ground reference - -
Figure 6 GP I/O Board 725-05045C-001 and 725-06200C-001 Test Points
Document: MCP-209
Revision: F
Hardware
Analog Inputs
The 725-06319C-001 General Purpose I/O Board has sixteen channels of
analog input. The factory-configured program defines the purpose and
scaling for each of these inputs. Each input has jumpers to make it
electrically compatible with 0-5V/1-5V, 4-20mA, and ICTD (integrated-circuit
temperature device) signals. Inputs can be factory configured to accept 0-5V,
0-20mA or 0-24mA signals in addition to standard 1-5V or 4-20 mA ranges.
The inputs can tolerate excursions up to 24VDC above and below ground
without generating erroneous readings. If the input signal goes above
5.00V(20mA) or below 0V a fault flag is set and an alarm is annunciated.
Test points are provided to monitor the inputs to the analog to digital
converter. These are always voltage readings. To convert a 4-20mA signal to
voltage multiply the current by 250 ohms.
Figure 7 GPIO II Analog Input Jumpers
GPIO Boards 725-05045C-001 and 725-06200C-001 have a set of jumpers for channels
13 through 16 to accommodate ICTDs scaled -50°C to +150°C(-58°F to +302°F). When
scaling an ICTD for this range the jumper for the desired channel on J7 must be set to
‘ICTD OR VOLTAGE’ and the jumper on J8 must be set to ‘-50 TO +150 ICTD’. If the
channel is used for a full range ICTD, 4-20 mA transducer or Voltage Output transducer
J8 must be set to ‘VOLTAGE ICTD OR 4-20 mA’. Increased resolution of the ADC on
725-06319C-001 eliminated the need for these jumpers. If the Process Temperature
option is used channel 16 is configured as a -50°C to +150°C ICTD.
Fault detection is not available on 725-05045C-001 and 725-06200C-001.
Figure 8 Old Style GPIO Board Analog Input Jumpers
The connectors plugged into P5 and P6 are a

spring clamp type that will accept a 24-16 AWG
wire. Each row of the connector provides
connections for a two or three wire sensor, the
red terminal is +24V, the gray terminal is the
signal and the blue is the common. To insert or
release a wire press gently on the colored pin
with a small screwdriver, insert or remove the
wire and release. IMPORTANT The two red
terminals in the top row and two blue terminals
in the bottom row must be jumpered as shown
to connect the common power supplies on the
connector.
Figure 9 Analog Input Power Jumpers Figure 10 Inserting and Removing Wire
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Hardware
Land analog cable shields on rail with yellow and green terminals in the
upper right corner of the panel. Multiple shields may be twisted together
and landed on a single clamp.
Figure 11 Shield Rail
Programming and configuration jumpers. The Slave Address jumpers

determine the communications address for the General Purpose I/O
Board. Each board in the system must have a unique address. In a
compressor control panel the address is always set to ‘1’ for the board
that controls basic compressor functions. The addresses of any additional
General Purpose I/O boards will be specified on the Enclosure Diagram.
Figure 13 shows the jumpers configurations for all possible addresses. J4
configures communications cable termination, all jumpers should be in the
‘OFF’ position. J1 is used to update the General Purpose I/O board
firmware, for normal operation there must be a jumper on the pair of pins
above the heart symbol.
Figure 12 Configuration Jumpers
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
1 ON 12 ON ON 23 ON ON ON ON
2 ON 13 ON ON ON 24 ON ON
3 ON ON 14 ON ON ON 25 ON ON ON
4 ON 15 ON ON ON ON 26 ON ON ON
5 ON ON 16 ON 27 ON ON ON ON
6 ON ON 17 ON ON 28 ON ON ON
7 ON ON ON 18 ON ON 29 ON ON ON ON
8 ON 19 ON ON ON 30 ON ON ON ON
9 ON ON 20 ON ON 31 ON ON ON ON ON
10 ON ON 21 ON ON ON
11 ON ON ON 22 ON ON ON
Figure 13 Communications Address Table
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Hardware
Analog Overcurrent Reset
The analog over current circuitry is located on the lower left side of the
processor board. LED5 in the lower right corner of the board glows green
normally, LED6 should be off. If excessive current is drawn by a sensor
connected to P5 or P6, the analog over current circuitry will interrupt the
+24VDC supplied to the sensors and LED5 will go off and LED6 will glow
red. If the analog over current circuit is tripped, the user should examine
the analog sensors and related wiring for shorts. Once the fault has been
discovered, press the Analog Overcurrent Reset button SW2. If the fault
has been removed, LED 6 will go off and LED5 will again glow green.
Figure 14 Analog Overcurrent Section

Digital I/O Racks
Each digital I/O rack supports up to 24 I/O modules. Each
General Purpose I/O board will support two I/O Racks. I/O
modules are equipped with an integral LED status indicator and
output modules have a built-in fuse. Modules are color coded for
operating voltage and function. AC output modules for 120 or
240V are black, AC input modules are yellow. DC outputs are
red, DC inputs are white. A special low current dry contact
module for PLC interface is also red, this can switch 120V AC
loads that are less than 100 mW. Both the input and output
modules are available with Hand-Off-Auto switches, these can
be used for an HOA function on the outputs as long as the logic
power to the I/O rack is available. Input modules with the HOA
option are recommended only for testing and trouble-shooting.
The second input module from the right in the bottom row is
equipped with an HOA switch.
Figure 15 Digital I/O Rack
Analog Outputs
GPIO Board II 725-06319C-001.There are up to twelve available channels of
analog output. They may be added in groups of four outputs. The factory-
configuration defines the purpose and scaling for each these outputs. For a
specific application, these outputs may be used to control a compressor motor
VFD, a variable speed fan, or modulate a control valve. In addition to the software
configuration, optional hardware components must be installed to use the analog
outputs. 4-20mA Output Cards (FES part number 725-06320C-001) may be
installed in one or more of the three available locations on the GPIO Board II. The
example shows a single output card installed. (This is equivalent to a 725-05045C-
001 or 725-06200C-001 GPIO board with four AD420AN chips installed.) A
connector is included on each output card. On each card, jumper block J1
determines the power source for the DACs. Both halves of J1 must be moved
together. With J1 in the lower position, the GForce™ Panel’s +24VDC power
supply will energize the 4-20mA current loop (all four channels). External devices
connected using this configuration must have fully differential inputs (not
referenced to ground). If ground isolation is necessary, move both halves of J1 to
the upper position and apply an external floating +24VDC source to P1-1 (positive)
and P1-2 (negative). The four channels on each output card share a common
ground, the grounds on the individual output cards may be isolated from each
other.
Figure 16 Analog Output Card
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Hardware
Each output channel is equipped with fault detection circuitry; if the current set by the GForce does not match the
current flowing in the loop an alarm is annunciated. If field devices are not connected these alarms will not be able
to be cleared. If a field device is not available, a resistor between 250 and 400 ohms may be temporarily installed
between the + and – terminals to allow the alarm to be cleared.
GPIO Boards 725-05045C-001 and 725-06200C-001. Plug P8

must be installed and an AD420AN transmitter integrated circuit
must be installed for each channel required. The AD420AN must
be installed in order from channel 1 through channel 4, upper
channels will not work if the chip for any lower channel is removed.
The example shown in Figure 17 has two channels configured
using the GForce™ internal power supply. The power supply
configuration is similar, substitute P8 for P1 and J1 for J9. All of the
outputs on this assembly share a common ground.
Figure 17 Old Style Analog Output Section
Line Voltage Monitor

This circuit monitors the line voltage present at the panel to annunciate low-line or
brown-out conditions. A small transformer mounted on the lower left corner of the
panel back plate provides isolation.
Figure 18 Line Voltage Monitor
Panel Temperature Monitor

Control panel temperature is monitored by U18 on the General Purpose I/O Board.
An alarm will be annunciated if this temperature exceeds 135°F (57.2°C).
Figure 19 Panel Temperature Monitor
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Hardware
Power Supply
The power supply is rated for 3A at 24VDC and is sized to support a
minimum of 20 4-20 mA loop powered transmitters and the IntelliSOC™
Control Valve option. The output of the power supply is adjustable and
should be set between 23.0V and 25.0V when the panel is operating. This
device carries a UL NEC Class 2 rating and must only be replaced with a
Class 2 device to insure continued safe operation.
Figure 20 Power Supply
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Hardware
Optional Hardware
CT/4-20 mA Converter
The GForce™ Control Panel is designed to accept a 4-20 mA
signal as a compressor motor current input. If the motor starter is
not equipped with a 4-20 mA output, such as on a retrofit, a CT/4-
20 mA Converter is provided in the panel. This converter is
mounted in the lower left corner of the panel. When shipped from
the factory this units is setup for a 5A CT current. If a 1A CT
current is required, a DIP switch setting inside the converter must
be changed. The converter manufacturer’s manual is included in
the control panel drawing pocket to assist in configuration.
Figure 21 CT/4-20 mA Converter
4-20mA Loop Isolator

In some cases it is necessary to isolate in incoming 4-20 mA signal to avoid ground loop
problems. Typically this device is mounted on the power supply terminal rail. There are no jumper
settings required for this module.
Figure 22 Current Loop Isolator
Motor Thermal Monitor

This optional device may be present in some control panels equipped to
control VFD motors. It monitors a PTC thermistor in the compressor motor
and issues a shutdown if the motor is overheating. It is mounted at the
bottom of the main terminal rail on the left side of the enclosure.
Figure 23 Motor Thermal Overload Monitor
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Hardware
Slide Valve Potentiometer Interface Board
The pot interface board provides a constant current drive for a slide valve potentiometer and
converts the output to a voltage signal usable by the GForce control panel. It is normally
mounted on the terminal rail to the right of the DC power supply. Two of these devices are
®
required for Frick continuously variable Vi compressor retrofits.
Figure 24 Slide Valve Pot Interface Board
ESP Board
The ESP board is required to interface to the slide
valve position indicator on FES L and L-C series
compressors. It may be mounted on the bottom right
corner of the backplate or on the lower right wall of
the enclosure. Refer to MCP-187 for calibration and
setup.
Figure 25 ESP Board
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Historical Data
Historical Data
Historical Data is present in both tabular and graphical formats. Data is captured based on the period set by the
‘Long Term Sampling Period’ parameter. This file is saved daily for later reference. Several months of data can be
maintained on the GForce™ Panel and these files can be copied to a USB memory device using the ‘File
Manager’. Data is stored in a Microsoft Excel compatible TXT file format. The filename is based on the date as
shown in this example, for November 21, 2006, the file name is ‘11_21_06.txt’. RxTrend data is captured every 10
seconds and a 10 minute snapshot of this data is saved when an alarm or shutdown occurs. File names include
the time, date and annunciation that caused the data to be saved. For example the file name, ’Auxiliary Shutdown
#1_11_15_06 11_14_40.txt’ indicates a shutdown from the Auxiliary Shutdown #1 input at 11:14:40 on November
15, 2006. The Historical Table and Historical Graph are described in detail on the following pages.
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Historical Data
Historical Table
The Historical Table displays data in a spreadsheet format for a 24 hour period starting and ending at midnight.
Data is displayed without units, the value is scaled based on the units that were selected at the time the sample
was taken. The most recent entry is displayed at the top. When power cycles, entries with a value of ‘0’ are
created to indicate that the control panel was off-line. An alarm or shutdown row will be highlighted in yellow or
red. Touching or clicking one of these rows displays the annunciation with a button to view Rx-Trend data.
Figure 26 Example Historical Table window
The current date may be selected using the controls at the top center for
the screen, the dropdown opens a calendar to select a date, the [<] and [>]
buttons move to the previous and next days respectively.
[Select Columns] opens a form that allows the operator to select which
columns are displayed in the table.
The [Interval] button opens a dialog to set the Long-Term Sampling Period.
This value is also displayed in the Operating Parameters frame of the
OmniView. The sampling interval is adjustable from one to one hundred
and twenty minutes. The Long-Term Historical data file can record
approximately six months worth of data. A sample is recorded each time
the Long-Term Sampling Period timer expires or whenever a Shutdown or
Alarm occurs. This data is intended to provide a record of compressor and
system activity.
Figure 27 Table Column Selection
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Historical Data
Historical Graph
The Historical Graph displays data for a 24 hour period starting and ending at midnight. Data is displayed without
units, the value is scaled based on the units that were selected at the time the sample was taken. When power
cycles, entries with a value of ‘0’ are created to indicate that the control panel was off-line, this forces all traces to
drop to the baseline. As a default the first eight entries on the Analog Display are selected. Values can be added
or removed using the pull-down above the cursor position frame and the [Add] and [Remove] buttons. To remove
an item, select it in the pull-down and touch [Remove]. To add an item, again select it in the pull-down and touch
add. Both analog and digital entries can be displayed. Up to eight pens may be displayed.
Figure 28 Example Historical Graph Window
Touching the graph window moves the cursor to the point of touch, the time and value at that point are displayed.
Digital values have a value of 10 when they are ‘ON’ and 0 when they are ‘OFF’. The date of the displayed data
set can be selected in the lower left corner, the right and left arrows move one day previous and one day next
respectively.
To zoom in on an area of the display touch-drag a window around the desired area, the display will be redrawn
showing only that area of the graph. The [Reset Zoom] button sets the display back to the default range of two
hours. The Historical Graph window is not real-time, it must be closed and re-opened to update.
The combo box in the lower left portion of the chart is used to select the range of the X-axis in hours. The combo
box has a range of values from 1 hour to 24 hours.
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Historical Data
RX-Trends
Figure 29 Example RX-Trends window
The RX-Trends window displays real-time data for the number of minutes selected in the pull-down in the lower
left corner. Data is displayed without units, the value is scaled based on the units that were selected at the time
the sample was taken. Sample period is five seconds. As a default the first eight entries on the Analog Display are
selected. Values can be added or removed using the pull-down and the [Add] and [Remove] buttons. To remove
an item, select it in the pull-down and touch [Remove]. To add an item, again select it in the pull-down and touch
add. Both analog and digital entries can be displayed. Digital values have a value of 10 when they are ‘ON’ and 0
when they are ‘OFF’. Alarm and shutdown generated trends files can be selected and viewed using the pull-down
at the top of the window.
The combo box in the lower left portion of the chart is used to select the Y-axis interval. The combo box has a
range of values from 5 to 50.
The [Save Snapshot] button records the current view of the RX-Trend to a text file, saved as "No
Alarm_DD_DD_DD TT_TT_TT.txt" (where DD is the current date and TT is current time). The files are saved on
the GForce™ Control Panel under the RX-Trend Alarms directory.
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Historical Data
Alarm/Shutdown History
Figure 30 Example Alarm/Shutdown History window
The Alarm/Shutdown History window shows a table of alarms and shutdowns with both the time the annunciation
occurred and the time it was cleared. The operator can elect to show just alarms, just shutdowns or a combined
list of both alarms and shutdowns using the three buttons in the lower left corner of the window. Files are stored
by day and files from previous days can be reviewed using the pull-down or navigation arrows at the bottom of the
window. Touching any Alarm/Shutdown, when it was issued, will bring up the Rx-Trend.
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Documentation
Documentation
All of the GForce™ Control Panel manuals and drawings are available to be viewed on the built-in display or via a
remote viewer. As shipped all pertinent drawings and manuals are filed on
the system. Manuals and drawings can be updated using a USB memory
device and the ‘File Manager’, only FES supplied drawings and manuals can
be placed in the ‘Drawings’ and ‘Manuals’ folders. A ‘User’ folder is available
for customer documentation. All documents must be in PDF format and can
be copied both to and from a USB memory device.
Figure 31 Documentation Menu
While a PDF is loading, a white page with a loading bar shown to the right may
appear. The loading time depends on the file size of the pdf. This loading status
indicator is also displayed during large data or log file transfers.
Figure 32 PDF Viewer Loading
Figure 33 Example PDF Viewer window
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Intranet
Intranet
® ®
The Intranet screen is used to configure remote viewing capabilities for GForce™ Panel(s), VTrac and Life Trac
vibration monitors and other Ethernet capable devices. The ‘Intranet’ menu selection is disabled when the user
®
level is set to ‘Basic’. The top grid is used to configure GForce™ panel connections and the lower is for Life Trac
and other browser capable devices. The [Add Entry] buttons will add a device to the respectable grid. After adding
entries, the IP address can be configured by touching the combo boxes in the grid. To delete entries highlight the
row by touching it and touch the [Delete] button.
The [Edit] button is used to modify the device

description as well as security password
configuration for GForce™ remote viewing.
To connect to the device, highlight the grid row of

the device you want to connect to and touch the
[Connect] button. This will launch a browser in a
new window.
Figure 34 Intranet GForce™ Edit Screen
Figure 35 Intranet Screen
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Revision: F
Service Menu
Service Menu
This menu is active only when in the ‘Service’ user level. Functions in this menu
should be used only by properly trained personnel. Earlier versions of the programs
may have the selections in a different order and not all selections may be available.
Figure 36 Service Menu
File Manager
The File manager shows files available to transfer
after a USB memory device is connected to the
GForce™ Panel. Select the desired tab on the
GForce™ side and all files in an acceptable
format will be shown. Touch the arrow button to
move the files in the desired direction. Data files
are exported to a folder named ‘x:GForce:\project
number\...’ on the external drive. PDF and
graphic files are exported to the root directory of
the external drive.
Figure 37 File Manager window

Parameter Backup/Restore
Parameter Backup/Restore copies all of the
parameters settings to or from the removable
drive. The name of the archive may be set using
the keyboard, multiple archives may be created
with different configurations if desired. Files are
stored in a folder named ‘ParamArchive’ in the
root of the removable drive.
Figure 38 Parameter Backup/Restore window
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Service Menu
Export Panel Data Report to USB
Exports a list of all configured analog inputs and outputs, digital inputs and outputs, custom alarm and shutdown
annunciations, keypad layout, and all parameters with values and Modbus addresses. The output is a .pdf file
and also includes the current analog/digital states for startup report purposes.
Copy GForce Historian to USB

Copies the GForce Historian application to a removable USB device. This application may be installed on a
Windows PC to view GForce™ Historical Files. Microsoft .NET framework 1.1 must be installed on the PC. The
Historian includes a built-in ‘Help’ file.
Maintenance
This window provides a list of recommended service
procedures, the time they were last performed and a
countdown to the next time they should be performed.
The technician touches the checkbox when the service
procedure is complete to log the date. The ‘Count Down’
hours are calculated from the time the task was last
performed, the recommended interval and the current
runtime hours. In the example on the left the motor
bearings were greased at 1211.3 hours and a Class A
inspection is now due.
Figure 39 Maintenance Table
Touch [Log] to open the form shown to the right. When

the checkbox under ‘Performed’ is touch an entry is
made in this field. The entry indicating that the bearings
have been greased was created in this manner. The
operator may make entries in this field using the
keypad. Error log files may be viewed by selecting them
in the combo box at the top of the screen.
Figure 40 Maintenance Log File
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Revision: F
Service Menu
Setup Network
These settings are used for remote communication
and viewing. The upper group corresponds to the
port marked ‘1’ on the processor assembly
photograph and the lower group is for the port
marked ‘2’. Standard GForce™ panels use only the
lower group. The Adapter Name and MAC Address
are hardware descriptions and cannot be changed.
The IP Address, Subnet Mask and Default Gateway
are not stored until the [Save] button is touched.
Typically this information is provided by your network
administrator.
DHCP Enabled checkbox. DHCP (Dynamic Host

Configuration Protocol) is enabled when this box is
checked. The GForce™ control panel should have a
static IP address and in most cases this box should
not be checked.
Figure 41 Network Setup
The computer name is displayed to the right of the upper DHCP

checkbox, this string cannot be edited.
The control panel Node ID is displayed in the lower right corner of

the frame. This Node ID is used for Compressor Sequencing and
other inter-panel functions. Touching the [?] icon will open ‘MCP-
180 – GForce Network Installation’ if document is present in the
manuals directory.
Lower frame on screen (2)
Upper frame on screen (1)
Figure 42 Processor Assembly Ethernet Ports

Email Setup
Email setup is accessed from the Network Setup
screen. The GForce control panel can be setup to send
emails when alarms and/or shutdowns occur. The panel
must be connected to the Internet to make use of this
feature. Emails may be triggered on either alarms only,
shutdowns only or both. RX-Trend or Historical data
files can be automatically attached if desired. These
files are typically 20k to 30k in size. The “Text SMS
Message” checkbox will make the message sent out be
a more compact message. This will be used when
sending the message to a phone so it will receive the
whole message in one text message. Most service
providers have an e-mail address that will forward
messages to your phone.
Figure 43 Email Setup Display

Document: MCP- 209
Revision: F
Service Menu
The ‘Local Email Address’ is the email address of the panel. This is the address that is used as the source ‘From:’
address and as the destination address to acknowledge messages and to request additional historical data. This
address must be defined with a user name and password by the end user. FES recommends that password
authentication be used to maintain security.
The SMTP server must be setup for the panel to send messages. The POP3 server must be setup to receive
messages. The SMTP and POP3 ports shown are for illustration only and must be confirmed with the network
administrator.
Clicking the ‘Test Connection’ button you can send test messages using the entered data. In the dialog it will
show diagnostic messages to help troubleshooting.
The timeout delay determines both the delay between the attempts to contact the Level 1 and Level 2 addresses
and the timeout after contacting Level 2.
The email addresses of the desired recipients are assigned either Level 1 or Level 2, multiple addresses may be
assigned on each level.
When an alarm or shutdown occurs an email is set to any Level 1 email addresses. If none of these recipients
respond within the allotted time, emails will be sent to the Level 2 addresses. If the timeout delay elapses a
second time the panel will no longer accept a response.
Sample email from GForce™ indicating a High Discharge Pressure Shutdown:

From: GForce@coldcompany.com [mailto:GForce@coldcompany.com]
Sent: Friday, November 13, 2009 1:07 PM
To: Smith, John
Subject: GForce (GForce 1) : High Discharge Pressure [11/17/09 14:25:34][A5/0]
GForce 1 reported a "High Discharge Pressure" Alarm @ 11/17/2009 2:25:34 PM.
You can reply with the following commands:

(Note: Commands are in quotes and must start at the body of the message with "GForce"
starting the subject.)
- "Clear" to attempt to clear the annunciation.

- "Off" to return the Alarm and Shutdown Status Outputs to a normal state.
- "Data X" to return all historical data from the specified number of days X.
(Note: 45 is the maximum number allowed for X.)
Confidentiality note
This e-mail, including any attachment, may contain confidential and privileged
information. If you have received it by mistake, please notify us by reply e-mail and then
delete this e-mail and any attachment from your system.
Figure 44 Sample GForce™ Email
Subject: GForce: High Discharge Pressure
GForce #1 reported a "High Discharge Pressure" Alarm @ 11/17/2009 2:25:34 PM.
Figure 45 Sample GForce™ SMS
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Service Menu
If Rx-Trend and/or Historical data was selected it will be included as a text attachment. Follow the instructions in
the email to respond to the panel. If desired the attached files may be compressed in a ‘.zip’ format.
Response email to the GForce™ requesting two days worth of historical data:
From: John Smith

To: GForce@coldcompany.com
Subject: RE: GForce (GForce 1) : High Discharge Pressure [11/17/09 14:25:34][A5/0]
Data 2
John Smith
Utilities Manager
Cold Company
Figure 46 Sample Historical Data Request
Sample email from GForce™ sending historical data:
From: GForce@coldcompany.com [mailto:GForce@coldcompany.com]

To: Smith, John
See attached GForce data…
You can reply with the following commands:

(Note: Commands are in quotes and must start at the body of the message with "GForce"
starting the subject.)
- "Clear" to attempt to clear the annunciation.

- "Off" to return the Alarm and Shutdown Status Outputs to a normal state.
- "Data X" to return all historical data from the specified number of days X.
(Note: 45 is the maximum number allowed for X.)
Confidentiality note
This e-mail, including any attachment, may contain confidential and privileged
information. If you have received it by mistake, please notify us by reply e-mail and then
delete this e-mail and any attachment from your system.
Figure 47 Email with Historical Data Attached
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Service Menu
Historical data and alarm/shutdown files will be attached as text files.
Sample email to GForce™ clearing the annunciation:
From: John Smith

To: GForce@coldcompany.com
Clear
John Smith
Utilities Manager
Cold Company
Figure 48 Email Clearing Shutdown Annunciation
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Revision: F
Service Menu
Viewer Configuration
Opens the viewer configuration screen where you can specify authentication information for your remote viewing
capabilities. To enable a security password, check the “Use Password Auth.” checkbox, type the desired
password in both the “New” and “Confirm New” textboxes, and touch the [Save] button. To disable the security
password, uncheck the “Use Password Auth.” checkbox and touch the [Save] button.
Figure 49 Remote Viewer Setup

Copy Remote Viewer to USB
The VNC Viewer software is provided with the GForce™ control panel, use this selection to copy the viewer to an
external USB memory device to transfer the program to another PC.
Start/Restart Viewer Server

This selection starts or restarts the VNC server, this can be used to try to correct a remote communications
problem without rebooting the GForce™ control panel.
Washdown
The washdown screen is provided to allow the operator to clean the
GForce control panel touch screen without generating any unwanted
touches. When this screen comes up, a series of five targets are
displayed, the operator must touch these targets in sequence as they
pop up to exit washdown mode.
Figure 50 Washdown window
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Revision: F
Service Menu
Calibrate Touch Screen
If the operator is having difficulty activating the buttons and keys on the touch screen or the active area appears
to be offset from the graphic, touch screen calibration may be required. A confirmation dialog is displayed before
starting the process.
The calibration process varies based on the GForce Processor Assembly serial number.
It is printed on the label affixed to the lower right corner of the of the processor
assembly. The correct process is automatically initiated when choosing ‘Calibrate Touch
Screen’ from the ‘Service’ menu. Double tapping in the blue area of the Intranet screen
or compressor graphic will initiate a touch screen calibration as well.
Figure 51 Serial Number
Serial numbers P000xx and G00001-G00380

A blank white screen is displayed. A sequence of targets will be displayed in succession. Touch each target as
instructed. The green dot in the center of the target will change to red when the touch is accepted. After touching
the three targets the operator will be prompted to test or accept the calibration. The ‘Test’ option displays a grid
and will register a small tic where touched. Tap twice to exit the test. The operator is prompted to accept this
calibration or to start the procedure again.
Figure 52 Touch Screen Calibration Method 1
Additional calibrations on following pages…
Document: MCP-209
Revision: F
Service Menu
Serial numbers G00381-G00510
The dialog shown on the left in Figure 52 is displayed. Touch [Advanced] to open dialog on the right in Figure 52,
touch [25 pts Cal] button. A sequence of 25 targets will be displayed in succession. The flashing red/green target
will change to green when the touch is accepted. The yellow and blue bar at the bottom of the screen indicates
the time remaining to complete each touch. Refer to Figure 53.
Figure 53 Touch Screen Calibration Method 2 Dialogs
Additional calibration on the following page…
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Revision: F
Service Menu
Serial number G00511 and above
A blank light gray screen is displayed. A sequence of targets will be displayed in succession. Touch each target
as instructed. Prompts will change from ‘Touch’ to ‘Hold’ and then ‘Release’. After touching the four targets the
operator will be prompted to test calibration. A target is displayed that will follow a touch on the screen. The
operator may [Cancel] or [Accept] the calibration. A count-down timer is displayed on the [Cancel] button. When
this counter reaches 0 the calibration will be aborted.
Document: MCP-209
Revision: F
Service Menu
Update Software
This procedure allows a technician to load new software onto the GForce™ control panel. If the compressor is
running the operator will be prompted to shut down the compressor before proceeding. Please note that ALL
control functions performed by this panel are suspended during this procedure. On this screen ‘Program’ refers to
the application running on the GForce™ panel that provides all control and user interface functions. The
‘Configuration’ refers the factory configured items that are unique to this machine. If there are problems with either
the GForce™ program or panel configuration detected during the boot process the Update Utility is opened to
allow new software to be installed. Please note: on the GForce panel the Update Utility screen is black, it is
shown here in white to make it easier to read in print.
Figure 56 Update Utility Screen
Update Program will copy a new GForce™ Control application, GForce™.exe from a user selectable location,
either from the backup location on the GForce™ panel or a USB mass storage device.
It is recommended that a backup of the current application be made before updating software.
Backup Program to USB copies the current GForce™ Control application to a USB mass storage device.
Backup Program to GForce™ copies the current GForce™ Control application to a backup location in the
GForce™ control panel.
The text at the top of the ‘Configuration’ frame indicates the config file name, the project number and configuration
revision of the configuration file currently loaded in the panel.
Update Configuration will copy a new GForce™ control panel configuration file, “config.xml”, from a user
selectable location, either from the backup location on the GForce panel or a USB mass storage device.
It is recommended that a backup of the current configuration be made before an update.

Document: MCP- 209
Revision: F
Service Menu
Backup Configuration to USB copies the current GForce™ configuration file to a USB mass storage device.
Backup Configuration to GForce copies the current GForce™ configuration file to a backup location in the
GForce control panel.
Full System Backup copies all files from GForce™ configuration file to a USB mass storage device. The file will
be stored in a folder named “GForceXXXXXXXXX” where “XXXXXXXXX” is the FES project or contract number.
Figure 57 Full System Backup Prompt
Figure 58 Full System Backup Screen
Document: MCP-209
Revision: F
Service Menu
System Restore allows the user to specify which files that were saved by a previous “Full System Backup” are to
be restored to the GForce™ panel. Select the files to be restored by touching the desired checkbox.
Figure 59 System Restore Selections
Important! The Configuration (“config.xml”) MUST be loaded into the panel before any “System Restore
Options” will be enabled. If separate copy of the appropriate configuration file is not available, it is
possible to navigate to the file stored in the “Full System Backup” on the removable drive. The
project/contract number of the panel MUST match the project/contract number of the folder before any
restore options are enabled.
Figure 60 Navigating to ‘config.xml’
If no selections are enabled, use ‘Update Configuration’ to bring up the screen shown above. Navigate to the file
‘config.xml’ and touch OK. After the file has loaded touch ‘System Restore’ again to bring up the selection screen
shown in Figure 59.
Document: MCP- 209

Revision: F
Service Menu
Factory Reset
Use this procedure to reset all operator configurable values to the factory default settings and to clear all
calibration factors. The operator is prompted for a confirmation before the parameters and calibrations are reset. It
is recommended that a backup of the current panel settings are created before doing a Factory Reset. Refer to
the File Manager section for the backup procedure.
Document: MCP-209
Revision: F
Service Menu
About Screen
The ‘About’ screen displays contract and program
information, this information is required when contacting
FES for technical assistance.
Figure 61 About Screen
Document: MCP- 209

Revision: F
User Level
User Level
Three different user levels are provided. Two of them are password
protected.
Figure 62 User Level Menu
Basic Level
This mode allows the operator to navigate through the screens, clear alarms and shutdowns and by default
stop the compressor. Setpoints may not be changed. No password is required to change to this level. The
ability to start and stop the compressor on this level can be set on the panel settings screen. Options
available are ‘Enable Stop’(default), ‘Enable Start/ Stop’ or ‘Disable Start/Stop’.
User Level
The User Level includes all Basic Level functions and allows the operator to start the compressor, change
operating parameters and to transfer files from the GForce™ panel to an external USB memory device This
level also allows the transfer of PDF documents from an external USB memory device to the ‘User’ folder on
the GForce™ panel.
Service Level
All Basic and User Level functions are available at this level. At this level the operator or technician has full
access to all features of the GForce™ control panel. This includes transducer calibrations and the ability to
clear the compressor motor anti-recycle and oil drain timers. Updates to control panel configuration files,
factory documentation and base program are also made at this level.
Auto Logoff
‘Auto Logoff’ may be turned on to
change the access level back to User
or Basic mode after a predetermined
time. Please refer to the ‘Panel
Settings’ section of the compressor
Figure 63 Auto Logoff Setup operation manual for more
information.
Changing Passwords
Selecting ‘Service’ or ‘User’ under ‘Change Passwords’ brings up the keypad
shown in Figure 63. Enter the old password and new password and touch
[Enter]. The ‘Service’ password may be used to reset the ‘User’ password if
the ‘User’ password is lost. If the ‘Service’ password has been lost, touch the
[?] key and a four digit code will be displayed at the top of the keypad.
Contact FES with this code and a new temporary password will be provided.
This temporary password is good for ten minutes from the time the [?] key is
touched.
The default ‘Service’ password is ‘1236547890’. The default ‘User’ password

is ‘12345’.
Figure 64 Password Keypad
Document: MCP-209
Revision: F
Boot Sequence
Boot Sequence
1. At initial power-up a screen showing the GForce™ logo and GEA FES Inc. with address and phone
number is displayed.
2. The screen is black with the text ‘Verifying DMA pool data…’ in the lower left corner.
3. The screen returns to the same one shown in step 1, the GForce™ logo and GEA FES Inc. with
address and phone number.
®
4. A blue screen with some Windows XPe dialogs flashes up followed by the pointer and hour glass.
5. A blue and black screen with a large white GForce™ logo in the center and an animated activity bar
across the bottom is displayed.
6. The initial operating screen is displayed and control begins. The initial display may be set on the
‘Panel Settings’ display.
Step 1 Step 2 Step 3
Step 4 Step 5 Step 6
Figure 65 Boot Screen Sequence
Document: MCP- 209

Revision: F
Appendices
Appendix A: Table of Figures
Figure 1 GForce™ Screen with Overlay ..................................................................................................................................... 1
Figure 2 Processor Assembly .................................................................................................................................... 2
Figure 3 GP I/O Board II ............................................................................................................................................................. 2
Figure 4 GP I/O Board Status LEDs ............................................................................................................................................ 3
Figure 5 GP I/O Board 725-06319C-001 Test Points .................................................................................................................. 3
Figure 6 GP I/O Board 725-05045C-001 and 725-06200C-001 Test Points ............................................................................... 3
Figure 7 GPIO II Analog Input Jumpers ..................................................................................................................................... 4
Figure 8 Old Style GPIO Board Analog Input Jumpers .............................................................................................................. 4
Figure 9 Analog Input Power Jumpers ........................................................................................................................................ 4
Figure 10 Inserting and Removing Wire ..................................................................................................................................... 4
Figure 11 Shield Rail ................................................................................................................................................................... 5
Figure 12 Configuration Jumpers ................................................................................................................................................ 5
Figure 13 Communications Address Table.................................................................................................................................. 5
Figure 14 Analog Overcurrent Section ........................................................................................................................................ 6
Figure 15 Digital I/O Rack .......................................................................................................................................................... 6
Figure 16 Analog Output Card .................................................................................................................................................... 6
Figure 17 Old Style Analog Output Section ................................................................................................................................ 7
Figure 18 Line Voltage Monitor .................................................................................................................................................. 7
Figure 19 Panel Temperature Monitor......................................................................................................................................... 7
Figure 20 Power Supply .............................................................................................................................................................. 8
Figure 21 CT/4-20 mA Converter ............................................................................................................................................... 9
Figure 22 Current Loop Isolator .................................................................................................................................................. 9
Figure 23 Motor Thermal Overload Monitor............................................................................................................................... 9
Figure 24 Slide Valve Pot Interface Board ................................................................................................................................ 10
Figure 25 ESP Board ................................................................................................................................................................. 10
Figure 26 Example Historical Table window ............................................................................................................................ 12
Figure 27 Table Column Selection ............................................................................................................................................ 12
Figure 28 Example Historical Graph Window .......................................................................................................................... 13
Figure 29 Example RX-Trends window .................................................................................................................................... 14
Figure 30 Example Alarm/Shutdown History window.............................................................................................................. 15
Figure 31 Documentation Menu ................................................................................................................................................ 16
Figure 32 PDF Viewer Loading ................................................................................................................................................ 16
Figure 33 Example PDF Viewer window .................................................................................................................................. 16
Figure 34 Intranet GForce™ Edit Screen .................................................................................................................................. 17
Figure 35 Intranet Screen........................................................................................................................................................... 17
Figure 36 Service Menu ............................................................................................................................................................ 18
Figure 37 File Manager window................................................................................................................................................ 18
Figure 38 Parameter Backup/Restore window .......................................................................................................................... 18
Figure 39 Maintenance Table .................................................................................................................................................... 19
Figure 40 Maintenance Log File................................................................................................................................................ 19
Figure 41 Network Setup ........................................................................................................................................................... 20
Figure 42 Processor Assembly Ethernet Ports ........................................................................................................................... 20
Figure 43 Email Setup Display .................................................................................................................................................. 20
Figure 44 Sample GForce™ Email ........................................................................................................................................... 21
Figure 45 Sample GForce™ SMS ............................................................................................................................................. 21
Figure 46 Sample Historical Data Request ................................................................................................................................ 22
Figure 47 Email with Historical Data Attached ......................................................................................................................... 22
Figure 48 Email Clearing Shutdown Annunciation ................................................................................................................... 23
Figure 49 Remote Viewer Setup................................................................................................................................................ 24
Figure 50 Washdown window ................................................................................................................................................... 24
Figure 51 Serial Number ........................................................................................................................................................... 25
Figure 52 Touch Screen Calibration Method 1.......................................................................................................................... 25
Figure 53 Touch Screen Calibration Method 2 Dialogs ............................................................................................................ 26
Document: MCP-209
Revision: F
Appendices
Figure 56 Update Utility Screen ................................................................................................................................................ 28
Figure 57 Full System Backup Prompt ...................................................................................................................................... 29
Figure 58 Full System Backup Screen ....................................................................................................................................... 29
Figure 59 System Restore Selections ......................................................................................................................................... 30
Figure 60 Navigating to ‘config.xml’ ........................................................................................................................................ 30
Figure 61 About Screen ............................................................................................................................................................. 32
Figure 62 User Level Menu ....................................................................................................................................................... 33
Figure 63 Auto Logoff Setup ..................................................................................................................................................... 33
Figure 64 Password Keypad ...................................................................................................................................................... 33
Figure 65 Boot Screen Sequence ............................................................................................................................................... 34
Document: MCP- 209

Revision: F
Appendices
Appendix B: Compressor Operations Manuals
One of the following manuals is to be used in conjunction with this document to describe the operation of a
GForce™ Compressor Control Panel.
MCP-169 GForce™ FES G and FES X Series Operations Manual

MCP-184 GForce™ FES S Series, FES WRV, Howden, Mycom Fixed Vi and Dunham-Bush Operations Manual
MCP-185 GForce™ FES H-E Series Operations Manual
MCP-186 GForce™ Frick Retrofit Operations Manual
MCP-187 GForce™ FES L & L-C Series Operations Manual
MCP-188 GForce™ FES R Series and FES XRV Series Operations Manual
MCP-189 GForce™ Sullair Retrofit Operations Manual
MCP-190 GForce™ Mycom Step Variable Vi Operations Manual
MCP-196 GForce™ Hall Screw Operations Manual
MCP-200 GForce™ Vilter Single Screw Retrofit Operations Manual
MCP-202 GForce™ Sabroe Retrofit Operations Manual
MCP-206 GForce™ Stal Retrofit Operations Manual
MCP-213 GForce™ Centrifugal Compressor Operations Manual
Document: MCP-209
Revision: F
Appendices
Appendix C: Revisions
Revision NEW 10/02/09
Created from MCP-203 revision New.
Revision A 11/17/09
Updated overlay image.
Updated several interior images to reflect hardware changes.
Added descriptions and images for 4-20 mA loop isolator, motor thermal monitor, pot interface board and ESP board.
Added image of line monitor transformer.
Updated image and text for ‘Update Utility’.
Updated ‘About’ screen image.
Improved description of Maintenance log, added image of log file, noted ability to access error logs.
Updated ‘Viewer Setup’ to include [Clear] key.
Updated methods to initiate touch screen calibration.
Historical pens now limited to eight.
Basic mode now locks the user out of the intranet screen.
Setpoints can no longer be changed while in Basic mode.
Added description of boot sequence.
Added description of Parameter Backup/Restore.
Updated file manager screen and text, USB drive detection is now automatic.
Added email capability, see Setup Network section.
Updated ‘Loading’ graphic for PDF and data file transfers.
Added a help icon to the Network Screen.
Added description of the auto logoff feature.
Revision B 01/22/10
Updated ‘Full System Backup/Restore’ description.
Added boot sequence screen shots.
Corrected missing caption on page 28.
Revision C 01/10/11, current GForce™ application revision 10.6

Added information for GPIO II, 725-06319C-001 and 725-06320C-001.
Updated ‘Update Utility’ description to 3.3.
Updated PDF viewer info. (application rev 10.1)
Updated email attachment handling.(application rev 10.1)
Updated Service Menu
Added "Export Panel Data Report to USB" menu item. (application rev 10.2)
Added "Copy GForce Historian to USB" menu item on the Service menu (application rev 10.2)
Added button to File Manager "Export Data to Historian" w (application rev 10.2)
Updated keyboard images, added “-/_” (application rev 10.2)
Updated Historical Data screen and features. (application rev 10.5)
Added description of [Select Columns] button on Historical Table (application rev 10.5)
Updated several images, screen shots and figures.
Added appendix listing individual Compressor Operations Manual document numbers.
Corrected reference to Figure 60 in ‘Changing Passwords’.
Added references to VTrac Vibration Monitor.
Testpoints for analog references for old style GPIO boards were reversed in the table.
Updated password section, added default passwords.
Revision D 09/1911, current GForce™ application revision 10.6

Added Screen shot and description for show test connection button in e-mail setup.
Revision E 5/8/12
Added description for SMS messages.
Updated screen shot to show the SMS message checkbox
Revision F 7/12
Added Description for bring up the Rx-Trend of a annunciation in the Alarm/Shutdown screen
Document: MCP- 209
Revision: F
GForce™ Network Installation
And Users Guide
TABLE OF CONTENTS
GForce™ Communications Network ......................................................................................................... 2
Installing the Network ................................................................................................................................ 3
Connecting the Panels .............................................................................................................................. 4
Configuring the Panel ................................................................................................................................ 5
Configuring GCommII ................................................................................................................................ 6
Assigning an IP Address to the GCommII ............................................................................................. 6
GCommII Slave Setup (Serial Settings) ................................................................................................ 7
GCommII Master Setup (Serial Settings) .............................................................................................. 9
Setting Up FES Vibration Monitoring Systems ........................................................................................ 12
®
Configuring VTrac .............................................................................................................................. 12
®
Configuring Life Trac .......................................................................................................................... 12
Interfacing with the Host .......................................................................................................................... 13
Configure Laptop / Desktop PC Network Settings ............................................................................... 13
Modbus ................................................................................................................................................ 15
Ethernet/IP™ ....................................................................................................................................... 17
Install GForce™ Electronic Data Sheet File for RSLinx ................................................................... 17
Identify GForce™ Panel(s) Using RSLinx ........................................................................................ 18
Allen-Bradley ControlLogix PLC I/O Communication Example ....................................................... 20
Allen-Bradley ControlLogix PLC Messaging Communication Example ........................................... 24
Allen-Bradley Ethernet ......................................................................................................................... 27
Allen-Bradley SLC 5/05 PLC Messaging Communication Example ................................................ 27
Remote Viewing Software ................................................................................................................... 29
Remote Viewing behind a Firewall ................................................................................................... 29
Panel Configuration ............................................................................................................................. 29
Remote Viewing from a PC Device ..................................................................................................... 30
Alternate Remote Access -- Microsoft Internet Explorer ..................................................................... 31
Trouble-shooting the Network ................................................................................................................. 32
GForce™ Panel ................................................................................................................................... 32
GComm ................................................................................................................................................ 32
®
VTrac .................................................................................................................................................. 32
®
Life Trac ............................................................................................................................................. 32
Document: MCP-180
Revision: G
Page 1 of 32 Effective: 04-2012
GForce™ Communications Network
GForce™ Control Panels are connected to each other and to supervisory systems using an industry
standard IEEE 802.3 10/100 Ethernet network. Network media may be Cat 5e cable, optical fiber or
wireless. Protocol is Modbus Ethernet; refer to MCP-170 GForce™ Communications Protocol for a list of
data points.
The FES GComm interface allows connection of devices on the GForce™ Ethernet network to existing
FES ComMENT networks. The GComm interface operates in two modes, Master and Slave.
Master mode is used when a GForce™ Control Panel is sequencing compressors on a ComMENT
network. In this mode, data from the GForce™ Panel is not available on the ComMENT network.
Communications from the GForce™ panel to other GForce™ Panels, a supervisory system, plant
intranet, or the Internet are handled over Ethernet. Only one GComm interface is required per ComMENT
network when operating in this mode.
Slave mode is used when a GForce™ Control Panel is being sequenced by a panel on the ComMENT
network or if it is desirable to obtain data from the GForce™ over ComMENT for a supervisory system not
equipped with Ethernet. A GComm interface is required for each GForce™ panel connected to the
ComMENT network. Not all data points described in MCP-170 are available through a GComm Slave
Interface, only basic compressor data is available. MCP-170 indicates which data points are available
when GComm is operating in Slave mode. If access to the full GForce™ communications protocol is
required the Ethernet interface must be used.
FES does not recommend any specific cable but it must be a minimum of CAT5e. The cable may be run
in open air or in a communications conduit or cable tray but never with AC control or high voltage wiring.
Maximum length of any cable run is 300 feet (100 meters). Longer distances require the installation of a
hub or switch.
Typical Ethernet Network
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Revision: G
Installing the Network
Installation and testing of the cables and network hubs/switches is the responsibility of the customer’s IT
department or contractor designated by the customer. All wiring must be per the latest edition of the NEC
and all local codes.
Reference Drawings
725-06066C Sheet 1 GForce™ only Network
725-06066C Sheet 2
GForce™ with ComMENT, GComm Master sequencing
devices on the ComMENT Network
725-06066C Sheet 3
GForce™ with ComMENT, GComm Slave being sequenced or
polled via ComMENT
Each GForce™ control panel requires a cable from the central Ethernet hub or switch. The GComm
® ®
interface and the VTrac or Life Trac interface both require there own respective cable runs. If both a
® ®
GComm and a VTrac or Life Trac are installed in a panel, a total of three cables must be pulled.
All cable runs must be tested before connection to the GForce™ Control Panels.
Document: MCP-180
Revision: G
Connecting the Panels
Plug the connectors on the cables into the RJ45 jacks as shown in the figures below:
Port 1
Port 2
GForce™ Processor Assembly VTrac®
GCommII Life Trac®
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Revision: G
Configuring the Panel
The GForce™ panel can be setup to use DHCP or a static IP
address. DHCP can be used primarily in a stand alone environment
where sequencing of the particular panel that is being configured is
not required or the panel is acting as a master sequencer to other
panels. In most cases, a static IP address will and should be used.
To get to the Setup Network form, navigate through the menu bar to
the service menu item and select Setup Network in the drop down list.
Note that you must be a ‘Service’ level user to gain access to this
screen.
The Setup Network screen contains two panel areas, one for each Ethernet network port on the
motherboard. The top panel corresponds to Port #2 and the bottom
panel corresponds to Port #1. It is advised by FES that only Port #1,
which is shown in the picture at right, is used.
To setup the panel to use DHCP, touch the checkbox in the bottom Port 1
left corner of particular Ethernet port that is active. Click the
[REFRESH] button to view the IP address that was assigned to the
panel by the DHCP routing device.
To setup the panel with a static IP address, ensure that the DHCP
checkbox is not checked. Then click in the IP Address textbox and
enter the IP Address you wish to assign the panel in the keypad. It is Port 2
also required that you enter the subnet mask and default gateway in
order for a static IP address to work appropriately. Please see your Figure 1 Ethernet Ports
network system administrator for the proper values to enter if you are unsure.
Document: MCP-180
Revision: G
Configuring GCommII
If you need to communicate from a GForce™ to legacy FES micro panels a GCommII master will bridge
the Ethernet and ComMENT networks. If you need to communicate from a legacy FES micro panels to
GForce™ panels, a GComm slave device will bridge ComMENT and Ethernet (note: one GCommII Slave
device will be needed per GForce™ control panel which is on the ComMENT network).
This is not necessary in all applications. However, when it is required, please follow the instructions below
to set an IP address, verify serial settings, and if necessary configure the routing table for each device.
A GCommII slave is typically used when a MicroIII control panel is performing compressor sequencing
and there is a single or multiple GForce™ compressor panels which will be sequenced. A GCommII
slave is installed in each the GForce™ panels. It is important to note that proper configuration of the
GCommII slave AND the GForce™ panel is required in order for proper operation on the ComMENT
network. The IP address of the slave GForce must be configured to match the Node ID as set in the
operating parameter as well as the rotary switches of the GCommII slave card.
GForce™ IP = 192.168.1.4 Decimal

Operating Parameter Node ID = 4 Decimal
Rotary Switches on GCommII slave = 04 Hexadecimal
It is also important to note that the IP address of the GCommII slave should be set to something unique
and high in the valid range (ex. 192.168.1.94)
A GCommII master is typically used when a GForce™ control panel is performing compressor
sequencing and there are legacy FES micro panels on a ComMENT network which will be sequenced.
The GCommII master is typically installed in the GForce™ sequencing panel and will bridge all of the
legacy FES micro panels. The IP address of the GCommII master is entered in the GForce™
compressor sequencing screen for each of the legacy FES panels as well as the corresponding
ComMENT node ID. The GCommII master node ID (rotary switches) should be set to a unique number
high in the valid range (ex. FF, FE, FD, FC, etc…).
Reference FES Drawing # 726-06009C to verify appropriate dipswitch settings.

Reference FES Drawing # 726-00512D for GComm ComMENT wiring information.
Assigning an IP Address to the GCommII

The GCommII’s default IP address is set at the factory to a static IP address of 192.168.1.101.
To reassign the IP address, connect a PC or laptop to the GCommII Ethernet port with an
Ethernet crossover cable. Ensure that the GForce™ is powered up and the appropriate Lantronix
DeviceInstaller software is installed on the PC or laptop that is being used to configure the
GCommII.
1. Click Start Programs  Lantronix DeviceInstaller  DeviceInstaller. If your PC has more

than one network adapter, a message displays. Select an adapter and click OK.
2. Highlight the device on the right pane of the window. Then click the Assign IP button in the
top button bar.
3. If prompted, enter the hardware address (on the product label) and click Next.
4. Select “Assign a Specific IP Address” and click the Next button.
5. Enter the IP address,Subnet Mask and Default Gateway as determined by your network
administrator. If your network consists of only FES GForce™ and GCommII devices, you can
assign IP addresses in the range “192.168.1.nnn” where nnn is any unique number 1 – 255.
The Subnet mask displays automatically based on the IP address; if desired, you may
change it. On a simple local network, you can leave the Default gateway blank (all zeros).
Click the Next button.
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Revision: G
6. NOTE: Clicking the “Assign” button will attempt to assign the Serial-to-Ethernet converter a
new IP address. If you are unsure of the settings or what they mean, click the “Cancel”
button to exit out of the current action and consult your network administrator or FES service
for more information. If you are sure you want to assign the IP address, Click the Assign
button and wait until a confirmation message displays. Then click the “Finish” button.
To Verify IP address settings, select the device from the main window list and select Ping from
the Tools menu. The Ping Device dialog box shows the IP address of the selected unit.
From the Tools menu, click the Ping button. The results display in the Status window. Click the
Clear status button to clear the window so you can ping the device again. Note: If you do not
receive “Reply” messages, make sure the unit is attached to the network properly and the IP
address assigned is valid for the particular network segment you are working with. If you are not
sure, check with your network administrator.
Click the Close button to close the dialog box and return to the main window.
GCommII Slave Setup (Serial Settings)

After you have set the IP address, you can use the DeviceInstaller software to telnet into the
device and set / verify the proper settings for GCommII slave operation.
1. Highlight the IP address in the device tree view. Then click on the “Telnet Configuration” tab
on the right pane of the window (at the top).
2. The IP address and port will be listed of the selected device. Click on the “Connect” button to
start a telnet session with the device.
3. Once connected, press the “Enter” key (on the keyboard) once. This will display the
configuration menu of the device.
Modbus/TCP to RTU Bridge Setup

1) Network/IP Settings:
IP Address ................. – 192.168.1.101
Default Gateway ............ --- not set ---
Netmask .................... --- not set ---
2) Serial & Mode Settings:
Protocol ................... Modbus/RTU,Master attached
Serial Interface ........... 115200,8,N,1,RS232
3) Modem/Configurable Pin Settings:
CP1 ...... Not Used
CP2 ...... Not Used
CP3 ...... Not Used
4) Advanced Modbus Protocol settings:
MB/TCP Exception Codes ..... Yes (return 00AH and 00BH)
Char, Message Timeout ...... 00050msec, 05000msec
5) Unit ID -> IP Address Table:
Close Idle Sockets ......... 10sec
Redundant Entry Retry ...... Feature Disabled
D)efault settings, S)ave, Q)uit without save
4. Press 2 on the keyboard to modify the Serial Settings for the Lantronix Device. Please note:
after each typed response, press the enter key to go to the next prompt.
Document: MCP-180
Revision: G
Prompts:
Attached Device (1=Slave 2=Master) (1) ? 2
Serial Protocol (1=Modbus/RTU 2=Modbus/ASCII) (1) ? 1
Interface Type (1=RS232 2=RS422/RS485+4-wire 3=RS485+2-wire) (1) ? 1
Enter serial parameters (38400,8,N,1) 115200,8,N,1
Please Note: Match the serial port baud rate as configured on the comment board’s dipswitches (SW3).
5. Press 5 on the keyboard to modify the Node ID to IP Address routing table.
Prompts:
Close Idle TCP sockets after (3-60 sec, 0=leave open) (10) 10
Redundant entry retries after (15-60 sec, 0=disable feature) (0) 0
(Set 4th octet to 0 to use Slave Address as part of IP)

A)dd, D)elete, E)xit - select function A
Modbus addr from (1) 1
Modbus addr to (1) 255
Slave IP address (000) 192.
Slave IP address (000)192.(000) 168.
Slave IP address (000)192.(000) 168.(000) 1.
Slave IP address (000)192.(000) 168.(000) 1.(000) 0
Please Note: The IP address entered is a typical configuration – if the IP address of the GForce panel is
not in the range 192.168.1.xxx then the above should be changed to match. PLEASE NOTE: If the last
octet of the GCommII IP address is set to 0, the last octet of the GForce™ IP address and the
GForce™ Node ID as well as the ComMENT board’s Node ID Rotary switches must all be set to be the
same).
Prompts:
1): 001-255: 192.168.001.000+SLV
A)dd, D)elete, E)xit - select function E
Document: MCP-180
Revision: G
The menu should now refresh with the information entered in the previous steps.

IP Address ................. – 192.168.1.101
Netmask .................... --- not set ---
Protocol ................... Modbus/RTU,Master attached
CP1 ...... Not Used
CP2 ...... Not Used
CP3 ...... Not Used
001-255: 192.168.001.000+SLV

Select Command or parameter set (1..5) to change:
If you are satisfied with the settings, press the S key on the keyboard to save the parameters and
make them permanent. The unit will then go through the process of saving the parameters –
rebooting the device, and resetting the connection.
If you have changed the baud rate dipswitches or Node ID of the ComMENT board, you will need
to reset the ComMENT board for the new settings to become active.
Connect the GForce™ panel and the GCommII back into the network with Ethernet cables as
shown in the FES Drawing # 725-06066C (unless otherwise directed by your network
administrator).
The GCommII’s status lights should now be flashing to indicate send and receive activity between
the GForce™ panel and the GCommII module. Please note that the ComMENT CPU light will
NOT flash a typical heartbeat status until communications have been established between the
GCommII daughter-card and the ComMENT card itself.
GCommII Master Setup (Serial Settings)

After you have set the IP address, you can use the DeviceInstaller software to telnet into the
device and set / verify the proper settings for GCommII slave operation.
1. Highlight the IP address in the device tree view. Then click on the “Telnet Configuration” tab
on the right pane of the window (at the top).
2. The IP address and port will be listed of the selected device. Click on the “Connect” button to
start a telnet session with the device.
3. Once connected, press the “Enter” key (on the keyboard) once. This will display the
configuration menu of the device.
Document: MCP-180
Revision: G
IP Address ................. – 192.168.1.101
Netmask .................... --- not set ---
Protocol ................... Modbus/RTU,Slave attached
CP1 ...... Not Used
CP2 ...... Not Used
CP3 ...... Not Used
4. Press 2 on the keyboard to modify the Serial Settings for the Lantronix Device. Please note:
after each typed response, press the enter key to go to the next prompt.
Prompts:
Attached Device (1=Slave 2=Master) (1) ? 1
Serial Protocol (1=Modbus/RTU 2=Modbus/ASCII) (1) ? 1
Interface Type (1=RS232 2=RS422/RS485+4-wire 3=RS485+2-wire) (1) ? 1
Enter serial parameters (38400,8,N,1) 115200,8,N,1
Please Note: Match the serial port baud rate as configured on the comment board’s dipswitches (SW3).
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The menu should now refresh with the information entered in the previous steps.

IP Address ................. – 192.168.1.101
Netmask .................... --- not set ---
Protocol ................... Modbus/RTU,Slave attached
CP1 ...... Not Used
CP2 ...... Not Used
CP3 ...... Not Used

Select Command or parameter set (1..5) to change:
If you are satisfied with the settings, press the S key on the keyboard to save the parameters and
make them permanent. The unit will then go through the process of saving the parameters –
rebooting the device, and resetting the connection.
If you have changed the baud rate dipswitches or Node ID of the ComMENT board, you will need
to reset the ComMENT board for the new settings to become active.
Connect the GForce™ panel and the GCommII back into the network with Ethernet cables as
shown in the FES Drawing # 725-06066C (unless otherwise directed by your network
administrator).
The status lights on the GCommII board will flash only when the GForce™ panel is requesting
data and when the ComMENT network is responding to the request. Please note that the
ComMENT CPU light will flash on and off as a heartbeat status as soon as power is applied to
the GCommII board THIS IS DIFFERENT THEN THE GFORCE SLAVE CPU LIGHT
FLASHING.
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Setting Up FES Vibration Monitoring Systems
Configuring VTrac®
Please reference manual MCP-215 – VTrac User Manual for detailed information regarding setup and
configuration of the VTrac device.
Setting up GForce™ to View VTrac®

® ®
Select Intranet/ VTrac on the menu bar to access the VTrac screens.
Configuring Life Trac®

Please reference manual MCP-156 – Life Trac User Manual for detailed information regarding setup and
configuration of the Life Trac device.
Setting up GForce™ to View Life Trac®

Select ‘Intranet’ on the menu bar and then ‘Configure Remote Devices’ to enter the intranet setup and
®
connections screen. Add an entry to the Life Trac grid by touching the [ADD ENTRY] button. After the
entry is added, configure the IP address by touching the drop down boxes in the grid. You must touch the
[SAVE] button to retain new entries and IP address changes. Touch the [CONNECT] button to connect to
the device.
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Interfacing with the Host
Configure Laptop / Desktop PC Network Settings

Note, the following section is only applicable when a PC or Laptop device is being plugged
directly into the GForce™ panel’s Ethernet port.
On your PC:
Go to Control Panel – Network Connections
Disable all other network connections except your Local Area Connection (wired – 10/100
Ethernet connection). Then, highlight the Local Area Connection and get the properties of the
connection by clicking the “Change Settings of this connection”.
The connection properties window has a list titled, “This connection uses the following items:”
Look for Internet Protocol (TCP/IP) in the list of items. Highlight that item, and click on the
properties button.
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A window titled Internet Protocol (TCP/IP) Properties is opened with options to change the
settings of the TCP/IP connection.
Static IP address / Fixed IP address
Under the General Tab, select the “Use the following IP address:” option button.
Enter the following numbers into the respective fields:
IP address: 192.168.1.xxx (where xxx is any number between 1 and 254).
Subnet mask: 255.255.255.0 (this should automatically be entered when choosing the above IP
address)
Default gateway: (this should be left blank)
Click the OK button to accept the changes. Then click the OK button on the connection
properties to accept the changes.
Connect the Ethernet cable from the GForce™ to your PC. REMINDER: This is a special cable,
called a cross-over cable, which allows you to connect two MDI Ethernet ports (one on the
GForce™ and one on your PC) without any additional devices.
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Modbus
GForce™ follows standard Modbus RTU Ethernet Protocol with 6-bit addressing. The address
structure can be found in MCP-170 GForce™ Communications Protocol. To connect you must
specify an IP Address of the GForce™ panel you wish to connect to, the TCP/IP port which is the
Modbus standard port 502, the device ID (“Network ID”), and all data is read from the Holding
Registers. The device ID can be modified from the GForce™ OmniView window operating
parameter grid, by touching the “Network ID (1-255)” parameter. PLEASE NOTE: If you are
connecting from a PC or laptop to the GForce™ panel directly, a crossover Ethernet cable is
required, otherwise ensure that you are on the same network as the panel you wish to connect to.
The following is a step by step instruction guide on how connect, poll, and verify valid
communications with a GForce™ panel via Modbus using a third party tool called ModScan32.
This tool can be downloaded with a free 30-Day Trial period from http://www.win-tech.com/ by
clicking the [Free Trial Demos] button in the navigation menu on the left side of the website.
Download and install the software on the appropriate PC. Follow any instructions provided by the
software supplier.
After installing, you can connect to the GForce™ device by selecting Connection  Connect in
the menu bar as shown below.
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Select ‘Remote Modbus TCP Server’ from the ‘Connect Using’ drop down box. Enter the IP
Address of the GForce™ panel that you will be connecting to and the Service Port should be left
at the default (502). Click [OK] to connect.
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Ethernet/IP™
GForce™ follows standard Ethernet/IP™ protocol communication and is capable of communicating
with Allen-Bradley PLC(s) via explicit messaging commands (PLC-5, SLC505) and/or remote I/O
(ControlLogix with 1756-ENBT/A or 1756-ENET/B) communications. The address structure can be
found in MCP-170 GForce™ Communications Protocol. The following examples describe how to
install the GForce™ EDS file for identification in RSLinx and how to communicate using various Allen-
Bradley PLCs.
Install GForce™ Electronic Data Sheet File for RSLinx

Refer to MCP-209 or MCP-203 to obtain a copy of the .eds file from the GForce™
1. Open EDS Hardware Installation Tool (Programs  Rockwell Software  RSLinx  Tools)
2. Click the ‘Add’ button
3. Select the ‘Register a single file’ radio button , select the path to the GForce.eds file, and click
‘Next’
4. Click ‘Next’ three times to verify and register the file

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5. Click ‘Finish’ to complete the installation and you can close the EDS Hardware Installation
Tool
Identify GForce™ Panel(s) Using RSLinx
1. Open RSLinx Classic (Programs  Rockwell Software  RSLinx)
2. Click ‘Communications’ from the top menu, then click ‘Configure Drivers…’ to open the dialog
shown below. A driver for ‘Ethernet Devices’ (AB_ETH-1 A-B Ethernet) and a ‘Ethernet/IP
Driver’ (AB_ETHIP-1 A-B Ethernet) driver should be configured and running.
3. Click ‘Communications’ from the top menu, then click ‘RSWho’ to send a broadcast message
on the connected network identifying supporting devices. Any GForce™ panels connected to
the same Ethernet network should be displayed under the AB_ETHIP-1, Ethernet tree node.
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4. To communicate with a GForce™ using the AB_ETH-1 A-B Ethernet driver, right-click the
‘AB_ETH-1, Ethernet’ node then ‘Configure Driver.’ When ‘Configure driver’ dialog opens,
enter the IP Address in the ‘Host Name’ field of an open station row and click ‘OK.’
5. You should now see communications to the GForce™ under both drivers as shown below
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Allen-Bradley ControlLogix PLC I/O Communication Example
1. Open RSLogix 5000 and create a new project
2. Add a 1756-ENBT/A or a 1756 ENET/B to the project

a. Go to offline mode
b. Right-click on the I/O Configuration node in the Controller tree-view and select ‘New
Module…’
c. In the ‘Select Module’ dialog, select 1756-ENBT/A or 1756-ENET/B under the
‘Communications’ tree
d. Enter the desired property values in the ‘New Module’ dialog and click the ‘OK’ button to add
the module to the project
e. Download the configuration and go to online mode

f. Right-click on the newly added communications module and select ‘Properties’
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g. On the ‘Port Configuration’ tab of the ‘Module Properties’ dialog, enter the desired network
settings and click the ‘OK’ button to save the settings
h. Verify the network communications with the module
3. Add GForce™ Refrigeration Control Panel to the project

a. Go to offline mode
b. Right-click on the communications module that was added in step #2 and click
‘Add Module…’
c. In the ‘Select Module Type’ dialog, select ‘ETHERNET-MODULE Generic
Ethernet Module’ and click ‘OK’
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d. In the ‘Module Properties’ dialog that opens, enter a ‘Name’ to identify the
module, an IP address of the GForce™ Panel, and the ‘Connection Parameters’
as shown below: (Comm Format = Data – INT, Input Assembly Instance = 1,
Input Size = 250, Output Assembly Instance = 2, Output Size = 248,
Configuration = 1, Configuration Size = 0)
e. On the ‘Module Properties’ dialog that opens, enter 1000.0 ms for the
‘Requested Packet Interval (RPI)’
f. Click ‘Finish’ to add the GForce™ module to the project
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4. Download the new configuration to the PLC and go to online mode
There will be a new ‘ETHERNET-MODULE GForce_1’ node under the ‘I/O Configuration’ tree
node. The PLC should have established a Class 1 connection to the GForce™ Panel. Open the
‘Controller Tags’ to view the three new tag entries created: GForce_1:I representing input data
from GForce™ panel, GForce_1:O representing output data to the GForce™ panel, and
GForce_1:C representing the configuration data. The input and output data definitions can be
found in MCP-170 GForce™ Communications Protocol.
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Allen-Bradley ControlLogix PLC Messaging Communication Example
2. Create the following two tags: GForce_1_Input_Data – DINT[250], GForce_1_Read –

MESSAGE
3. Add a new MSG instruction to a rung and set the ‘Message Control’ to the
GForce_1_Read tag that was created in step #2
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4. Click the ‘…’ button on the MSG instruction to setup to configure the message: On the
‘Configuration’ tab set the ‘Message Type’ to ‘SLC_Typed_Read’, set the ‘Source
Element’ to the desired start address, set the ‘Number Of Elements’ to read and select
the ‘Destination Element’ to the program tag where you want to store the data. On the
‘Communication’ tab, set the ‘Path’ to [Name of PLC],2,[IP Address of GForce™ Panel]
and select ‘CIP’ as the ‘Communication Method’ where 2 represents the Ethernet port on
the PLC. (The address definitions can be found in MCP-170 GForce™ Communications
Protocol.)
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5. You should now see data in the program tag you selected as the ‘Destination Element’ in
step #4
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Allen-Bradley Ethernet
Allen-Bradley SLC 5/05 PLC Messaging Communication Example
2. Add a new MSG instruction to a rung for ‘Read/Write Message.’ Set the following
properties: ‘Type’ to ‘Peer-To-Peer,’ ‘Read/Write’ to desired function, ‘Target Device’ to
‘500CPU,’ ‘Local/Remote’ to ‘Local,’ ‘Control Block’ to the desired file number to hold
message status data.
3. Click the ‘Setup Screen,’ and set the following: ‘Data Table Address’ to the desired
address to store the data in the PLC, ‘Size in Elements’ to the number of data values to
read/write, ‘Channel’ to 1, ‘Message Timeout’ to the desired timeout, ‘Data Table
Address’ to the address to read/write in the GForce™, ‘Ethernet (IP) Address’ to the IP
Address of the GForce™, and ‘MultiHop’ to No. (The address definitions can be found in
MCP-170 GForce™ Communications Protocol.)
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Remote Viewing Software
The GForce™ panel is equipped with the ability to remotely view another GForce™ panel. You may also
view a GForce™ panel from a device such as a PC or laptop that is connected on the same network as
the panel.
Remote Viewing behind a Firewall

If the panel is behind a firewall, certain ports will need to be open to connect to the panel. Port 5800 will
need to be open for the Java implementation of VNC (i.e. web browser client). Port 5900 will need to be
open for the native VNC application (i.e. Remote Viewer client software downloaded from the panel or a
third-party native VNC client).
Panel Configuration
To configure the GForce™ device that you wish to view via another GForce™ panel, Select Intranet on
the menu bar to enter the intranet setup and connections screen. Add an entry to the GForce™ grid by
touching the [ADD ENTRY] button. After the entry is added, configure the IP address by touching the drop
down boxes in the grid. You must touch the [SAVE] button to retain new entries and IP address changes.
Touch the [CONNECT] button to connect to the device.
To edit the name and password authentication options for the GForce™ panel, touch the [Edit] button on
the intranet screen. Here you may specify an alias for the GForce™ panel and setup authentication
information. To specify that a password is necessary to connect to the panel, check the ‘Use Password
Auth.’ checkbox and key in the password. Ensure that the [Save] button is touched before leaving this
screen.
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Remote Viewing from a PC Device
You can download the Remote Viewer Client Software from the GForce™ panel by selecting “Copy
Remote Viewer to USB” from the <Service> menu item. This will transfer the software from the GForce™
to a USB thumb-drive. You can then transfer it to your computer from the USB thumb-drive. Please note
that the device that you are attempting to view a GForce™ panel from should be connected to the same
network as the panel.
See picture below for the appropriate USB ports.
USE ANY OF THESE

USB PORTS FOR
THUMB DRIVE
ACCESS.
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After Copying the Remote Viewer Client software to your PC, double click the vncviewer.exe application
icon.
After double clicking on the icon, the FES Viewer : Connection Details window will open and prompt you
to enter the IP address of the Viewer software. Enter the IP address of the GForce™, 192.168.1.101.
Then click the OK button to accept the IP address and connect to the server. Note, if the GForce™ panel
you are trying to connect to has password authentication enabled, you will be prompted to enter a
password after clicking the [OK] button.
Alternate Remote Access -- Microsoft Internet Explorer

You can also use Microsoft Internet Explorer to view the GForce™ Control Panel, but this method has
some disadvantages, most notably, it is not able to display full color -- colors may not exactly match what
is displayed on the GForce™. It is advised to use the Remote Viewer Software when possible.
On your PC, double click the Microsoft Internet Explorer application icon. In the address field, type:
http://192.168.1.101:5800/ , followed by the enter key (press the ‘Go’ button).
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Trouble-shooting the Network
GForce™ Panel
Ensure that all of the information (static IP, gateway, subnet, etc…) entered on the panel is correct and to
your network specifications. To ensure that the panel’s network hardware is working appropriately and
that the drop you have is live, look at the LED’s on the Ethernet port you are plugged into. If all is working,
you should see a flashing green LED.
GComm
Check the GComm drawings to ensure that all of the dipswitches and jumpers are in the appropriate
locations. Also, check and ensure that the comMENT and Ethernet drops are live and configured
properly.
VTrac®
Please reference manual MCP-215 – VTrac User Manual for detailed information regarding setup and
®
configuration of the VTrac device.
Life Trac®
Please reference manual MCP-156 – Life Trac User Manual for detailed information regarding setup and
®
configuration of the Life Trac device.
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GL SERIES SCREW
COMPRESSOR PACKAGES
SECTION 4 COMPRESSOR STARTUP PROCEDURE
TABLE OF CONTENTS
PAGE
Introduction ...........................................................................................................................1
Pre Startup Requirements ...................................................................................................1
Required Actions-Installing Mechanic ...............................................................................1
Required Services-FES Startup Representative ................................................................1
Initial Startup Sequence .......................................................................................................2
Parameter Setup....................................................................................................................4
Normal Shutdown Sequence ................................................................................................4
Normal Startup Procedure...................................................................................................5
GL SERIES SCREW
COMPRESSOR PACKAGES
SECTION 4 COMPRESSOR STARTUP PROCEDURE
Introduction
This section contains information for conducting initial startup, normal operational startup, and restart
after power failure.
Pre Startup Requirements
Initial startup must be supervised by an FES authorized startup representative. Failure to have this
person present will void the compressor package warranty. This section should be carefully read and
understood to prevent damage to the compressor or system.
Required Actions-Installing Mechanic
A. Make all refrigerant piping connections.
B. Provide liquid refrigerant line for liquid injection or thermosiphon oil cooling. Provide water
piping if water cooled oil cooler is used. A high pressure refrigerant gas line must be provided
for TX liquid injection cooled booster compressors for external equalizing of the liquid injection
expansion control valve (not required for IntelliSOC™). Compressor package drawings supplied
with the package will show compressor connections.
C. Pressure test all refrigerant connections, before insulation is applied, and charge the system with
refrigerant.
D. Connect all power, control and auxiliary equipment. Do not energize control (120 or 220 volt)
power supply to the GForce™ panel.
E. Fill the oil sump with the initial charge of oil to midway on the top sightglass. Some packages
are precharged with oil but the oil may not be visible since some of it may have moved to the
secondary side of the separator during shipment. Shipping documents should be checked to
find if an initial oil charge was installed.
F. Do not turn on the oil heaters prior to the arrival of the FES startup representative.
G. Do not energize motor circuits for rotation check prior to the arrival of the FES startup
representative.
CAUTION: The oil pump, compressor, and microprocessor are to be initially started only under the
direct supervision of the FES startup representative.
Required Services-FES Startup Representative
A. Verify that all electrical connections are correct.
B. Check the function and settings of all electrical and mechanical controls of the screw compressor
package.
C. Verify the alignment of the compressor and compressor motor.
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D. Instruct the operating personnel in the operation and maintenance of the GL Series compressor
package.
E. Inspect the system for obvious faults or defects which may damage the compressor.
After the initial checkout procedures are completed, the compressor startup will proceed as described
below in "Initial Startup Sequence". After as many hours as possible (at least three hours), but before
the FES Startup Representative leaves the job, the customer must inspect and clean the oil pump suction
screen, and compressor suction strainer screen. If the oil filter pressure drop is 15 psid the oil filter
should be changed at this time. Otherwise, the spare filter should be kept for future use.
Initial Startup Sequence
After the prestartup checks have been conducted for a new installation or for restart after maintenance or
service shutdown, the following procedure should be observed when starting the compressor:
A. Check the oil level in the oil sump. During shutdown the oil level should be at the middle of the
top sight glass. When the compressor is operating, the oil level will not be below the lower sight
glass.
B. Check for the correct position of all valves as shown below:
1. Compressor suction valve should be open.
2. Compressor discharge valve should be open.
3. For external oil cooled applications, open the main oil injection metering valve as
required to maintain the desired discharge temperature. For liquid injection applications,
open the main oil injection metering valve ¼ - ½ open (where applicable). Throttling the
main oil injection valve may be required to reduce noise or vibration caused by excessive
oil flow. If the package is supplied with an auxiliary main oil injection valve, this valve
should be opened as required to maintain an acceptable discharge temperature and/or
acceptable noise/vibration levels.
4. Open the oil feed valves to ports L, K, and G.
5. Open all valves feeding transducers on the microprocessor control panel. Be sure the
vent and purge valves are closed.
6. Open the oil supply valve to the oil header.
NOTE: If dual oil filters are supplied the standby oil filter supply service valves will be closed, and
the outlet valve must be open.
7. Open the secondary oil return metering valve 1 turn open. The service stop valves should
be fully open.
8. Open the service valve from the oil differential relief regulator.
9. If this is a liquid injection cooled compressor, open the liquid supply to the feed station.
If this is an externally cooled compressor, the water feed valves or refrigerant supply
valves should be open.
10. If economized, the economizer supply should be closed. It should be opened slowly after
initial compressor operation is confirmed.
11. Refer to the compressor schematic supplied with package and set any other valves to the
position for normal operation.
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Effective: 04-08 2
C. Set the control power circuit breaker (1CB) to the on position.
D. Close the oil heater circuit breakers so power will be applied to oil heaters. Power should be
applied 24 hours prior to compressor startup or as required to attain a minimum oil temperature
of 90°F.
E. Ensure the disconnect to the compressor motor is open.
NOTE: Some starters do not have a separate motor and control voltage disconnect, in which case the
motor leads must be disconnected from the starter.
This is necessary only if this is the initial start up or the motor or the wiring to the motor has
been changed.
F. Put the panel in service mode, use the 'User Level' selection on the menu bar at the top of the
screen. A password is required. Start the oil pump by pressing the [OIL PUMP] button. Allow
the oil pump to run for approximately 30 seconds to lubricate the compressor bearings. Stop the
oil pump by pressing the [OIL PUMP] button.
G. Close the disconnect or reconnect the motor leads to the compressor motor. See step E above.
H. Check compressor rotation. Facing the compressor shaft, the rotation should be CLOCKWISE.
To check rotation, touch the [LOCAL START] button and after going through the normal
starting sequence, the compressor will start. As soon as the direction of rotation is confirmed,
stop the compressor motor by pressing the [STOP] button. This check is only necessary if this is
the initial startup or the motor or wiring has been changed.
I. Enter variable setpoints into the GForce™ control panel.
J. Depress the [AUTO] capacity control button or the [EXTERNAL] button, if controlled by an
auxiliary control. This will allow the machine to control capacity.
K. Press the [LOCAL START] button, or if the compressor is to be sequenced by an auxiliary
control, push the [REMOTE START] button (the button will be illuminated, and the button will
go dark). This will enable the compressor to start depending on set up. From this point the
startup sequence will be automatic and the following will occur:
1. If the compressor was started previously within the anti-recycle time delay period, the
[ANTI-RECYCLE] button will be illuminated. The compressor start will be delayed
until the anti-recycle timer has completed its timing cycle. The compressor data display
screen will also show an "Oil Drain Time". This is the amount of time required to
properly drain oil from the compressor prior to restarting. The compressor start will be
delayed until the oil drain timer has completed its timing cycle.
2. If the compressor has not been started recently or the anti-recycle timer has timed out, the
following will occur simultaneously:
a. The [OIL PUMP] button will be illuminated. The oil pump will start and establish
oil pressure. Oil pressure must be established within 10 seconds or the startup
sequence will terminate and the compressor will not start.
b. The slide valve will move to the unload position (less than 5%). The compressor
must unload within 180 seconds or the start sequence will terminate.
3. Once the compressor slide valve has reached less than 5% and oil pressure has been
established, the following will occur:
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a. The compressor will start.
b. A loss of oil pressure for 6 seconds is allowed at this time.
c. There will be a 15 second delay before the compressor begins to load.
d. The elapsed time meter will start timing to display compressor operating hours as soon as
the compressor starts.
The compressor will now operate automatically. The capacity controller will cause the compressor slide
valve to load and unload to maintain the desired system pressure or temperature.
Parameter Setup
Once the compressor conditions have stabilized and normal suction and discharge conditions have been
reached, there are several compressor operating parameters that must be set. The settings and
adjustments that must be made are as follows:
A. Adjust the liquid injection oil cooling. Refer to Figure 2-2 for system explanation and
schematics. Adjust the outlet pressure regulating valve (OPRV) per instructions in Section 2 to
maintain the oil temperature listed in Table 2-1. Allow the compressor to run for several hours
to observe any changes in oil temperature. If the oil temperature should drop more than 5°F
below the recommended limits, adjust the OPRV for a higher pressure which will reduce the
refrigerant flow for oil cooling. If the oil temperature should increase more than 5°F above the
recommended limits, adjust the OPRV for a lower pressure which will increase refrigerant flow
for oil cooling. Do not adjust the thermal expansion valve (#5 or #10) to control oil temperature.
After system equilibrium is obtained, the liquid injection oil cooling system will operate
automatically without manual adjustment.
B. Once the oil temperature has reached operating temperature, some decrease in oil pressure may
be experienced. The oil pressure should be adjusted to the requirements given in Table 2-1. Oil
pressure is adjusted by changing the setting of the vee ported plug type regulating valve in the oil
bypass line to the separator. This valve is adjusted by removing the top cover and turning the
stem clockwise to increase oil pressure and counterclockwise to decrease oil pressure.
C. When oil pressure and temperature are stable, adjust the compressor slide valve load and unload
rate. GL Series compressor packages employ a double hydraulic cylinder to operate the slide
valve as illustrated in Figure 2-4. The rate of slide valve movement is adjusted by means of the
three needle check valve settings (two for load, one for unload). The load and unload valves are
identified in Figure 2-5. Closing the needle valves slows the rate of slide valve movement. Set
the needle valves such that is takes 30 to 60 seconds to load or unload the compressor from 0%
to 100% and from 100% to 0%, respectively.
Normal Shutdown Sequence
It is recommended that the compressor is first unloaded before shutdown. The normal shutdown
sequence is initiated by pressing the [STOP] button. This will cause the following:
A. The compressor will stop immediately and the [STOP] button will be illuminated.
B. The oil pump will continue to run until the slide valve moves to the less than 5% position or for a
minimum of 5 seconds, and then it shuts down.
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Effective: 04-08 4
Normal Startup Procedure
A. Ensure that system conditions will allow a safe startup.
B. Depress the [AUTO] capacity control button (or external if controlled by an auxiliary controller).
C. Press the [LOCAL START], or if the compressor is controlled by an auxiliary control press the
[REMOTE START].
D. The start sequence will now be automatic.
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5 Effective: 04-08
GL SERIES SCREW
COMPRESSOR PACKAGES
SECTION 5 MAINTENANCE
TABLE OF CONTENTS
PAGE
Introduction ...........................................................................................................................1
Normal Maintenance ............................................................................................................1
A. Compressor Shutdown and Restart .....................................................................1
B. Oil Filters ................................................................................................................2
C. Main Oil Filter........................................................................................................2
D. Strainer ...................................................................................................................3
E. Liquid Refrigerant Strainers ................................................................................3
F. General Component Replacement........................................................................4
G. Coalescer Filter Replacement ...............................................................................4
H. Replace Compressor Unit Oil ...............................................................................5
I. Motor Bearings.......................................................................................................5
J. Motor Alignment ....................................................................................................5
K. Suction Strainer Service ........................................................................................5
Recommended Maintenance ................................................................................................6
A. Oil Quality and Analysis .......................................................................................6
B. Vibration Analysis .................................................................................................6
C. Maintenance Schedule ...........................................................................................7
D. Class A, B, & C Inspection Summary ..................................................................8
E. Operating Log ......................................................................................................10
Parts and Warranty Contact Information .......................................................................12
A. Warranty Return Material Procedure...............................................................13
B. Parts Warranty ....................................................................................................13
C. Restocking Policy .................................................................................................13
GL SERIES SCREW
COMPRESSOR PACKAGES
SECTION 5 MAINTENANCE
INTRODUCTION
This section of the manual contains information on maintenance, service, and troubleshooting for the GL
Series compressor package. It is organized into two sections, Normal Maintenance and Recommended
Maintenance.
IN ORDER TO PROPERLY AND SAFELY MAINTAIN THE GL SERIES COMPRESSOR
THE INFORMATION CONTAINED IN THIS SECTION MUST BE READ AND
UNDERSTOOD. ALL MAINTENANCE ON THE PACKAGE SHOULD BE PERFORMED
ONLY BY A TRAINED REFRIGERATION MECHANIC QUALIFIED TO WORK WITH THE
SPECIFIC REFRIGERANT BEING USED.
When performing service or maintenance operations, care must always be exercised and safety
precautions obeyed or serious injury or damage could result. Therefore, before performing any work
requiring the opening of refrigerant containing parts, servicing high voltage components, or working
near or on rotating components, follow these precautions:
• Before servicing the compressor or any other moving parts, press the compressor STOP
button, then turn off the control power and open power disconnects to the compressor and
oil pump starter. Tag and lock all disconnects in the open position while conducting
service work.
• Be sure the working space is adequately ventilated.
• Wear protective clothing and gear as required.
• Obey safety guidelines for the refrigerant being used in the system.
• READ AND UNDERSTAND THE MAINTENANCE SECTION OF THIS MANUAL.
NORMAL MAINTENANCE
The Normal Maintenance section identifies those service tasks which are necessary for the proper
operation of the compressor package.
A. Compressor Shutdown and Restart
When the compressor is shutdown for prolonged periods such as seasonal shutdown, the following
procedure should be followed:
a. Depress STOP to shutdown the compressor.
b. Turn CONTROL POWER to the OFF position. Open oil heater circuit breakers.
c. Open disconnects to the compressor and oil heaters.
d. Close the suction and discharge valves. If used, close liquid injection feed and economizer feed
valves. Attach CLOSED tags.
e. If water cooled, close the water supply and return valves and attach CLOSED tags. Provisions
should be made to protect from rust and corrosion during shutdown.
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Also, if the package will be exposed to below freezing temperatures during shutdown, the oil cooler and
piping must be heated or drained.
To restart after extended shutdown use the following procedure:
a. If water cooled, take necessary action to return cooling water to the cooler. Open the supply and
return valves and remove CLOSED tags.
b. Inspect the compressor for any damage or corrosion that may have occurred during prolonged
shutdown.
c. Open the compressor suction and discharge valves, and if supplied, the liquid injection feed stop
valve. Remove CLOSED tags. If economized, the supply valve will be opened after startup.
d. Close disconnects to the compressor and oil pump.
e. Turn the CONTROL POWER switch to the ON position. Close the circuit breakers to the oil
heaters. Allow the oil to warm to 90°F.
f. Proceed with the startup as described in Section 4.
B. Oil Filters
All GL Series compressor packages are furnished with one main 15 micron high efficiency single or
multiple cartridge oil filter. As an option, dual oil filters are available so that the compressor can
continue to operate while one filter is being changed (Only one filter is used during operation, the
second serves as 100% backup).
C. Main Oil Filter
UNLESS DUAL OIL FILTERS ARE SUPPLIED, IT IS NECESSARY TO SHUT DOWN THE
COMPRESSOR BEFORE REPLACING FILTER ELEMENTS.
Filter elements should be changed when the pressure drop across the filter exceeds 15 psid or yearly.
The procedure for changing the main oil filter is as follows:
a. If a single oil filter was supplied, shut down the package by depressing the STOP button and
open the disconnects to the compressor and oil pump.
If dual oil filters were supplied, SLOWLY open the upstream service stop valve to the filter not in use.
The valve must be opened slowly to prevent a sudden lowering of oil pressure.
b. Close the service stop valves to the filter that is having the elements replaced.
c. Connect a hose to the purge and drain valves at the bottom of the oil filter (located on oil supply
pipe). Insert the free end of the hose into a container to collect oil drained from the filter.
SLOWLY open the purge (use the oil pressure transducer vent valve) and drain valves to release
pressure.
d. Loosen the capscrews retaining the filter cover and cover O-ring. Remove and retain the
capscrews after the oil has drained from housing.
e. Remove and keep the nuts holding the filter cartridge retainer. Remove and keep the filter
cartridge retainer.
f. Remove the front oil filter cartridge and then remove the back cartridge(s). Used cartridges can
then be properly disposed. Be sure to clean sealing surfaces to remove any gasket material from
previous filter elements.
g. Clean the canister interior with clean oil and wipe with a clean lint free cloth.
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Effective: 05-09 2
h. Install the new filters and retainer. Reinstall the retainer nuts.
i. Install the cover and oil soaked O-ring using the original capscrews.
j. Close the purge and drain valve.
k. Slowly open the inlet stop valve to the oil filter. Then slowly open the outlet stop valve from oil
filter.
l. If a single oil filter was supplied, the filter is now ready to be placed in service and the
compressor is ready to be restarted.
If a dual oil filter was supplied, this filter becomes the back up and the inlet stop valve should be
closed (outlet open) until the other filter is changed.
D. Strainer
Cleaning the oil pump strainer REQUIRES COMPRESSOR SHUTDOWN. To clean the strainer use
the following procedure:
a. Stop the compressor by depressing STOP. Open the disconnects to the compressor and oil
pump.
b. Close the stop valves to and from the oil strainer and close the stop valve at the outlet of the oil
differential pressure regulator.
c. Open the strainer purge and drain valves. Collect the oil in a container for disposal.
d. Loosen and remove the capscrews on the cover. Keep the capscrews for later use. Remove the
cover and O-ring.
e. Remove the strainer basket and wash in solvent. Blow with air to dry and clean.
f. Wipe the inside of the strainer housing with a clean dry lint free cloth.
g. Replace the strainer basket and install the cover and O-ring using the original capscrews.
h. Close the vent and drain valves and open the stop valves closed in Step b. Close the disconnects
to the compressor and oil pump motors.
i. The compressor can now be restarted.
E. Liquid Refrigerant Strainers
A number of liquid refrigerant strainers may be used on the GL Series compressor depending on the
type of oil cooling and other optional equipment supplied. For this reason a general procedure is given
that can be used for the equipment supplied. Refer to the equipment schematic provided with the
package to find specific locations of valves. The procedure is as follows:
a. Stop the compressor by depressing STOP and open the disconnects to the compressor and motor.
b. Close the liquid supply stop valve to the strainer and solenoid valve.
c. OPEN THE SOLENOID MANUALLY BY SCREWING IN THE VALVE STEM AT THE
BOTTOM OF THE VALVE. This will prevent liquid from being trapped between the solenoid
valve and the stop valve.
d. Allow time for the liquid refrigerant to evaporate then close the stop valve immediately down
stream of the solenoid valve.
e. When it can be determined that there is no remaining refrigerant in the strainer body or basket,
cautiously loosen the bolts holding the strainer cover.
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f. Carefully remove the cover and strainer basket.
g. Wash the strainer basket in solvent and dry with compressed air.
h. Reassemble the strainer.
i. Open the stop valve downstream of the solenoid valve and perform a leak check.
j. Unscrew the manual open stem at the bottom of solenoid valve.
k. Slowly open the liquid supply stop valve.
l. Close the disconnects to the compressor and pump motors. The compressor is ready for
operation.
F. General Component Replacement
When repairing or replacing components that can not be individually isolated, the following procedure
should be used.
a. Stop the compressor by depressing STOP. Open the disconnects to the compressor and pump
motors. Open the oil heater circuit breakers.
b. Close the compressor package discharge stop valve.
c. If provided, close the liquid injection liquid feed stop valve and stop valve at compressor port
H13 and the economizer supply stop valve. Close the high pressure gas supply stop valve to the
liquid injection oil cooling outlet pressure regulator (if liquid injection cooled).
d. Open the compressor suction check valve bypass valve to allow the refrigerant in the compressor
package to be transferred to the system suction.
e. Close the compressor suction stop valve and the suction check valve bypass valve.
f. Vent the oil separator using the oil fill connection to purge any remaining refrigerant. Carefully
handle and dispose of refrigerant as required by applicable safety codes.
g. Complete service repair or replacement.
h. Evacuate package if required for refrigerant type used.
i. Return valves to their original operating positions following the previous procedure in reverse.
Conduct a leak test.
j. Close the compressor and pump motor disconnects. Close the oil heater circuit breakers.
k. The compressor is now ready for operation.
G. Coalescer Filter Replacement
Coalescer filter elements should be replaced when the pressure drop across the elements exceeds 5 psid.
The procedure for replacement is as follows:
a. Refer to "General Component Replacement" above and utilize steps a through f to prepare for
coalescer service.
b. Loosen the manway cover retainer bolts. Remove the retainer, manway cover and cover gasket.
Do not reuse the cover gasket.
c. Remove and keep the two nuts and cover plate from each rod retaining coalescers. Slide the
coalescer elements off of rod and properly dispose.
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d. Install new coalescer elements by sliding them one at a time over the rod until the first element is
against the rear baffle. The end of the coalescer with the larger diameter o-ring (this end is
stamped "B") should contact the oil separator baffle plate. All elements should touch each other.
e. Install the cover plates. Tighten the first nut to 35 ft-lb. and use the second nut to lock the first
nut in place.
f. Install the manway cover being sure to use a new gasket.
g. Tighten the manway bolts. Recheck bolts after applying pressure to the oil separator since they
may loosen.
h. Refer to "General Component Replacement" above and use steps h through k to complete this
procedure.
H. Replace Compressor Unit Oil
When it is necessary to change the compressor package oil charge, the compressor must be shutdown.
Oil filters must be drained and filter elements replaced, along with all oil strainers being cleaned. The
procedure is as follows:
a. Refer to "General Component Replacement" Section and follow steps a through f.
b. Vent the compressor using the oil fill connection leaving the valve open during the oil draining
procedure.
c. Drain the oil into a suitable container using the oil filter drain valve and a hose connected to the
oil filter drain valve. Open this valve to drain the oil from the compressor.
d. Change the oil filters and clean the oil strainer as previously described.
e. Once step D is complete, and the filters and strainer are reassembled, close the oil filter drain
valve.
f. Add oil through the oil fill connection until the oil level reaches the middle of the top sight glass
on the oil separator.
g. The oil fill connection can be used to purge or evacuate the oil separator as required. When
complete, close the oil fill connection. The approximate oil charge is given in Table 1-10.
h. Refer to "General Component Replacement" Section and follow Steps h through k to complete
this procedure.
I. Motor Bearings
Refer to the motor manufacturer recommendations for maintenance.
J. Motor Alignment
If motor alignment needs to be checked or adjusted, it should be conducted in accordance with the
procedures in Section 1.
K. Suction Strainer Service
The suction strainer protects the compressor from system debris that could damage the compressor.
This strainer would normally be cleaned as part of the initial startup procedure or if the refrigerating
system has been opened up (i.e. for repairs, plant expansion, etc.) The procedure for cleaning this
strainer is as follows:
a. Stop the compressor.
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b. Refer to "General Component Replacement" Section and utilize steps a through f to prepare for
suction strainer inspection and cleaning.
c. Carefully loosen the nuts and bolts on the suction housing cover flange. When it is determined
that refrigerant or pressure is not present, remove and retain the nuts, bolts and flange. Discard
the cover gasket.
d. Remove and inspect the strainer basket. Clean by washing in solvent and drying with dry
compressed air.
e. Install the strainer in the strainer housing.
f. Using a new cover gasket, install the cover flange with the original nuts and bolts.
g. Refer to "General Component Replacement" Section and use steps h through k to complete the
procedure.
RECOMMENDED MAINTENANCE
The compressor package can operate at peak performance only when it is properly maintained and
serviced. To ensure dependable and long life performance, a regular scheduled maintenance program
should be followed.
An operating log should be kept showing when maintenance was performed as well as results from
machine inspections for leaks, vibration, noise, oil quality, etc. A reference point for inspections should
be established when the package is placed in operation. A check for unusual or abnormal conditions
should be made on a daily basis. A Condition Based Monitoring Program should be employed. It should
include vibration surveys, oil analysis and at least axial float checks on the thrust bearings.
A. Oil Quality and Analysis
The proper type and condition of refrigeration oil is essential for maintaining compressor performance
and useful life. Oil quality changes rapidly and reflects both system and compressor mechanical
problems. Conditions such as bearing wear, contaminants, excessive temperature, and moisture are all
indicated by oil condition. Use the following recommendations to maintain the required quality from
the compressor oil.
a. Use only the oil recommended by FES for the refrigerant and duty specified. Contact the FES
service department if there are any question concerning the proper oil to use.
b. At start up, take two 8 oz. oil samples and place them in clean containers. One sample should be
used as a visual reference point to compare to later samples. Oil that appears murky, discolored,
milky or markedly different from the original sample indicates a possible problem requiring
further analysis. The second sample is to be sent to a laboratory for analysis. The analysis
should show, as a minimum, wear particle analysis, viscosity, contaminants (i.e. iron, copper,
etc.), and moisture content. The second sample's laboratory report will then be the reference
point for future samples. Each time the oil is changed new reference samples must be taken.
c. The FES service department can provide oil analysis services if a local laboratory is unavailable.
B. Vibration Analysis
The analysis of changes in vibration patterns and levels can provide valuable information on both
machine and structural components. In order for the vibration analysis to provide useful data, the
following guidelines should be used.
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a. Initial data should be taken at startup to use as a reference for later readings. Data should include
the location and orientation of each reading, the slide valve setting, the Vi setting, and the main
oil injection setting. Any future readings should be taken at these same conditions.
b. Vibration readings are most useful if spectrum data is taken. This data shows both the velocity
and frequency of the vibration.
c. Vibration surveys should be conducted at least every six months or every 4000hrs, whichever
comes first.
d. Vibration data can be misleading if not interpreted properly. Also, vibration can occur as a result
of other nearby equipment or be amplified by structural resonance. Questions concerning
vibration data and its application should be referred to the FES service department.
C. Maintenance Schedule
A recommended maintenance schedule for normal refrigeration duty is shown as Table 5-1. This
program should be followed if maximum compressor package performance and life is to be obtained.
Service Interval in Hours (Services shown are to be repeated at the same intervals beyond 20,000 hours)
Item
Maintenance to be Performed
No.
Start-up 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000
1 Class A Inspection X X X X X X X X X X X
2 Class B Inspection X X
3 Class C Inspection <----------------- Every 25,000 - 30,000 Hours or determined by condition based monitoring --------------------->
4 Check and Clean Suction Strainer X X X
5 Clean Oil Strainer X X X
6 Change Oil Filters X X X
7 Check Oil Pump X X X
8 Check & Clean Oil Return Strainer X X X
9 Clean Refrigerant Strainers X X X
10 Change Coalescers X X
11 Check Coupling X X X
12 Check Oil Pressure Regulator X X X
13 Clean Package X X X
14 Oil Analysis X X X X X X X X X X X
15 Change Oil --------------------------------------------------------- As Indicated by Item #14 --------------------------------------------------------
16 Grease Motor Bearings ------------------------------------------------------- Per Manufacturer's Specs. -------------------------------------------------------
17 Vibration Surveys X X X X X
Table 5-1: Compressor Maintenance Schedule

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D. Class A, B & C Inspection Summary
Class A Inspection
Service Interval: Quarterly
Service Time Required: 4-8 Hours
• Log Machine Properly
• Check Coalescer Pressure Drop
• Take Vibration Readings
• Check Motor Current Draw
• Check Motor Load Control
• Calibrate Pressure Sensors
• Calibrate Temperature Sensors
• Calibrate Motor Current Transformer
• Adjust Load/Unload Solenoid Valve
• Check Axial Float in Male Rotor Shaft
• Check Motor/Compressor Alignment
• Check Operation of all Safeties
Class B Inspection
Service Interval: Annually
Service Time Required: 32 Hours
GENERAL
• Perform FES Class A Inspection
• Inspect Skid for Rust and Corrosion
REFRIGERANT CIRCUIT
• Clean Suction Strainer
• Clean Liquid Injection Strainer
• Check Operation of Liquid Injection Valve
• Inspect all External Refrigerant Lines
• Leak Check Machine Properly
ELECTRICAL CIRCUIT
• Inspect Motor Terminals
• Grease Motor Bearings
• Check all Connections in Starter
• Inspect Condition of Contactors
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Effective: 05-09 8
• Check Relays in Starter and Control Panel
• Check Timers in Starter and Control Panel
• Check Starter & Control Panel for Proper Operation
LUBRICATION CIRCUIT
• Change Oil if Warranted by Analysis
• Replace Oil Filters
• Inspect Coalescer Elements
• Clean Oil Pump Suction Strainer
• Check Oil Pump Alignment
• Inspect all External Oil Lines
• Check Oil Pressure Regulator
• Check Operation of Oil Return System
• Check Operation of Oil Heaters
Class C Inspection
Service Interval: 25,000 Hours – 30,000 Hours or determined by condition based monitoring. Service
interval may exceed 30,000 hours when using condition based monitoring.
Service Time Required: 40-48 Hours
DISASSEMBLE COMPRESSOR COMPLETELY
Thoroughly Inspect the following:
• Male and Female Rotors
• Shaft Journals
• Slide Valve
• Balance Piston
• Unloader Piston
• Sleeve Bearings
Carefully Inspect the Following Critical Clearances:
• Journal Bearings
• Sleeve Bearings
• Slide Valve
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9 Effective: 05-09
Reassemble Compressor Using the Following New Parts:
• Sleeve Bearings (If necessary & possible)
• Thrust Bearings
• Gaskets (as required)
• O-Ring (as required)
• Shaft Seal Kit
DISMANTLE OIL PUMP
Check Gear and Idler for Wear
Rebuild and Set Proper Clearances
PERFORM CLASS A INSPECTION
• (AFTER COMPRESSOR IS INSTALLED ON PACKAGE)
E. Operating Log
The operating log is an essential tool used to understand and document the operating characteristics of a
refrigeration system. Recording temperatures, pressures, and other system data (refer to Table 5-2)
allows one to be familiar with the system operation and to identify any changes in the normal operating
conditions.
FES recommends that readings be taken at intervals of 2-4 hours of compressor operation.
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Table 5-2: GL Series Compressor Operating Log
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PARTS AND WARRANTY CONTACT INFORMATION
FES offers technical support to our customer over the telephone. To efficiently assist you when you
call, please have the following information available:
a. Your company name.
b. The name of the end user.
c. A telephone number and fax number for us to contact you.
d. The contract number of the machine. Check the inside of the control panel door or the cover of
the instruction manual.
e. The model number and serial number of the machine you are working on.
f. The manual and drawings supplied with the unit.
g. An accurate description of the problem.
h. If applicable, the analog failure data and the failure message from the failure annunciator.
The FES York telephone number is (717) 767-6411. The FES Stockton phone number is (209) 931-
3970. The FES Houston phone number is (281) 456-8500. Please ask for the service department.
Before scheduling a startup, we will forward some checklists. Complete these forms and return them to
FES. This insures that we are aware of any outstanding work. If start-up is not included in the capital
purchase, a purchase order number is required before a service technician is scheduled.
If you have a technical question or need parts after 5:00 PM EST, you can reach the FES service & parts
department in Stockton, CA until 8:00 PM EST, or Houston until 6:00 PM EST.
FES also has an EMERGENCY after hours service. Call FES York and the answering service will take
a message and have someone call you.
To order spare parts you should call FES York, Stockton or Houston. Please have the following
available:
c. A telephone number and fax number for us to contact you.
d. The contract number of the machine. Check the inside of the control panel door or the cover of
the instruction manual.
e. The model number and serial number of the machine you are working on.
f. A purchase order number.
g. A ship to address and telephone number.
h. Either a part number or a detailed description of the part required.
i. Method of shipping.
j. For airfreight, details of your airfreight account.
If your problem requires parts and is covered by warranty, call FES York, Stockton or Houston. If you
know the part you need and do not need any technical support, you may call the Warranty department
directly. Please have the following available and ask for the Warranty department.
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Effective: 05-09 12
c. A telephone number and fax number where we can contact you.
d. Contract number, model number and serial number of the unit.
e. Description of problem.
f. Purchase order number to insure defective parts are returned.
g. Ship to address and telephone number.
A. Warranty Return Material Procedure
Return authorization forms will be supplied with replacement parts and an in-warranty invoice
submitted. This invoice will be canceled with return of alleged defective parts providing there is no
evidence of customer neglect. Prompt payment of invoice is expected if parts are not returned within 30
days of date of shipment from the FES factory (90 days for international shipments). FES cannot be
responsible for material returned to the factory without the proper Return Material Authorization Forms.
All transportation charges to and from the factory must be paid by the purchaser.
B. Parts Warranty
FES parts are shipped in new condition. FES will supply warranty replacements for parts claimed
defective at the time of receipt. Claims against damaged goods must be made directly with the carrier.
Parts claimed defective might be returned for warranty consideration. Warranty consideration will be at
the discretion of the FES Quality Assurance department after inspection of the material. Warranty will
not be considered for defects resulting from mishandling, improper installation, abuse, and/or
unauthorized modification.
A return material authorization form must accompany all return material and will be issued upon
providing FES the sales order number and invoice number under which FES supplied the material. All
warranty claims must be submitted through the FES service department.
C. Restocking Policy
New/unused parts may be returned to FES by requesting a return material authorization from the Parts
Department. A return authorization will be issued upon providing FES the FES sales order and invoice
number for which FES supplied the material.
Credit will be issued after inspection by the FES Quality Assurance department for all material supplied
from FES stores. Credit for new/unused material is subject to a 20% restocking charge.
Credit will be issued upon receipt of same for material purchased from outside vendors on behalf of FES
customers subject to a minimum, but not limited to, a 20% restocking charge.
Document: GL-4
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13 Effective: 05-09
Component Literature
GL Series
AMOT CONTROL VALVE – MODEL R, FORM 1349

AWP STOP VALVES
AWP OPERATING INSTRUCTIONS FOR STOP VALVES
CYRUS SHANK SAFETY RELIEF VALVE
DANFOSS PRESSURE TRANSDUCER - AKS 3000
DANFOSS SERVICE VALVES, TYPE SNV-ST
DANFOSS STOP VALVES, TYPE SVA-ST
DANFOSS STOP VALVES INSTALLATION MANUAL, TYPE SVA
DANFOSS STOP VALVES MAINTENANCE MANUAL, TYPE SVA
FES SECONDARY OIL RETURN VALVE – 018-00017B
GRASSO SOLENOID VALVE BLOCK
HANSEN SAFETY PRECAUTIONS, SPe
HANSEN PRESSURE RELIEF VALVE, BULLETIN K109f
HANSEN ST STRAINER, BULLETIN T479e
MECHANICAL SHAFT SEAL REPLACEMENT PROCEDURE
REFRIGERATING SPECIALTIES SAFETY BULLETIN RSBCV
REFRIGERATING SPECIALTIES DIFFERENTIAL PRESSURE RELIEF REGULATOR,
BULLETIN 23-10A
REFRIGERATING SPECIALTIES FOR SAFETY RELIEF VALVES,
BULLETIN 73-00A
VIKING PUMP TECHNICAL SERVICE MANUAL, SERIES 4195 & 495,
SECTION TSM 144
VIKING PUMP TECHNICAL SERVICE MANUAL, INSTALLATION, START-UP
TROUBLESHOOTING, PREVENTATIVE MAINTENANCE, DO’S & DON’TS,
SECTION TSM000
WEG MOTOR INFORMATION ( 300 HP)
WEIDMULLER PRS PLUG SERIES RELAY
WRC INPUT/OUTPUT MODULES
Model R
Thermostatic Valve
Features
■ Flow Rates of 12 - 116 USGPM
■ Weldable Connections
~ Element Easily Removed While
Valve Remains In-Line
■ Tamper-Proof Temperature Settings
■ Minimal Leakage Paths to Atmosphere
■ Ideal for Refrigeration Service with

Ammonia or other Refrigerants Pate
nt P
endi
ng
Operation Specifications
The valve is supplied with the temperature element Valve Body .............................................................. Steel
assembly factory-set to the nominal temperature set- Internal Trim Materials ......... Steel/Stainless Steel/Brass
ting. Temperature is sensed at Port A which remains Standard Seal Material ..................................... Neoprene
open to Port B (bypass) until the fluid temperature Maximum Differential Pressure ............. 20 psi (140 kPa)
reaches a point 8-10°F below the nominal setting. As Valve Pressure Rating ...................... 500 psi (3447 kPa)
the temperature continues to rise, the sliding valve Net Shipping Weight ........................................... 7-15 lbs
moves to close off Port B and open Port C (connected
to the cooler or heat exchanger). Port B is fully closed Installation
8-10°F above the nominal setting. The valve continu-
ally modulates the fluid flow to maintain the nominal
temperature. For optimum control, the system should AMOT Thermostatic Valves operate in any position and
be sized so about half the total fluid flow passes may be located at the convenience of the system de-
through the cooler at full load. signer. The valve can be supported by the connecting
pipe but should not be subjected to excessive bending.
For long life, AMOT Model R valves should not be Line up the piping before tightening the pipe threads or
exposed to continuous temperatures exceeding 65°F welding. Make sure to leave approximately 3.5" space for
above their nominal temperature setting. For occa- element removal when installing.
sional short periods, such as 1/2 hour, they can be
exposed to temperatures up to 90°F above their nomi- If the valve is mounted at the high point of the system, the
nal setting, but 250°F is the maximum temperature system should be properly vented to prevent trapping air
allowable. at the temperature element assemblies.
Caution:
Remove element and O-rings before welding to
prevent possible damage to these components.
Refer to Form 913, AMOT Thermostatic Valves General

Information for typical piping diagram.
FORM 1349
Selection Table
All flow rates in USGPM
Water or Lubrication Oil (at 100°F)
Water or SAE 10-20 SAE 30 SAE 40
Water/ Glycol SSU 170-550 SSU 550-800 SSU 800-1100
Flow Rate Flow Rate Flow Rate Flow Rate
Size Model No. Cv Min. Max. Min. Max. Min. Max. Min. Max.
3/4" (20) RT2 12 17 32 13 24 12 23 12 22
1" (25) RT3 18 25 48 20 39 18 35 18 33
1-1/2" (40) RT5 27 38 71 29 55 28 52 26 49
2" (50) RT6 38 54 101 41 77 39 73 37 69
2-1/2" (65) RT7 44 62 116 48 89 45 84 43 80
Model Code System

RT 5 B S A E N - ( )
Table D Special Requirements
Table E (MTO) Made to Order
Table F Table G
Table A Table B Table C

Model Type Code Nominal Bore inches (mm) Connection Code No.
Code Type Code Size Cv Code Description
RT Standard 2 3/4" (20) 12 A Butt Weld DIN 2448 PN40
3 1" (25) 18 B Socket Weld ANSI B16.11
5 1 1/2" (40) 27 *C NPT threads
6 2" (50) 38 *D Butt Weld ANSI B36.10 Sch. 40
Table D 7 2 1/2" (65) 44 * Currently unavailable in all sizes
Valve Material
Code Material Table F
S Steel Temperature Code No. Table G
Code Nominal Temp. Element Leak Hole
˚F (˚C) Code Inches (mm)
Table E
A 95 (35) N None None
Element Specification Code No. B 100 (37) 2 0.08 (2)
Code Description C 110 (43) 3 0.12 (3)
D 120 (48) 4 0.16 (4)
A Neoprene / electroless nickel E 130 (54)
B Neoprene / Unplated 5 0.20 (5)
F 140 (60) 6 0.25 (6)
C Viton / electroless nickel G 150 (65)
D Viton / Unplated 8 0.31 (8)
H 160 (71)
E Buna N / electroless nickel J 170 (76)
F Buna N / Unplated K 175 (79)
L 180 (82)
Maintenance
Properly applied and installed, AMOT Thermostatic Valves require minimal maintenance.
If necessary, the temperature element assembly may be easily replaced without disturbing the valve connection piping as
follows: Remove bolts and separate the Cover / Element Cartridge (2) and Sleeve O-Ring (4) from the valve body. Remove
Element Assembly (3) and Element O-Ring (5). Lubricate new Element O-Ring (5) with a good grade of petroleum grease
and install in the O-ring groove in the valve body. Insert the Element Assembly (3) through the Element O-Ring (5) of the
element cartridge with a twisting motion. Install new Sleeve O-Ring (4) and bolt on the valve Cover / Element Cartridge (2).
Dimensions
Nominal Valve
Dimensions Size/Connection Type
(in.) 3/4", 1", 1-1/2" 2", 2-1/2"
Butt Socket Butt Socket
A 3.35 3.50 3.90 4.30
B 4.10 4.50 5.15 5.55
C 2.05 2.05 2.50 2.50
D 3.85 3.85 4.65 4.65
Dimensions (in.) Butt Weld PN40

Nominal Bore 3/4" 1" 1-1/2" 2" 2-1/2"
E 0.75 1.00 1.50 2.00 2.50
F 1.05 1.35 1.90 2.35 2.95
Weight(lbs) 7 7 8 15 15
Dimensions (in.) Socket Weld ANSI

Nominal Bore 3/4" 1" 1-1/2" 2" 2-1/2"
E 0.75 1.00 1.50 2.00 2.50
F 1.50 1.80 2.42 2.89 3.59
G 0.50 0.50 0.50 0.62 0.62
H 1.06 1.32 1.87 2.39 2.89
Weight(lbs) 7 8 9 15 15
Recommended Spare Parts
VALVE SIZES 3/4", 1", 1-1/2" VALVE SIZES 2", 2-1/2"
Ref. P/N Qty Description Ref. P/N Qty Description

3 5435K(temp) 1 Element, Plated 3 46856K(temp) 1 Element, Plated
3 5435X(temp) 1 Element, Unplated 3 46256X(temp) 1 Element, Unplated
KIT No. 46857X003 Neoprene KIT No. 46858X003 Neoprene

4 43639L003 1 Sleeve O-Ring 4 46870L003 1 Sleeve O-Ring
5 1919L002 1 Element O-Ring 5 1183L003 1 Element O-Ring
6 43088L025 4 Capscew 6 43090L030 4 Capscew
7 43010L080 4 Spring Washer 7 43010L100 4 Spring Washer
KIT No. 46857X002 Viton KIT No. 46858X002 Viton

5 1919L001 1 Element O-Ring 5 1183L002 1 Element O-Ring
6 43088L025 4 Capscrew 6 43090L030 4 Capscrew
KIT No. 43857X001 Buna N KIT No. 46858X001 Buna N

5 1919 1 Element O-Ring 5 1183 1 Element O-Ring
6 43088L025 4 Capscrew 6 43090L030 4 Capscrew
Cut Away
AMOT Controls Corporation AMOT Controls Ltd. AMOT Controls Corporation

401 First Street Western Way 230 Orchard Road
Richmond, CA 94801-2906 Bury St. Edmunds IP33 3SZ # 09-230 Faber House
Tel: (510) 236-8300 Suffolk England Singapore 238854
Fax: (510) 234-9950 Tel: (01284) 762222 Tel: (65) 235-8187
Fax: (01284) 760256 Fax: (65) 235-8869
©1998 AMOT Controls Corp. Form 1349 B981
2.0-2.20.cdr
AVR 01.01.2009
Absperrventil -elast. PTFE -Ring- AVR shut off valve -elastic PTFE -ring-
TS [°C] - 60 - 10 + 50 + 150
PS [bar] 18,7 25 25 25
PS [bar] 30 40 40 40
Durchgangsform / Eckform straight way type / angle type
mit und ohne Deckelverlängerung with and without cover extension
DN 125 - 400 DN 6 - 100
1
1
2
2
3
3
4
5 4
6 5
7 7
8 8
9 6
10 9
11 10
13 11
13
15
16 15
16
Pos. Teil / part Material

1 Kappe cap 3.2341
2 Handrad handwheel Stahlblech
3 Abstreifring scraper NBR-85
4 O-Ring A O - ring seal A CR-70
5 O-Ring B O - ring seal B CR-70
6 Schrauben screws 8.8 / A2 - 70
7 elast.PTFE-Ring elastic PTFE - ring 1.4571 / PTFE
8 Flachdichtring SB flat sealing ring SB AFM - asbestfrei
9 Spindel kpl. stem cmpl. 1.4305
10 Flachdichtring K flat sealing ring K 3.0255 / PTFE
11 Deckel cover 1.0038 / 1.0488
1.4305
13 Flachdichtring R flat sealing ring R PTFE
14 O-Ring D O - ring seal D HNBR-70 / PTFE
15 Flachdichtring S flat sealing ring S PTFE
16 Gehäuse body 1.0305 / 1.0488
1.4541 / 1.4301
GEA AWP GmbH
Gewerbegebiet Ost, Straße A1, 17291 Prenzlau, Germany
2.0-2.20.cdr Tel: +49 3984 8559-0 Fax: +49 3984 8559-18
2.0 www.awpvalves.com e-mail: info@awpvalves.com
2.0-2.20.cdr
AVR 01.01.2009
AVR Absperrventil -elast.PTFE-Ring- shut off valve -elastic PTFE-ring-
AVR D AE
h2
D - Durchgangsform / straight way type
AE - Anschweißenden / butt welding ends
d2
h
AVR D AE DV
D - Durchgangsform / straight way type
h1
DV - Deckelverlängerung / cover extension
s
Deckelverlängerung als Isolierkit - s. Kapitel 17.4
DN
cover extension insulation extension - d1
Einbaulängen / lengths in mm :
Anschweißenden / butt welding ends
Reihe 1 / range 1 Reihe 2 / range 2 ANSI Sched 40
DN INCH d1 s d1 s d1 s l h h1 h2 d2
25 1 33,7 2,6 32,0 3,0 33,4 3,4 140 50 193 (243) 65 125
32 11/4 42,4 2,6 38,0 3,0 42,2 3,6 153 50 193 (243) 65 125
40 11/2 48,3 2,6 45,0 3,0 48,3 3,7 155 50 192 (242) 75 150
50 2 60,3 2,9 57,0 3,2 60,3 3,9 180 50 198 (248) 75 150
65 21/2 76,1 2,9 76,1 3,6 73,0 5,2 255 60 236 (296) 85 200
80 3 88,9 3,2 88,9 4,0 88,9 5,5 306 60 286 (346) 115 200
100 4 114,3 3,6 108,0 4,0 114,3 6,0 385 60 305 (365) 115 250
125 5 139,7 4,0 133,0 4,0 141,3 6,6 468 80 398 (478) 165 300
150 6 168,3 4,5 159,0 4,5 168,3 7,1 535 80 431 (511) 190 400
200 8 219,1 6,3 - - 219,1 8,2 708 80 602 (682) 270 630
250 10 273,0 7,1 - - 273,0 9,3 875 100 733 (733) 400 630
300 12 323,9 8,0 - - 323,8 10,3 1045 100 810 (810) 500 630
350 14 355,6 8,0 - - 355,6 11,1 1215 100 901 (901) 600 630
400 16 - - - - - - - - - - -
500 18 - - - - - - - - - - -
Varianten / variants :
DN / INCH DN / INCH Werkstoff Ausführung / design Anschweißenden / butt welding ends
material Eingang / inlet Ausgang / outlet
25 1 100 4 1.0305 Handrad Kappe Reihe 1 / range 1

32 11/4 125 5 1.0488 handwheel cap Reihe 2 / range 2
40 11/2 150 6 1.4301 - - ANSI Schedule 40
50 2 200 8 1.4541 x -
65 21/2 250 10 - x
80 3 300 12 x x
350 14
400 16
500 18
GEA AWP GmbH

2.4 Tel: +49 3984 8559-0 Fax: +49 3984 8559-18
www.awpvalves.com e-mail: info@awpvalves.com
2.0-2.20.cdr
AVR 01.01.2009
AVR Absperrventil -elast.PTFE-Ring- shut off valve -elastic PTFE-ring-
AVR E AE
h2
E - Eckform / angle type
d2
AVR E AE DV
h1
E - Eckform / angle type
h
DV - Deckelverlängerung / cover extension
s
DN
d1
l2
l1
Einbaulängen / lengths in mm :
Anschweißenden / butt welding ends
Reihe 1 / range 1 Reihe 2 / range 2 ANSI Sched 40
DN INCH d1 s d1 s d1 s l1 l2 h h1 h2 d2
25 1 33,7 2,6 32,0 3,0 33,4 3,4 60 60 51 189 (204) 115 125
32 11/4 42,4 2,6 38,0 3,0 42,2 3,6 60 60 51 189 (204) 115 125
40 11/2 48,3 2,6 45,0 3,0 48,3 3,7 70 70 54 212 (241) 130 150
50 2 60,3 2,9 57,0 3,2 60,3 3,9 70 70 54 212 (241) 130 150
65 21/2 76,1 2,9 76,1 3,6 73,0 5,2 85 85 67 220 (267) 145 200
80 3 88,9 3,2 88,9 4,0 88,9 5,5 100 100 63 272 (332) 170 200
100 4 114,3 3,6 108,0 4,0 114,3 6,0 120 120 63 277 (337) 170 250
125 5 139,7 4,0 133,0 4,0 141,3 6,6 200 200 82 332 (412) 240 300
150 6 168,3 4,5 159,0 4,5 168,3 7,1 225 225 82 349 (429) 270 400
200 8 219,1 6,3 - - 219,1 8,2 275 275 82 509 (589) 425 630
250 10 273,0 7,1 - - 273,0 9,3 325 325 100 626 500 630
300 12 323,9 8,0 - - 323,8 10,3 375 375 107 673 600 630
350 14 355,6 8,0 - - 355,6 11,1 425 425 107 708 700 630
400 16 - - - - - - - - - - - -
500 18 - - - - - - - - - - - -
h, ( ) für Deckelverlängerung, for cover extension
Varianten / variants :
DN / INCH DN / INCH Werkstoff Ausführung / design Anschweißenden / butt welding ends
material Eingang / inlet Ausgang / outlet
100 4 1.0305 Handrad Kappe Reihe 1 / range 1

25 1 125 5 1.0488 handwheel cap Reihe 2 / range 2
32 11/4 150 6 1.4301 - - ANSI Schedule 40
40 11/2 200 8 1.4541 x -
50 2 250 10 - x
65 21/2 300 12 x x
80 3 350 14
400 16
500 18
GEA AWP GmbH

2.6 Tel: +49 3984 8559-0 Fax: +49 3984 8559-18
www.awpvalves.com e-mail: info@awpvalves.com
Germany - 17291 Prenzlau, Gewerbegebiet Ost, Straße A1 Telefon +49 (0) 3984/ 8559 - 0
http://www.AWPvalves.com e-mail; info@AWPvalves.com Telefax +49 (0) 3984/ 8559 -18 Kälte · Klima · Armaturen GmbH
Betriebsvorschrift APS 06.30 - 10.1

Armaturen für die Kältetechnik
Operating Instructions
Valves for refrigeration
Absperrventile mit steigender Spindel Shut-Off Valves with rising stem

AVR - Typenvertreter: AVR - types :
mit elastischer PTFE-Ring Abdichtung an der Spindel with PTFE-ring seal on the stem
263 00, 264 00 Deckel geflanscht 263 00, 264 00 cover flanged
263 10, 264 10 Deckel geflanscht und verlängert 263 10, 264 10 cover flanged and extension
Ersatz für APS 06.30-41 verbindlich ab 01.04.1996 Replacement in lieu of APS 06.30-41,valid from April 1,1996
Inhaltsverzeichnis Seite Contents Page
1. Übersicht der Bauarten 2 1. Survey of Types 2
2. Technische Kennwerte 3 2. Technical Characteristics 3
3. Sicherheitshinweise 4 3. Safety Instructions 4
4. Anwendung 4 4. Application 4
5. Funktionsbeschreibung 4 5. Functional Description 4
6. Einbau 4 6. Installation 4
7. Wartung 5 7. Maintenance 5
8. Transport und Lagerung 7 8. Transport, Storage 7
9. Garantie 7 9. Warranty 7
10. Ersatzteile 7 10. Spare Parts 7
11. Kennzeichnung 10 11. Specification 10
12. Hinweis auf Restgefahren 10 12.Information on risks 10

AVR 263 00 08.05.2006
Haus- u. Lieferanschrift : Gewerbegebiet Ost, Straße A1

residence and delivery address: Germany - 17291 Prenzlau
e-mail : info@AWPvalves.com Telefon : (03984) 85 59 - 0
Kälte Klima Armaturen GmbH Internet: www.AWPvalves.com Fax: (03984) 85 59 18
1 / 10
1. Übersicht der Bauarten 1. Survey of types

APS 06.30 - 10.1
Typ / type: 263 00, 264 00, 263 10, 264 10

DN10 - 250
Handrad Kappe
hand wheel cap
Flachdichtring S Gewindestift headless pin Spindel kpl. Flachdichtring K
flat sealing-ring S DN 80 - 200 stem cmpl flat sealing-ring K
1.1
DN 10 - 32
Sitzdichtung S verschraubt
seat sealing-ring S screwed
DN 40 - 150 Schraubbuchse
Sitzdichtung S eingepresst screw bushing Abstreifring
seat sealing-ring S pressed scraper
1.0
Flachdichtring R
flat sealing-ring R Flachdichtring SB
flat sealing-ring SB
Typ / type: 263 00, 264 00

DN300 - 400
mit Ventiltellerentlastung / with balancing valve disc
Sitzdichtung S verschraubt
DN 200 - 400 B A
seat sealing-ring S screwed
PTFE-Ring O-Ringe
PTFE-ring seal O-Ring seals
AVR 263 00 08.05.2006
2.0
Flachdichtring S Spindel kpl. Flachdichtring R Flachdichtring K Handrad Kappe
flat sealing-ring S stem cmpl flat sealing-ring R flat sealing-ring K handwheel cap
2 / 10
APS 06.30 - 10.1

2. Technische Kennwerte 2. Technical characteristics
Gehäusewerkstoff St 35.8 I, RSt 37-2, X6.... 1.0305, 1.0039, 1.4541
Auswahl nach DIN 3158 , AD-W 10 TSt E 355, TTSt 35 N 1.0566, 1.0356.01
body material selection of material according to oder gleichwertige
German Standard DIN 3158, AD-W10 or any equivalent
bei Verwendung von Schrauben der Festigkeitsklasse 8.8

by using screws 8.8
PN TB (MWT) [ °C ] - 60* - 60** - 40 - 25 - 10 + 50 + 150
25 PS (MWP) [bar] 5 5 12,5 18,7 25 25 25
40 8 8 20 30 40 40 40
63 12,6 12,6 31,5 47,2 63 63 63
bei Verwendung von Schrauben der Festigkeitsklasse A2-70
by using screws A2-70
PN TB (MWT) [ °C ] - 60* - 60** - 10 + 50 + 150
25 PS (MWP) [bar] 18,7 25 25 25 25
40 30 40 40 40 40
63 47,2 63 63 63 63
** Beanspruchungsfall I / kind of straining I * Beanspruchungsfall II (nach AD2000-W10, EN 12284)
kind of straining II (after AD2000-W10, EN 12284)
zulässiger Umgebungstemperaturbereich [ °C ] - 50 bis/to + 50

permissible ambient temperature range
Achtung! TTSt35N ist nur für kurzzeitigen Attention! TTSt35N is only approved for
! Betrieb bei erhöhten Temperaturen (über
+50°C) zugelassen!
! short-term operation at increased
temperatures (above +50°C)!
Betriebsmedien working media
Kältemittel DIN 8975 Teil 1, EN 378 Teil 3, z.B.NH3, R22,cold brine basing on glycolrefrigerant DIN 8975 p.1,
R134a, Blends und Gemische mit Kältemaschinenöl, EN 378 p. 3 and mixtures with
nicht korrodierend wirkende Gase und Flüssigkeiten refrigerator oil, neutral, gaseous and liquid media,
Kühlsole auf Glycol-Basis,
Volumenstrom Kvs [ m³/h ]
flow factor
Typ DN
type 10 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400
263 00 2,35 5,56 8,87 12,7 18,6 30,0 42,0 66,5 109,0 151,0 245,0 352,0 526,0 800,0 960,0 1340,0 1930,0
264 00 2,28 5,78 9,07 13,8 22,2 37,0 53,5 80,0 159,0 231,0 373,0 464,0 1049,0 1180,0 1416,0 2120,0 3140,0
Einbaulage mouting position beliebig, Durchflußrichtung sollte eingehalten werden

in any desired position, the flow direction should be observed
Leckage leakage nach außen outward ( Kältemittel im Jahr )
(g/a) <5
Sitz seat ( refrigerant per year )
AVR 263 00 08.05.2006
3 / 10
APS 06.30 - 10.1

3. Safty instructions
3. Sicherheitshinweise ! !
! Ventile mit Transport- oder Lagerschäden dürfen ! Valves that have been damaged during transport or
nicht eingebaut werden. storage must not be installed.
! Ventile: ! Valves:
- müssem frei von Achskräften, Biege- und - no axial forces, bending or torsional moments
Torsionsmomenten sein. should act upon the valves.
- dürfen nicht als Fixpunkte von Rohrleitungen - must not be used as fixing points for pipes .
dienen.
! Bei Autogenschweißung oder Hartlötung darf die ! In the case of gase welding or brazing, the flame
Flamme das Ventil nicht berühren. may not reach the valve.
! Verunreinigungen jeglicher Art müssen vom ! Any kind of soiling has to be kept away from the
Innenraum der Ventile ferngehalten werden. inside of the valve.
! Schließen oder Öffnen der Ventile mit einer ! It is not allowed to open or close the valves by
Handradgabel oder sonstiger means of a handwheel wrench or any other
hebelarmverlängernder Gegenstände ist devices for extending the lever arm, as this may
unzulässig, da dies zur Beschädigung der damage the seat sealing.
Sitzdichtung führen kann.
! Demontage bzw. Ausbau der Ventile nur bei ! The valves may not be disassembled or detached
druckloser, abgesaugter und ausreichend before the pipe has been depressurized, sucked off
belüfteter Rohrleitung.
4. Anwendung 4. Application
AWP - Absperrventile sind geeignet für den Einsatz in AWP - Shut off valves are suitable for being employed
Kältemittelkreisläufen für Industrie-Kälteanlagen. in the refrigerant cycles for industrial refrigerating plants.
5. Funktionsbeschreibung 5. Functional discription
AWP - Absperrventile sind durch ein Handrad zu betä- AWP Shut off valves are actuated by a handwheel.
tigen.Die Ventile werden mit Blickrichtung auf das They are shut off clockwise in viewing direction towards
Handrad rechtsdrehend geschlossen und linksdre- the operating element and are opened counter-
hend geöffnet. clockwise. The valves are shut-off devices and may only
Die Ventile sind Absperrarmaturen und dürfen nur in be operated in "shut-off" or "open" position.
"Auf"- oder "Zu"-Stellung gefahren werden. When opening the valve, the stem has to be moved to the
Beim Öffnen des Ventils ist die Spindel bis zum An- limit stop into the uppermost position (compltly open).
schlag in die oberste Stellung zu fahren (voll geöffnet).
Die Ventile sind mit einer Rückdichtung ausgerüstet The valves are equipped with a back sealing (flat sealing
(Flachdichtring R). ring R).
Bei voll geöffnetem Ventil ist der gefahrlose Aus- When the valve is completely open, it is possible to re-
tausch der Dichtelemente (O-Ringe A,B, PTFE)an place the sealing elements (O-rings, A, B, PTFE) at
der Spindel, durch Herausschrauben der Schraub- the stem safety by unscrewing bushing.
buchse möglich. In case the flow medium reaches extreme temperatures,
Bei extremen Temperaturen ist das Ventil mit Schutz- the valve must be handled with protective gloves,
handschuhen zu bedienen. - danger of burning -.
Die Betätigung des Absperrventils gegen eine einge- Actuating the valve against a liquid in a closed section
schlossene Flüssigkeit ist zu vermeiden, da es durch should be avoid, as the motion of the stem sauses a chan-
die Bewegung der Spindel zur Volumenänderung ge in volume within the valve body.
kommt.Dies bedingt eine unzulässige Druckzunahme This, in turn, causes an inadmissible increase of pressure
im abgeschlossenen Rohrabschnitt. in the closed pipe section.
Das Schließen der Absperrventile in Flüssigkeitsleitun- Valves in pipes for liquids have to be shut off in direction to-
gen hat in Reihenfolge zu einem Behälter mit Gasvolu- wards a vessel containing gas.
men zu erfolgen.
! DN 250 bis 400 mit Ventiltellerentlastung ! ! DN 250 to 400 with balancing valve disk !
6. Einbau 6. Installation
Vor Einbau der Ventile sind Rohrleitungen und Anla- Before installing the valves, the pipelines and the compo-
genteile zu säubern. nents have to be cleaned.
AVR 263 00 08.05.2006
-bitte beachten- -please notice-

Die Abweichung von der Parallelität bzw. Rechtwinklig- The deviation from the parallelism or squareness of the
keit der Anschweißenden bzw. Flanschdichtflächen welding ends or, as the case may be, the sealing surfaces
darf 1° nicht überschreiten. of the flanges must not exceed1°.
Anschlußflansche müssen achsengleich sein. The connecting flanges have to be coaxial.
Ventile mit Transport- und Lagerschäden dürfen nicht Strainers that have been damaged during transport or sto-
eingebaut werden. rage must not be installed.
4 / 10
APS 06.30 - 10.1

Nach dem Entfernen der Rohrstopfen können die Ven- After the protective caps have been removed, the strai-
tile in beliebiger Lage eingeschweißt bzw. montiert wer- ners can be welded on, or installed in horizontal or vertical
den.Die Durchflußrichtung (siehe Pfeil auf Kennzei- position, in the latter case with the cover pointing
chenschild) sollte eingehalten werden.Eine entgegen- downwards. The flow direction ( see arrow on specifica-
gesetzte Durchflußrichtung ist zulässig, die Leistungs- tion label ) should be observed.
angaben gelten dann nicht. With modern welding processes ( such as TIG, CO2-
Bei Anwendung moderner Schweißverfahren shielded metal-arc ), the valves are not disassembled for
(z.B.WIG,CO2) werden die Ventile zum Einschweißen welding.
nicht demontiert.Das Handrad ist in Mittelstellung zu The fastening bolts and nuts have to be tightened cross-
bringen. wise and evenly.
Die Befestigungsschrauben und Muttern sind über After the installation has been performed, check whether
Kreuz und gleichmäßig anzuziehen. the handwheel runs smoothly within its entire lift range.
Nach dem Einbau ist die Leichtgängigkeit des Handra-
des im kompletten Hubbereich zu überprüfen. The thread of the cover for unscrewing the cap must not
Das Deckelgewinde zum Aufschrauben der Kappe hat be painted and has to be greased (e.g. with RENAX UNI-
farbfrei zu bleiben und ist zu fetten (z.B. mit RENAX TEMP 2).
UNITEMP 2). -please notice-
- bitte beachten- For disassembling the valve sufficient space has to be pro-
Zur Demontage des Einsatzes ist genügend Platz auf vided on the side of the cover.
der Deckelseite vorzusehen.
DN 10 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400

mm 85 85 85 115 115 130 130 145 170 170 240 270 425 600 800 1200 1200
7. Wartung 7. Maintanance
AWP - Absperrventile arbeiten wartungsfrei. AWP - shut off valves are maintenance-free.
Treten Mängel im Funktionsverhalten auf ist eine Repa- In case any defects in the functional performance of the
ratur möglich.Während der Garantiezeit dürfen Repa- valves occur, they can be repaired. During the term of war-
raturen nur durch AWP bzw. mit dessen Einverständnis ranty, repairs may only be carried out by the AWP or - with
durch geschultes Instandhaltungspersonaldes Betrei- his consent - by specially-trained maintenance personel
bers der Anlage vorgenommen werden. working for the plant operator.
! Sicherheitshinweise beachten ! Safty instructions please notice
- Auswechseln der Spindelabdichtung - - Replacing the stem sealing -

( bei Betrieb der Anlage ) ( during operation of the system )
1. Kappe abschrauben 1. Screw off the cap
DN 10 - 32 40 - 65 80 - 100 125 - 150 200 - 400

SW 41 60 41 85 90
2. Spindel mittels Handrad bis zum Anschlag in 2. Move the stem by means of the uppermost
die oberste Stellung fahren. position
3. Schraubbuchse linksherum herausschrauben. 3. Screw off the screw bushing counter-clockwise.
Auf eventuell austretendes restliches Kältemittel The screw bushing should be kept loosely in the
! achten.Bis zum völligen Druckausgleich
Schraubbuchse lose im Deckelbelassen.
! cover until the pressure has equalized totally.
Only then should it be unscrewed completly.
Erst danach völlig herausschrauben
DN 10 - 32 40 - 65 80 - 100 125 - 150 200 - 400

SW 22 27 32 46 55
4. O-Ringe A, B; PTFE-Ring und Abstreifring ent- 4. Remove the o-ring seals A, B; PTFE-ring and the
fernen und durch neue ersetzen. scraper and replace them by new ones.
AVR 263 00 08.05.2006
Flachdichtring SB aus dem Einbauraum im Remove flat sealing ring SB from the seal housing
Deckel entfernen. in the cover.
5. Spindel säubern. 5. Clean the stem.
6. Neuen Flachdichtring SB in Deckel einlegen. 6. Insert a new flat sealing-ring SB into the cover.
Schraubbuchse mit Kältefett Lubricate the screw bushing with low-temperature
(RENAX UNITEMP 2) bzw. gleichwertiges ein- grease (RENAX UNITEMP 2) or any other appro-
fetten und handfest anziehen. priate lubricant and fasten it fingertight.
5 / 10
APS 06.30 - 10.1
7. Zur Dichtheitskontrolle ist die Spindel in Mittel- 7. For leakage test move the stem into central posi-
stellung zu bringen und der Deckelbereich mit tion and coat the cover area with a foaming agent..
Schaummitteln einzupinseln.
- Auswechseln Flachdichtring S und R bzw. - Replacing the flat sealing ring S and R , or
Spindel kpl. stem cmpl. ,
1. Ventil bis Anschlag öffnen. Deckelschrauben 1. Open the valve up to the limit stop. Loosen the
DIN 912 und DIN 931 lösen. cover screws German Standard DIN 912,DIN 931.
Auf eventuell austretendes restliches Kältemittel The cover screws should be kept loosely in the
! achten.Bis zum völligen Druckausgleich
Deckelschrauben lose im Gehäuse belassen.
! body until the pressure has equalized totally.
Only then should it be unscrewed completly.
Erst danach völlig herausschrauben
Schrauben DN 10 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400

screws M 6 6 6 6 6 6 6 8 8 10 16 16 16 16 20 24
DIN 912 DIN 933
SW 5 5 5 5 5 5 5 13 13 16 24 24 24 24 30 36
2. Deckelschrauben herausschrauben und 2. Unscrew cover screws and draw out the cover
Deckel einschließlich Innenteile am Handrad including internal parts by means of the
herausziehen. handwheel.
3. Handrad von der Spindel abschrauben und die 3. Screw the handwheel from the stem and turn the
Spindel nach Entfernen des Gewindestiftes stem out of the cover after having removed the
( nur DN80 bis 200) aus dem Deckel herausdrehen. headless pin (only DN80 to 200).
4. Flachdichtring R herausnehmen und ersetzen. 4. Remove the flat sealing ring R and replace it.
5. DN 10 bis 32: (siehe Bild 1.1) 5. DN 10 to 32: (see picture 1.1)
Mutter lösen, Scheibe abnehmen Remove the nut and washer,
und Flachdichtring S herausnehmen, the flat seal S can be taken off.
DN40 bis 150: (siehe Bild 1.0) DN40 to 150: (see picture 1.0)
Durch geeignete Verfahren Remove crimps from the valve
(Feilen, Sägen) Entfernen der Sicken am plate by means of suitable methods (such as filing,
Ventilteller, so daß die Scheibe und der sawing), so that the washer and the
Flachdichtring S abgenommen werden können . flat sealing ring S can be taken off .
DN200 bis 400: (siehe Bild 2.0) DN 200 to 400: (see picture 2.0)
Schrauben lösen, Scheibe abnehmen Remove screws and washer,
und Flachdichtring S herausnehmen. the flat seal S can be taken off.
Schrauben DN 200 - 400
6. DN 10 - 32 screws M 6x20
6. DN 10 - 32
Einlegen des neuen Flachdichtringes S, DIN 933 SW 10 Put in new flat seal, use the
Sicherung durch Scheibe und anziehen washer to lock the seal and tighten the nut,
der Mutter DN 40 - 150
DN 40 - 150 , Press the crimps into the valve plate
Eindrücken der Sicken durch geeignete by means of suitable method
Verfahren (z.B. Handhebelpresse), (e.q. hand lever press),
DN 200 - 400 DN 200 - 400
anziehen der Schrauben Tighten the screws.
Vor der Montage sind alle Einzelteile der Ventile zu rei- Before mounting, clean all component parts of the val-
nigen, die Spindel und der Deckel einzufetten. ves; grease stem and the cover.
Anschließend wird noch ein Flachdichtring K einge- Afterwards another flat sealing ring is inserted, the co-
legt, der Deckel aufgesetzt und mit den Schrauben ver is put back in its place and is tightened by means
gleichmäßig und über Kreuz angezogen. of the screws evenly and crosswise.
AVR 263 00 08.05.2006
DN 10 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400

M 6x20 6x22 8x25 10x30 16x45 16x55 20x55 24x65
DIN 912 8.8 DIN 933 8.8
SW 5 5 5 5 5 5 5 13 13 16 24 24 24 24 30 36 36
Anziehdrehmoment tightening moment [Nm]
10 10 10 10 10 10 10 25 25 49 210 210 210 210 425 730 730
6 / 10
APS 06.30 - 10.1

8.Transport und Lagerung 8.Transport, Storage
AWP-Absperrventile werden stoßgeschützt, mit Folie During transport, AWP shut off valves are protected
abgedeckt transportiert. against shocks and covered with plastic sheeting.
Die Lagerung hat in trockenen Räumen zu erfolgen.Es They should be stored in dry rooms.
ist auf den unversehrten Verschluß der Anschlußstut- Care has to be taken that the plugs of the connecting pie-
zen zu achten. ces are not damaged.
Verschmutzungen jeglicher Art müssen vom Innen- Any kind of soiling has to be kept away from the inside of
raum ferngehalten werden. the fitting.
Die außenliegenden Flächen der Armaturen sind mit ei- The external surfaces of the valves are provided with a lay-
nem Korrosionsschutzanstrich für trockene Lagerung er of anticorrosive paint for dry storing at room temperatu-
bei Raumtemperatur versehen, der mindestens 1 Jahr re, which remains effective for at least 1 year.
wirksam ist. The anticorrosive paint which is based on esterified
Der Korrosionsschutzanstrich auf Basis Epoxidhar- epoxy resin in combination with zinc phosphate, is a
zester in Verbindung mit Zinkphosphat ist ein guter good bonding agent for one or two-pot finishing coating
Haftvermittler für Deckanstrichstoffe auf 1- und 2- Kom- paints.
ponenten-Basis.
9.Garantie 9. Warranty
Die Garantieleistung für Erzeugnisse ist entspre- The warranty services for our products have been de-
chend den vertraglichen Bestimmungen im Liefer- fined in compliance with the regulations stipulated in
vertrag festgelegt. the contract of delivery.
10.Ersatzteile 10. Spare parts

Ersatzteile entsprechend Bild Seite 2: Spare parts according to the illustration sheet page 2:
Ersatzteilbestellung:(muß enthalten) Ordering Spare parts:(an order must contain):

-Anzahl - quantity
-Bezeichnung entspr. Bild für Typ - designation according to illustration sheet page 2
-Bestell-Nummer - stock number
-Nennweite der Armatur - nominal diameter of the fitting
-Baujahr der Armatur - year of construction of the fitting
Bestellbeispiel: Example for ordering

3 Stück, Spindel kpl. AVR, 263 00 3 pieces, stem cmpl. AVR, 363 02
263 02.13.5 060 00 1, 363 02.13.5 060 00 1,
DN 32, 06 / 1992 DN 32, 06 / 1992
O-Ring A o-ring seal A -CR 70- O-Ring B o-ring seal B -CR 70-
DN Abmessung
Abmessung Bestell-Nummer stock number dimension
10
73 75 91 Ø14 x 3 15 73 75 22 Ø22,x 2
20
73 75 91 Ø14 x 3 25 73 75 22 Ø22 x 2
73 75 91 Ø14 x 3 32 73 75 22 Ø22 x 2
73 75 59 Ø16 x 3 40 73 75 01 2Ø2 x 3
73 75 59 Ø16 x 3 50 73 75 01 Ø22 x 3
73 75 59 Ø16 x 3 65 73 75 01 Ø22 x 3
73 75 25 Ø20 x 3 80 73 75 03 Ø28 x 3
73 75 25 Ø20 x 3 100 73 75 03 Ø28 x 3
73 75 96 Ø28 x 5 125 73 75 16 Ø40 x 3
150
AVR 263 00 08.05.2006
73 75 96 Ø28 x 5 73 75 16 Ø40 x 3
73 75 97 Ø35 x 5 200 73 75 27 Ø50 x 3
73 75 97 Ø35 x 5 250 73 75 27 Ø50 x 3
73 75 97 Ø35 x 5 300 73 75 27 Ø50 x 3
73 75 97 Ø35 x 5 350 73 75 27 Ø50 x 3
73 75 97 Ø35 x 5 400 73 75 27 Ø50 x 3
7 / 10
APS 06.30 - 10.1
Handrad handwheel Kappe cap

DN Abmessung
10
163 01.08.5 280 00 3 Ø100 x 12/17 15 164 02.13.3 180 00 3 M36 x 1,5
20
163 01.12.5 280 00 3 Ø125 x 12/17 25 164 02.13.3 180 00 3 M36 x 1,5
163 01.12.5 280 00 3 Ø125 x 12/17 32 164 02.13.3 180 00 3 M36 x 1,5
163 01.14.5 280 00 3 Ø150 x 14/20 40 164 02.15.3 180 00 3 M52 x 1,5
163 01.14.5 280 00 3 Ø150 x 14/20 50 164 02.15.3 180 00 3 M52 x 1,5
163 01.17.5 280 00 3 Ø200 x 14/20 65 164 02.15.3 180 00 3 M52 x 1,5
163 01.17.5 280 00 3 Ø200 x 14/20 80 164 02.18.3 180 00 3 M60 x 2,0
163 01.19.5 280 00 3 Ø250 x 15/20 100 164 02.18.3 180 00 3 M60 x 2,0
163 01.20.5 280 00 3 Ø300 x 22/26 125 164 02.21.3 180 00 3 M76 x 2,0
163 01.21.5 280 00 3 Ø400 x 22/26 150 164 02.21.3 180 00 3 M76 x 2,0
163 01.23.5 280 00 3 Ø600 x 28/46 200 164 02.23.3 180 00 3 M80 x 2,0
163 01.23.5 280 00 3 Ø600 x 28/46 250 164 02.23.3 180 00 3 M80 x 2,0
163 01.23.5 280 00 3 Ø600 x 28/46 300 164 02.23.3 180 00 3 M80 x 2,0
163 01.23.5 280 00 3 Ø600 x 28/46 350 164 02.23.3 180 00 3 M80 x 2,0
Ø600 x 28/46 400
PTFE-Ring PTFE-ring seal Abstreifring scraper -NBR 85-

Abmessung DN Abmessung
Bestell-Nummer stock number dimension Bestell-Nummer stock number dimension
10
72 84 00 Ø14 x Ø19 / 3,9 15 73 98 55 A 14
20
72 84 00 Ø14 x Ø19 / 3,9 25 73 98 55 A 14
72 84 00 Ø14 x Ø19 / 3,9 32 73 98 55 A 14
72 84 01 Ø16 x Ø21 / 3,9 40 73 98 38 A 16
72 84 01 Ø16 x Ø21 / 3,9 50 73 98 38 A 16
72 84 01 Ø16 x Ø21 / 3,9 65 73 98 38 A 16
72 84 02 Ø20 x Ø25 / 3,9 80 73 98 41 A 20
72 84 02 Ø20 x Ø25 / 3,9 100 73 98 41 A 20
72 84 03 Ø28 x Ø28 / 5,9 125 73 98 54 A 28
72 84 03 Ø28 x Ø28 / 5,9 150 73 98 54 A 28
72 84 04 Ø35 x Ø36,8 / 6,0 200 73 75 37 A 35
72 84 04 Ø35 x Ø36,8 / 6,0 250 73 75 37 A 35
72 84 04 Ø35 x Ø36,8 / 6,0 300 73 75 37 A 35
72 84 04 Ø35 x Ø36,8 / 6,0 350 73 75 37 A 35
72 84 04 Ø35 x Ø36,8 / 6,0 400 73 75 37 A 35
AVR 263 00 08.05.2006
8 / 10
APS 06.30 - 10.1

Schraubbuchse screw bushing Spindel kpl. stem cmpl Spindel kpl. stem cmpl
DN Typ type: 263 01, 264 01 Typ type: 263 04, 264 04 DN
Bestell-Nummer stock number Bestell-Nummer stock number Bestell-Nummer stock number
10 10
15 363 02.13.8 142 00 2 263 01.10.5 060 00 1 263 10.10.5 060 00 1 15
20 20
25 363 02.13.8 142 00 2 263 01.13.5 060 00 1 263 03.13.5 060 00 1 25
32 363 02.13.8 142 00 2 263 01.13.5 060 00 1 263 03.13.5 060 00 1 32
40 164 02.15.8 142 00 2 263 01.15.5 060 00 1 263 03.15.5 060 00 1 40
50 164 02.15.8 142 00 2 263 01.15.5 060 00 1 263 03.15.5 060 00 1 50
65 164 02.15.8 142 00 2 263 01.17.5 060 00 1 263 03.17.5 060 00 1 65
80 164 02.18.8 142 00 2 263 01.18.5 060 00 1 263 03.18.5 060 00 1 80
100 164 02.18.8 142 00 2 263 01.19.5 060 00 1 263 03.19.5 060 00 1 100
125 164 02.21.8 142 00 2 263 01.20.5 060 00 1 263 03.20.5 060 00 1 125
150 164 02.21.8 142 00 2 263 01.21.5 060 00 1 263 03.21.5 060 00 1 150
200 164 02.23.8 142 00 2 263 01.23.5 060 00 1 263 03.23.5 060 00 1 200
250 164 02.23.8 142 00 2 263 01.24.5 060 00 1 ------- 250
300 164 02.23.8 142 00 2 263 01.25.5 060 00 1 ------- 300
350 164 02.23.8 142 00 2 263 01.26.5 060 00 1 ------- 350
400 400
Flachdichtring SB flat sealing ring SB Flachdichtring K flat sealing ring K

AFM30 DN Abmessung
10
363 02.13.4 143 00 3 Ø14 x Ø25,5 x 2,0 15 163 01.10.4 146 00 3 Ø30 x Ø34,9 x 1,5
20
363 02.13.4 143 00 3 Ø14 x Ø25,5 x 2,0 25 163 01.13.4 146 00 3 Ø43 x Ø49,0 x 1,5
363 02.13.4 143 00 3 Ø14 x Ø25,5 x 2,0 32 163 01.13.4 146 00 3 Ø43 x Ø49,0 x 1,5
164 02.15.4 143 00 3 Ø16 x Ø26,9 x 2,0 40 163 01.15.4 146 00 3 Ø62 x Ø68,8 x 1,5
164 02.15.4 143 00 3 Ø16 x Ø26,9 x 2,0 50 163 01.15.4 146 00 3 Ø62 x Ø68,8 x 1,5
164 02.15.4 143 00 3 Ø16 x Ø26,9 x 2,0 65 163 01.17.4 146 00 3 Ø76 x Ø84,8 x 1,5
164 02.18.4 143 00 3 Ø20 x Ø32,9 x 2,0 80 163 01.18.4 146 00 3 Ø94 x Ø105 x 1,5
164 02.18.4 143 00 3 Ø20 x Ø32,9 x 2,0 100 163 01.19.4 146 00 3 Ø115 x Ø129 x 1,5
164 02.21.4 143 00 3 Ø28 x Ø45,9 x 2,0 125 163 01.20.4 146 00 3 Ø140 x Ø159 x 1,5
164 02.21.4 143 00 3 Ø28 x Ø45,9 x 2,0 150 163 01.21.4 146 00 3 Ø170 x Ø188,5 x 2,0
164 02.23.4 143 00 3 Ø35 x Ø54,9 x 2,0 200 163 01.23.4 146 00 3 Ø240 x Ø259 x 2,0
164 02.23.4 143 00 3 Ø35 x Ø54,9 x 2,0 250 163 01.24.4 146 00 3 Ø296 x Ø320 x 2,0
164 02.23.4 143 00 3 Ø35 x Ø54,9 x 2,0 300 263 02.25.4 146 00 3 Ø338 x Ø366 x 2,0
164 02.23.4 143 00 3 Ø35 x Ø54,9 x 2,0 350 263 02.26.4 146 00 3 Ø370 x Ø400 x 2,0
Ø35 x Ø54,9 x 2,0 400 26300B27.4146 00 3 440 x 478 x 2,0
Flachdichtring R flat sealing ring R PTFE Flachdichtring S flat sealing ring S PTFE
Abmessung DN Abmessung
Bestell-Nummer stock number dimension Bestell-Nummer stock number dimension
10
164 02.10.2 145 00 3 Ø16 x Ø21,6 x 2,0 15 163 01.10.2 144 00 3 Ø10,2 x Ø24,8 x 3,0
20
164 02.10.2 145 00 3 Ø16 x Ø21,6 x 2,0 25 163 01.13.2 144 00 3 Ø20,2 x Ø33,8 x 3,0
164 02.10.2 145 00 3 Ø16 x Ø21,6 x 2,0 32 163 01.13.2 144 00 3 Ø20,2 x Ø33,8 x 3,0
264 00.17.2 145 00 3 Ø20 x Ø33,9 x 2,0 40 163 01.15.2 144 00 3 Ø32,2 x Ø47,8 x 4,0
264 00.17.2 145 00 3 Ø20 x Ø33,9 x 2,0 50 163 01.15.2 144 00 3 Ø32,2 x Ø57,8 x 4,0
264 00.17.2 145 00 3 Ø20 x Ø33,9 x 2,0 65 163 01.17.2 144 00 3 Ø55,2 x Ø71,0 x 4,0
164 02.18.2 145 00 3 Ø26 x Ø40,0 x 3,0 80 163 01.18.2 144 00 3 Ø68,0 x Ø89,0 x 5,0
164 02.18.2 145 00 3 Ø26 x Ø40,0 x 3,0 100 163 01.19.2 144 00 3 Ø 86 x Ø109 x 5,0
164 02.21.2 145 00 3 Ø36 x Ø52,0 x 3,0 125 163 01.20.2 144 00 3 Ø112 x Ø134 x 6,0
AVR 263 00 08.05.2006
164 02.21.2 145 00 3 Ø36 x Ø52,0 x 3,0 150 163 01.21.2 144 00 3 Ø130 x Ø163 x 6,0
164 02.23.2 145 00 3 Ø45 x Ø70,0 x 3,0 200 163 01.23.2 144 00 3 Ø185 x Ø218 x 6,0
164 02.23.2 145 00 3 Ø45 x Ø70,0 x 3,0 250 163 01.24.2 144 00 3 Ø230 x Ø275 x 6,0
164 02.23.2 145 00 3 Ø45 x Ø70,0 x 3,0 300 263 02.25.2 144 01 3 Ø289 x Ø322 x 6,0
164 02.23.2 145 00 3 Ø45 x Ø70,0 x 3,0 350 263 02.26.2 144 00 3 Ø322 x Ø355 x 6,0
Ø45 x Ø70,0 x 3,0 400 26300B27.2144 00 3 Ø361 x Ø398 x 8,0
9 / 10
APS 06.30 - 10.1

11.Kennzeichnung 11. Specification
Die Kennzeichnung der AWP-Absperrventil The specification of the AWP-shut-off valves complies
erfolgt entsprechend DIN 3158 . with German Standard DIN 3158 .
- Kennzeichenschild auf Gehäuse - specification label of the casing
month/year
Typ type EN 12284
DN - PN ,PS
maker's - no. Made in Germany
siehe Seite 2 see page 2
PS [bar] - maximal zulässiger Betriebsüberdruck
permissible working pressure
PN [--] - Nenndruckstufe als Kennzeichen gleicher Anschlußmaße bei gleicher DN
level of nominal pressure as a characteristic for corresponding fitting dimensions and DN
DN [mm] - Nennweite nominal diameter
EN 12284 - Kältemittelarmaturen, Sicherheitstechnische Festlegungen, Prüfung, Kennzeichnung
European Standard: refrigerant valves; requirements, testing, marking
12. Hinweis auf Restgefahren 12. Information on risks in conformance to

entsprechend der Druckgerätericht- pressure appliance directive
linie (97/23/EG) (97/23/EG)
Vom Hersteller nicht zu vermeidende Remaining risks which cannon be avoided by the
Restgefahren bestehen durch: manifacturer arise because of:
- unbefugtes Lösen des Deckels - unauthorised loosening of the cover

während des Betriebes bzw. Lösen during operation or removing of the screw
der Schraubbuchse ohne bushing without activation of the back sealing
Aktivierung der Rückdichtung
- unsachgemäße Montage von Flanschver- - incorrect assembly of the flange connections

bindungen (Eingangs- und Ausgangsflansch, (inlet and outlet flange, lid)
Deckel)
- Verschmutzungen im Betriebsmedium bzw. - dirt in the service medium or inappropiate
unsachgemäßer Umgang mit Einbauteilen handling of the internal fittings may cause
können zu Beschädigungen an der damage to the seat seal
Sitzdichtung führen
- Nichtbeachtung der Einsatzgrenzen - ignore of operating range and

und Herstellervorschriften entsprechend manufacturer rules acc. to this
AVR 263 00 08.05.2006
dieser Betriebsvorschrift operating instruction
10 / 10
Engineering Sheet
Instruction sheet
Pressure and
Customer: FES System Inc. US Temperature Controls
Pressure Transmitter Type : AKS 3000

Measuring range
Customer P/N [psi]
745-007000-100 Pa 0 to 100 psia
745-007000-500 Pe 1) 0 to 500 psig
1)
sealed gauge
Dimensions: In mm
17
ø33
PR
TR
Typ Product label blue
40
xxx-xxxxxx-xxx No
Customer P/N
13
27
14.5
16
1/4"-18 NPT
Electrical
Connection :
Plug Pg 9 Output signal
1
EN 175301-803 4-20 mA
3 1 Supply +
2 Supply -
2 3 NC
Connected to enclosure
Technical Data: Output signal : 4 to 20 mA

Pressure connection : 1/4" - 18 NPT
Electrical connection : Without gasket and DIN plug EN 175301-803
Other specifications : Look next page
App. Corr. Valid serial no.
070508-1
Date Discontinued serial no. 070212-3
05-2007
Danfoss reserves the right to alter its produts without notice. This also applies to products already on order provided that such alterations can be
made without subsequential changes being necessary in specifications already agreed.
Engineering Sheet
Pressure Transmitter Type : AKS 3000
Performance, IEC 60770

Accuracy <± 1.0 %FS (typ.)
<± 2.0 %FS (max.)
Non-linearity (Best fit straight line) <± 0.5 %FS
Hysteresis and repeatability <± 0.1 %FS
Thermal zero point shift <± 0.2 %FS/10K
< ± 0.4 %FS/10K
Thermal sensitivity (span) shift <± 0.2 %FS/10K
< ± 0.4 %FS/10K
Response time < 4 ms
Overload pressure (static) 6xFS
MWP (Max working pressure 75 bar/ 1088 psi) or 2xFS
Burst pressure > 6xFS
Electrical specifications.
Nom. output signal 4-20 mA
Supply voltage [Vsupply], polarity protected 10 to 30 V dc
Voltage dependency < ± 0.2 %FS/10V
Current limitation 28 mA (typ.)
Vsupply - 10 [V]
Max. load [RL ] RL < --------------------- [Ohm]
0 .02 [A]
Environmental conditions.
Operating temperature range -40°F to +176°F
Compensated temperature range LP: -22°F to +104°F
HP: 32°F to +176°F
Transport temperature range -58°F to +185°F
EMC-Emission EN 61000-6-3
EMC-Immunity:
Electrostatic discharge Air mode 8 kV EN 61000-6-2
Contact mode 4 kV EN 61000-6-2
RF, field 10 V/m, 26 MHz - 1GHz EN 61000-6-2
RF, conducted 10 Vrms, 150 kHz - 30 MHz EN 61000-6-2
Transient, burst 4 kV (CM), Clamp EN 61000-6-2
Transient surge 1 kV (CM, DM), Rg = 42 Ohm EN 61000-6-2
Insulation resistance > 100 MOhm at 100 V dc
Mains frequency test 500 V, 50 Hz SEN 361503
Vibration stability Sinusoidal, 20g, 25 Hz - 2 kHz IEC 60068-2-6
Random, 7.5grms, 5 Hz - 1 kHz IEC 60068-2-34
IEC 06068-2-36
Shock resistance Shock, 500 g / 1 ms IEC 60068-2-27
Free fall IEC 60068-2-32
Enclosure IP 65 - IEC 60529
Mechanical characteristics
Wetted parts, material EN 10088-1
1.4404 (AISI316L)
Enclosure material EN 10088-1
1.4404 (AISI316L)
Weight 0.25 lbs.
UL recognized for sale in the USA and Canada File no. E310 24
CE marked according to the EMC directive 89/336/EC
Valid serial no.

070508-1
Discontinued serial no. 070212-3
Stop Needle Valves,
type SNV-ST
REFRIGERATION AND
AIR CONDITIONING Technical leaflet
Technical leaflet Stop Needle Valve, type SNV-ST
Contents Page
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Material specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Dimensions and weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2 RD7BB322 © Danfoss A/S (RC-CMS / MWA), 02 - 2005

Introduction
SNV-ST
SNV-ST (extended branch)
SNV-ST
(manometer connection)
SNV-ST valves are designed to meet all industrial

refrigeration application requirements. Designed
as service valves they provide favourable flow
characteristics.
Features Applicable to all common refrigerants Housing and bonnet are made from low
including R717 and R744 (CO2) and non temperature steel according to requirements
corrosive gases/liquids. of the Pressure Equipment Directive and other
Suitable for "heavy duty" industrial international classification authorities.
applications having a very sturdy and safe Valve safety is enhanced with the spindle
design including high pressures and wide being secured such that it cannot be
temperature range. unscrewed.
The SNV-ST valves have backseating (metal to Max. operating pressure:
metal). 52 bar g ( 754 psig)
Compact and light valve for easy handling and Valves for higher operating pressure available
installation on request
No special flow direction required. Full temperature range:
–60/+150°C (–76/+302°F)
Provide high flow characteristics.
Each valve type is clearly marked with type
and size.
Technical data Refrigerants Temperature range

Applicable to all common refrigerants –60/+150°C (–76/+302°F).
including R 717 and R744 (CO2) and Maximum working pressure
non corrosive gases/liquids. For further The valve is designed for: Maximum operating
information please see installation instruction pressure of 52 bar g ( 754 psig).
for SNV-ST. Valves for higher operating pressure available
on request.
For further information please contact your
local Danfoss Sales Company.
© Danfoss A/S (RC-CMS / MWA), 02 - 2005 RD7BB322 3

Design Connections Installation

Available with the following connections: No special flow direction is required.
CD Cutting ring The valve is designed to withstand high
internal pressures. However, the piping
MPT Male NPT ANSI system in general should be designed
FPT Female NPT ANSI to avoid liquid traps and reduce the risk
G of hydraulic pressure caused by thermal
W Welding connection expansion. For further information refer
to installation instruction for SNV-ST.
Housing
Made of special steel, approved for low
temperature operations.
Spindle
Equipped with stainless steel spindle, which is
ideal for O-ring sealing.
Connections
Cutting ring, DIN 3861 & DIN 3901 class L,

CD 6 du = 6 mm
CD10 Cutiing ring, DIN 3861 & DIN 3901 class L,
du = 10 mm
1/4 MPT du is external pipe diameter

1/4” male NPT
3/8 MPT 3/8” male NPT
1/ " male NPT Note: Fittings not included
1/ NPT 2
2
1/4 FPT 1/4” female NPT

3/8” female NPT
3/8 FPT
G 1/2 G 1/2”
1/2” welding connection

W OD = 21.3 mm (0.839 in.)
T = 2.3 mm (0.091 in.)

Material specification
SNV-ST
SNV-ST (extended branch)
No. Part Material EN JIS ASTM

1 Housing Steel P285QH SFL 2 LF2
EN 10222-4 G 3205 A350
2 Spindle Stainless steel X8CrNiS 18-9 SUS 303 AISI 303
EN 10088
3 Locking ring Steel
4 Sealing ring Teflon
5 Seal cap gasket Nylon
6 Gland nut Steel
7 Seal cap Steel

Dimensions and weights
SNV-ST SNV-ST
(manometer conn.)
Type C G Weight Type C G Weight
mm 115 32 0.36 kg SNV-ST mm 127 45 0.56 kg

SNV-ST
in. 4.53 1.26 0.79 lb (Man.) in. 5.00 1.77 1.22 lb
SNV-ST
(extended branch)
Type C G L Weight
SNV-ST mm 131 32 50 0.60 kg

Ext.branch in. 5.16 1.26 1.97 1.32 lb
SNV-ST mm 181 32 100 0.60 kg
Ext.branch in. 7.13 1.26 3.94 1.32 lb
SNV-ST mm 206 32 125 0.60 kg
Ext.branch in. 8.11 1.26 4.92 1.32 lb
SNV-ST mm 231 32 150 0.60 kg
Specified weights are approximate
values only. Ext.branch in. 9.10 1.26 5.91 1.32 lb

Ordering
How to order
The table below is used to
identify the valve required.
Please note that the type
codes only serve to identify
the valves, some of which may
not form part of the standard
product range. For further
information please contact
your local Danfoss Sales
Company.
Important!
Where products need to be
L
certified according to specific
certification societies or where
higher pressures are required,
the relevant information
should be included at the time SNV-ST SNV-ST (Extended Branch)
of order. Fig. 1 Fig. 2
See figure 1 Side branch connection Bottom branch connection Type Quantity Code No.
CD 10 CD 10 SNV-ST CD10-CD10 1 pc. 148B3740
CD 10 CD 10 SNV-ST CD10-CD10 30 pcs. 148B4177
CD 10 ¼ MPT SNV-ST CD10-1/4MPT 1 pc. 148B3741
CD 6 ¼ MPT SNV-ST CD6-1/4MPT 1 pc. 148B3742
CD 10 3/ MPT SNV-ST CD10-3/8MPT 1 pc. 148B3743
8
CD 6 3/ MPT SNV-ST CD6-3/8MPT 1 pc. 148B3744
8
G ½ (external) G ½ (external) SNV-ST G1/2-G1/2 1 pc. 148B3745
G ½ (external) G ½ (external) SNV-ST G1/2-G1/2 30 pcs. 148B4179
¼ FPT ¼ MPT SNV-ST 1/4FPT-1/4MPT 1 pc. 148B3746
¼ FPT ¼ MPT SNV-ST 1/4FPT-1/4MPT 30 pcs. 148B4180
3/ FPT 3/ MPT SNV-ST 3/8FPT-3/8MPT 1 pc. 148B3747
8 8
3/ FPT 3/ MPT SNV-ST 3/8FPT-3/8MPT 30 pcs. 148B4181
8 8
3/ FPT ½ MPT SNV-ST 3/8FPT-1/2MPT 30 pcs. 148B4233
8
CD ¼ (external) ¼ MPT (external) SNV-ST CD 1/4-1/4MPT 30 pcs. 148B4220
CD 3/8 3/ MPT
8 SNV-ST CD3/8-3/8MPT 30 pcs. 148B4221
CD 3/8 ¼ MPT SNV-ST CD3/8-1/4MPT 30 pcs. 148B4222
¼ FPT ¼ FPT SNV-ST 1/4FPT-1/4FPT 30 pcs. 148B4223
½ MPT ½ MPT SNV-ST 1/2MPT-1/2MPT 30 pcs. 148B4224
3/ FPT 3/ FPT SNV-ST 3/8FPT-3/8FPT 30 pcs. 148B4225
8 8
½ MPT 3/ FPT SNV-ST 1/2MPT-3/8FPT 30 pcs. 148B4226
8
CD 6 ¼ MPT SNV-ST CD6-1/4MPT* 30 pcs. 148B4216
7/ UNF ¼ MPT SNV-ST 7/16UNF-1/4MPT 30 pcs. 148B4230
16
* With handwheel
Extended Branch
See figure 2 Side branch connection Bottom branch connection Type Quantity Code No.
L50 = 50 mm (2 in.) CD10 W½ L100 SNV-ST CD10-W1/2 L100 1 pc. 148B3768
L100 = 100 mm (4 in.)
CD10 W½ L100 SNV-ST CD10-W1/2 L100 30 pcs. 148B4210
L150 = 150 mm (6 in.)
G½ W½ L100 SNV-ST G1/2-W1/2 L100 1 pc. 148B3769
G ½ (external) W½ L100 SNV-ST G1/2-W1/2 L100 30 pcs. 148B4211
G ¼ (internal) R¼ L50 (external) SNV-ST G1/4-R1/4 L50 30 pcs. 148B4231
¼ FPT ¼ MPT L100 SNV-ST 1/4FPT-1/4MPT L100 30 pcs. 148B4232

Ordering (cont.) Manometer connection

Side branch connection Bottom branch connection Type Quantity Code No.
G½ G½ SNV-ST G½ Man 1 pc. 148B3778
Accessories Type Connection type Quantity Code no.
Weld nipple incl. union nut

CD 10 1 pc. 2469+008
and O-ring
Blind nut incl. gasket G 1/2 1 pc. 2469+056
CD 6 Cutting ring + union nut CD 6 1 pc. 148B4182
1 pc. 148B4183
CD 10 Cutting ring + union nut CD 10
60 pcs. 148B4186

Refrigeration and Air Conditioning Controls
Technical leaflet
Stop valves,
Type SVA-ST and SVA-LT 15 (1/2 in.) - 200 (8 in.)
REFRIGERATION AND AIR CONDITIONING

Technical leaflet Stop valves, type SVA-ST and SVA-LT 15 (1/2 in.) - 200 ( 8 in.)
Contents Page
Introduction .................................................................................................................................. 3
Features ....................................................................................................................................... 3
Additional features for low temperature version (SVA-LT) ........................................................... 3
Technical data .............................................................................................................................. 4
Design .......................................................................................................................................... 4
Connections ................................................................................................................................. 5
Material specification ................................................................................................................... 6
SVA-ST and SVA-LT 15 - 40 (½ - 1½ in.) ............................................................................... 6
SVA-ST and SVA-LT 50 - 65 (2 - 2½ in.) ................................................................................ 7
SVA-ST and SVA-LT 80 - 200 (3 - 8 in.) ................................................................................. 8
Dimensions and weights .............................................................................................................. 9
SVA 15 - 40 (½ - 1½ in.) angle type with cap / handwheel ..................................................... 9
SVA 15 - 40 (½ - 1½ in.) globe type with cap / handwheel ................................................... 10
SVA 50 - 65 (2 - 2½ in.) angle type with cap / handwheel .................................................... 11
SVA 50 - 65 (2 - 2½ in.) globe type with cap / handwheel .................................................... 12
SVA 80 - 200 (3 - 8 in.) angle type with cap / handwheel ..................................................... 13
SVA 80 - 200 (3 - 8 in.) globe type with cap / handwheel ..................................................... 14
Ordering ..................................................................................................................................... 15
2 RD7AN322  Danfoss A/S (RC-CM / hbs), 01 - 2003

Introduction
SVA-ST and SVA-LT are angle and globe type The valves are designed to give favorable
stop valves which are designed to meet all flow characteristics and are easy to dismantle
industrial refrigeration application and repair when necessary. The valve cone is
requirements. designed to ensure perfect closing.
Features Applicable to all common refrigerants Internal metal backseating

including R 717 and non corrosive gases/ - DN 15 - 65 (1/2 - 21/2 in.)
liquids dependent on sealing material Internal PTFE backseating
compatibility - DN 80 - 200 (3 - 8 in.)
Available with heavy duty industrial Standard bonnet is suitable for installation in
handwheel for frequent operation or vented normal insulated systems
cap for infrequent operation
Housing and bonnet material are low
Available in angle and globe type with temperature steel according to requirements
standard bonnet or extended bonnet for of the Pressure Equipment Directive and
insulated systems other international classification authorities
Each valve is clearly marked with type, size Pressure range:

and performance range Standard version
SVA-ST: 40 bar g (580 psi g)
The seal cap can be fastened by seal wire
to prevent unauthorized operation Temperature range:
Standard version
Can accept flow in both directions –50/+150oC (–58/+302oF)
Classification: DNV, LR, SAQ, CRN, BV etc.

To get an updated list of certification on the
products please contact your local Danfoss
Sales Company
Additional features for low Low temperature version with extended Pressure range:
temperature version bonnet for insulated low temperature Low temperature version
(SVA-LT) applications SVA-LT: 40 bar g (580 psi g)
Special springloaded low temperature
Temperature range:
spindle seal
Low temperature version
–60/+150°C (–76/+302°F)
Stainless steel bolts
 Danfoss A/S (RC-CM / hbs), 01 - 2003 RD7AN322 3

Design Connections For further details / restrictions - see

Available with the following connections: Installation Instruction.
Butt-weld DIN (2448)
Butt-weld ANSI (B 36.10 Schedule 80), Installation
- DN 15 - 40 (1/2 - 11/2 in.) It is recommended that the valves be installed
Butt-weld ANSI (B 36.10 Schedule 40), in the direction of flow indicated by the arrow
- DN 50 - 200 (2 - 8 in.) on the valve body. The valve can be installed
Socket Weld (ANSI B 16.11), in the opposite direction but this slightly
- DN 15 - DN 50 (1/2 - 2 in.) reduces the kv-value (Cv-value).
FPT Female Pipe Thread, NPT The valve is designed to withstand high internal
(ANSI/ASME B 1.20.1) , pressure. However, the piping system in
- DN 15 - 32 (1/2 - 11/4 in.) general should be designed to avoid liquid traps
Housing and reduce the risk of hydraulic pressure
Made of special, cold resistant steel approved caused by thermal expansion.
for low temperature operations. For further information refer to installation
Valve cone instructions for SVA ST and LT.
The valve cone can be turned on the spindle,
thus there will be no friction between the cone
and the seat, when the valve is opened and
closed. A teflon tightening ring provides perfect
sealing with a minimum closing momentum.
Spindle
Made of polished stainless steel, ideal for
O-ring sealing.
Packing gland
Standard version (ST):
The standard packing gland ensures a perfect
tightness in the range: –50/+150°C
(–58/+302°F). The packing glands are Example of Marking Ring, Valve type SVA-ST
equipped with a scraper ring to prevent pene-
tration of dirt and ice into the packing gland.
Low temperature version (LT):
This comprises a springloaded seal packing
gland which ensures a perfect tightness in the
range: –60/+150°C (–76/+302°F). The packing
glands are equipped with a scraper ring to
prevent penetration of dirt and ice into the
packing gland.
Pressure Equipment Directive (PED)
SVA-ST and LT valves are approved
according to the European standard specified Example of Marking Ring, Valve type SVA-LT
in the Pressure Equipment Directive and are
CE marked.
SVA-ST and LT valves

Nominal bore DN≤ 25 mm (1 in.) DN32-80 mm (1¼ - 3 in.) DN100 - 200 mm (4 - 8 in.)
Classified for Fluid group I
Category Article 3, paragraph 3 II III
Technical data Refrigerants Temperature Range

Applicable to all common non flammable Standard version (ST):
refrigerants including R 717 and non –50/+150°C (–58/+302°F).
corrosive gases/liquids dependent on
sealing material compatability. Low temperature version (LT):
For further information please see –60/+150°C (–76/+302°F).
installation instruction for SVA ST and LT.
Pressure range
Flammable hydrocarbons are not The valves are designed for max. working
recommended. For further information please pressure 40 bar g (580 psig), for both
contact your local Danfoss Sales Company. standard and low temperature versions.

Connections Size Size OD T OD T kv-angle kv-globe Cv-angle Cv-globe

mm in. mm mm in. in. m3/h m3/h USgal/min USgal/min
DIN Butt-weld DIN (2448)

15 /2
1 21.3 2.3 0.839 0.091 7.0 4.9 8.1 5.7
20 /4
3 26.9 2.3 1.059 0.091 14.6 10.2 16.9 11.8
25 1 33.7 2.6 1.327 0.103 24.8 17.4 28.8 20.2
32 11/4 42.4 2.6 1.669 0.102 42.6 29.8 49.4 34.6
40 11/2 48.3 2.6 1.902 0.103 45.2 31.6 52.4 36.7
50 2 60.3 2.9 2.37 0.11 80 65 93 76
65 21/2 76.1 2.9 3 0.11 120 97 140 113
80 3 88.9 3.2 3.50 0.13 182 152 211 176
100 4 114.3 3.6 4.50 0.14 313 278 363 323
125 5 139.7 4.0 5.50 0.16 514 470 596 545
150 6 168.3 4.5 6.63 0.18 785 597 911 693
200 8 219.1 6.3 8.63 0.25 1168 1024 1355 1188
Size Size OD T OD T kv-angle kv-globe Cv-angle Cv-globe

mm in. mm mm in. in. m3/h m3/h USgal/min USgal/min
ANSI Butt-weld ANSI (B 36.10 Schedule 80)

15 1
/2 21.3 3.7 0.839 0.146 7.0 4.9 8.1 5.7
20 3
/4 26.9 4.0 1.059 0.158 14.6 10.2 16.9 11.8
25 1 33.7 4.6 1.327 0.181 24.8 17.4 28.8 20.2
32 11/4 42.4 4.9 1.669 0.193 42.6 29.8 49.4 34.6
40 11/2 48.3 5.1 1.902 0.201 45.2 31.6 52.4 36.7
Butt-weld ANSI (B 36.10 Schedule 40)

50 2 60.3 3.9 2.37 0.15 80 65 93 76
65 21/2 73.0 5.2 2.87 0.20 120 97 140 113
80 3 88.9 5.5 3.50 0.22 182 152 211 176
100 4 114.3 6.0 4.50 0.24 313 278 363 323
125 5 141.3 6.6 5.56 0.26 514 470 596 545
150 6 168.3 7.1 6.63 0.28 785 597 911 693
200 8 219.1 8.2 8.63 0.32 1168 1024 1355 1188
Size Size ID T ID T L L kv-angle kv-globe Cv-angle Cv-globe

mm in. mm mm in. in. mm in. m3/h m3/h USgal/min USgal/min
SOC Socket welding ANSI (B 16.11)

15 /2
1 21.8 6.0 0.858 0.235 10 0.39 7.0 4.9 8.1 5.7
20 /4
3 27.2 4.6 1.071 0.181 13 0.51 10.0 7.0 11.9 8.1
25 1 33.9 7.2 1.335 0.284 13 0.51 24.8 17.4 28.8 20.2
32 11/4 42.7 6.1 1.743 0.240 13 0.51 42.6 29.8 49.4 34.6
40 11/2 48.8 6.6 1.921 0.260 13 0.51 45.2 31.6 52.4 36.7
50 2 61.2 6.2 2.41 0.24 16 0.63 80 65 93 76
Size Size Inside pipe thread kv-angle kv-globe Cv-angle Cv-globe

mm in. m3/h m3/h USgal/min USgal/min
FPT FPT inside pipe thread, NPT (ANSI/ASME B 1.20.1)

15 1
/2 (1/2 × 14 NPT) 8.5 6.0 9.9 7.0
20 3
/4 (3/4 × 14 NPT) 10 7.0 11.6 8.1
25 1 (1 × 11.5 NPT) 32 22.4 37.1 26.0
32 11/4 (11/4 × 11.5 NPT) 36 25.2 41.8 29.3

Material specification
SVA-ST and SVA-LT 15 - 40 (1/2 - 11/2 in.)
SVA-ST and SVA-LT

No. Part Material DIN ISO ASTM
1 Housing Steel P285 QH LF2A350
EN10222-4
2 Bonnet, flange Steel P285 QH LF2A350

EN10222-4
3 Bonnet, Insert Steel 9SMn28 Type 2 1213

1651 R 683/9 SAE J403
4 Spindle Stainless steel X10CrNiS189 Type 17 AISI 303
17440 683/13
5 Cone Steel 9SMn28, 1651 Type 2, R 683/9 1213, SAE J403
Cone seal Teflon (PTFE)
8 Packing gland Steel 9SMn28, 1651 Type 2, R 683/9 1213, SAE J403
9 Packing washer Aluminium
- DN 15 - 20 (1/2 - 3/4 in.)
O-ring Cloroprene (Neoprene)
- DN 25 - 40 (1 - 11/2 in.)
10-11 O-ring Cloroprene (Neoprene)
13 O-ring Cloroprene (Neoprene)
14 Handwheel Steel
15 Washer Stainless steel (A2)
16 Screw Stainless steel (A2)
17 Cap Aluminium
18 Gasket for cap Nylon
20 Identification ring Stainless steel
SVA-ST
12 Bolts Steel Quality 8.8* Quality 8.8* Grade 5
SVA-LT
12 Bolts Stainless steel A2-70 A2-70 Type 308
25 U-sleeve sealing PTFE + Stainless steel
*) Special alloy for low temperature application. Alternatively A2-70.

SVA-ST and SVA-LT 50 - 65 (2 - 21/2 in.)
SVA-ST and SVA-LT

1 Housing Steel P285 QH LF2A350
EN10222-4
3 Valve bonnet Steel P285 QH LF2A350

EN10222-4
4 Spindle Stainless steel X8CrNiS18-9 Type 17 AISI 303

17440 R 683/13
8 Packing Gland Steel 9SMn28, 1651 Type 2, R 683/9 1213, SAE J403
14 Handwheel Steel
15 Washer Stainless steel (A2)
16 Nut Stainless steel (A2)
17 Cap Aluminium
18 Gasket for cap Nylon (PA 6)
SVA-ST
SVA-LT
10 U-sleve sealing PTFE + Stainless steel

SVA-ST and SVA-LT 80 - 200 (3 - 8 in.)
SVA-ST and SVA-LT

1 Housing Steel G20Mn5 QT LCC, A352
SEW 685
3 Valve bonnet Steel P285 QH TW6, 2604/3 LF2A350
EN10222-4
4 Spindle Stainless steel X5CrNi1810 Type 11, AISI 304,

17440 683/13 A276
8 Packing Gland Steel 9SMn28, 1651 Type 2, R 683/9 1213, SAE J403
14 Handwheel Steel
15 Washer Stainless steel
16 Nut Stainless steel
17 Cap Aluminium
18 Gasket for cap Nylon (PA 6)
19 Soft backseat Teflon (PTFE)
21 Wear ring Teflon (PTFE)
SVA-ST
SVA-LT
10 U-sleeve sealing PTFE + Stainless steel

Dimensions and weights SVA 15 - 40 (1/2 - 11/2 in. ) angle type with cap / handwheel
SVA-xx x x ANG CAP SVA-xx x x ANG H-WHEEL
Valve size K Cmax.1 Cmax.2 G ∅D1 ∅D2 H Weight

SVA-ST, Butt-weld and threaded
SVA 15 - 20 mm 4 178 189 45 60 38 60 1.4 kg
SVA (1/2 - 3/4) in. 0.16 7.00 7.44 1.77 2.36 1.5 2.36 3.1 lb
SVA 25 - 40 mm 12 234 268 55 80 50 70 2.4 kg
SVA (1 - 11/2) in. 0.47 9.21 10.55 2.17 3.15 1.97 2.76 5.3 lb
SVA-ST, Socket weld
SVA 32 - 40 mm 12 241 275 62 80 50 70 2.9 kg
SVA (11/4 - 11/2)in. 0.47 9.49 10.83 2.44 3.15 1.97 2.76 6.4 lb
SVA-LT, Butt-weld and threaded
SVA 15 - 20 mm 63 237 248 45 60 38 60 1.4 kg
SVA (1/2 - 3/4) in. 2.48 9.33 9.76 1.77 2.36 1.5 2.36 3.1 lb
SVA 25 - 40 mm 74 296 330 55 80 50 70 2.4 kg
SVA (1 - 11/2) in. 2.91 11.65 12.99 2.17 3.15 1.97 2.76 5.3 lb
SVA-LT, Socket weld
SVA 32 - 40 mm 74 303 337 62 80 50 70 2.9 kg
SVA (11/4 - 11/2)in. 2.91 11.93 13.27 2.44 3.15 1.97 2.76 6.4 lb
Specified weights are approximate values only.

Dimensions and weights SVA 15 - 40 (1/2 - 11/2 in. ) globe type with cap / handwheel
SVA-xx x x STR CAP SVA-xx x x STR H-WHEEL
Valve size K Cmax.1 Cmax.2 Bmax.1 Bmax.2 E G ∅D1 ∅D2 H Weight

SVA-ST, Butt-weld and threaded
SVA 15 - 20 mm 4 146 141 160 156 20 120 60 38 60 2.0 kg
SVA (1/2 - 3/4) in. 0.16 5.74 5.55 6.30 6.14 0.79 4.72 2.36 1.50 2.36 4.4 lb
SVA 25 - 40 mm 12 199 208 212 222 26 155 80 50 70 3.0 kg
SVA (1 - 11/2) in. 0.47 7.83 8.19 8.35 8.74 1.02 6.10 3.15 1.97 2.76 6.6 lb
SVA-ST, Socket weld
SVA 32 mm 12 200 209 212 222 27.4 155 80 50 70 3.0 kg
SVA (11/4) in. 0.47 7.87 8.23 8.35 8.74 1.08 6.10 3.15 1.97 2.76 6.6 lb
SVA 40 mm 12 204 213 212 222 31.0 155 80 50 70 3.0 kg
SVA (11/2) in. 0.47 8.03 8.39 8.35 8.74 1.22 6.10 3.15 1.97 2.76 6.6 lb
SVA-LT, Butt-weld and threaded
SVA 15 - 20 mm 63 188 184 202 198 20 120 60 38 60 2.0 kg
SVA (1/2 - 3/4) in. 2.48 7.40 7.24 7.95 7.80 0.79 4.72 2.36 1.50 2.36 4.4 lb
SVA 25 - 40 mm 74 243 252 256 265 26 155 80 50 70 3.0 kg
SVA (1 - 11/2) in. 2.91 9.57 9.92 10.08 10.43 1.02 6.10 3.15 1.97 2.76 6.6 lb
SVA-LT, Socket weld
SVA 32 mm 74 244 253 256 265 27.4 155 80 50 70 3.0 kg
SVA (11/4) in. 2.91 9.61 9.96 10.08 10.43 1.08 6.10 3.15 1.97 2.76 6.6 lb
SVA 40 mm 74 248 257 256 265 31.0 155 80 50 70 3.0 kg
SVA (11/2) in. 2.91 9.76 10.12 10.08 10.43 1.22 6.10 3.15 1.97 2.76 6.6 lb

Dimensions and weights SVA 50 - 65 (2 - 21/2 in.) angle type with cap / handwheel
Valve size K Cmax. 1 Cmax 2 G ∅D1 ∅D2 H Weight

SVA-ST, Butt-weld
SVA 50 mm 35 249 280 60 100 50 77 3.2 kg
SVA (2) in. 1.38 9.80 11.02 2.36 3.94 1.97 3.03 7.1 lb
SVA 65 mm 40 280 305 70 100 50 90 4.8 kg
SVA (21/2) in. 1.57 11.02 12.01 2.76 3.94 1.97 3.54 10.6 lb
SVA-ST, Socket weld
SVA 50 mm 35 254 285 65 100 50 77 4.1 kg
SVA (2) in. 1.38 10.00 11.22 2.56 3.94 1.97 3.03 9.0 lb
SVA-LT , Butt-weld
SVA 50 mm 70 284 315 60 100 50 77 3.2 kg
SVA (2) in. 2.76 11.18 12.40 2.36 3.94 1.97 3.03 7.1 lb
SVA 65 mm 70 310 335 70 100 50 90 4.8 kg
SVA (21/2) in. 2.76 12.20 13.19 2.76 3.94 1.97 3.54 10.6 lb
SVA-LT, Socket weld
SVA 50 mm 70 289 320 65 100 50 77 4.1 kg
SVA (2) in. 2.76 11.38 12.60 2.56 3.94 1.97 3.03 9.0 lb

Dimensions and weights SVA 50 - 65 (2 - 21/2 in.) globe type with cap / handwheel
Valve size K Bmax. 1 Bmax. 2 Cmax. 1 Cmax 2 E G ∅D1 ∅D2 H Weight

SVA-ST, Butt-weld
SVA 50 mm 35 234 234 232 232 32 148 100 50 77 4.2 kg
SVA (2) in. 1.38 9.21 9.21 9.13 9.13 1.26 5.83 3.94 1.97 3.03 9.3 lb
SVA 65 mm 40 262 258 262 258 40 176 100 50 90 6.3 kg
SVA (21/2) in. 1.57 10.31 10.16 10.31 10.16 1.57 6.93 3.94 1.97 3.54 13.9 lb
SVA-ST, Socket weld
SVA 50 mm 35 241 241 236 236 37 162 100 50 77 5.1 kg
SVA (2) in. 1.38 9.49 9.49 9.29 9.29 1.46 6.38 3.94 1.97 3.03 11.2 lb
SVA-LT, Butt-weld
SVA 50 mm 70 259 259 257 257 32 148 100 50 77 4.2 kg
SVA (2) in. 2.76 10.20 10.20 10.12 10.12 1.26 5.83 3.94 1.97 3.03 9.3 lb
SVA 65 mm 70 284 280 284 280 40 176 100 50 90 6.3 kg
SVA (21/2) in. 2.76 11.18 11.02 11.18 11.02 1.57 6.93 3.94 1.97 3.54 13.9 lb
SVA-LT, Socket weld
SVA 50 mm 70 266 266 261 261 37 62 100 50 77 5.1 kg
SVA (2) in. 2.76 10.47 10.47 10.28 10.28 1.26 6.38 3.94 1.97 3.03 11.2 lb

Dimensions and weights SVA 80 - 200 (3 - 8 in.) angle type with cap / handwheel
Valve size K Cmax.1 Cmax.2 G ∅D1 ∅D2 ∅H Weight

SVA-ST, Butt-weld
SVA 80 mm 41 338 353 90 200 58 129 9.2 kg
SVA (3) in. 1.61 13.31 13.90 3.54 7.87 2.28 5.08 20.3 lb
SVA 100 mm 43 382 388 106 250 58 156 14.8 kg
SVA (4) in. 1.69 15.04 15.28 4.17 9.84 2.28 6.14 32.6lb
SVA 125 mm 90 517 533 128 315 74 193 28.1 kg
SVA (5) in. 3.54 20.35 20.98 5.04 12.40 2.91 7.60 61.9lb
SVA 150 mm 90 564 568 145 315 74 219 39.7 kg
SVA (6) in. 3.54 22.20 22.36 5.71 12.40 2.91 8.62 87.5lb
SVA 200 mm 90 675 678 180 400 86 276 79.5 kg
SVA (8) in. 3.54 26.57 26.69 7.09 15.75 3.39 10.87 175.3 lb
SVA-LT, Butt-weld
SVA 80 mm 76 373 388 90 200 58 129 9.7 kg
SVA (3) in. 3.00 14.69 15.28 3.54 7.87 2.28 5.08 21.4 lb
SVA 100 mm 90 432 437 106 250 58 156 15.3 kg
SVA (4) in. 3.54 17.00 17.20 4.17 9.84 2.28 6.14 33.7 lb
SVA 125 mm 90 517 533 128 315 74 193 28.1 kg
SVA (5) in. 3.54 20.35 20.98 5.04 12.40 2.91 7.60 61.9 lb
SVA 150 mm 90 564 568 145 315 74 219 39.7 kg
SVA (6) in. 3.54 22.20 22.36 5.71 12.40 2.91 8.62 87.5 lb
SVA 200 mm 90 675 678 180 400 86 276 79.5 kg
SVA (8) in. 3.54 26.57 26.69 7.09 15.75 3.39 10.87 175.3 lb

Dimensions and weights SVA 80 - 200 (3 - 8 in.) globe type with cap / handwheel
Valve size K Bmax.1 Bmax.2 Cmax.1 Cmax.2 E G ∅D1 ∅D2 ∅H Weight

SVA-ST, Butt-weld
SVA 80 mm 41 340 296 342 298 48 216 200 58 129 10.4 kg
SVA (3) in. 1.61 13.38 11.65 13.46 11.73 1.89 8.50 7.87 2.28 5.08 22.9 lb
SVA 100 mm 43 400 331 408 339 60 264 250 58 156 17.7 kg
SVA (4) in. 1.69 15.75 13.03 16.06 13.35 2.36 10.39 9.84 2.28 6.14 39.0 lb
SVA 125 mm 90 526 444 538 456 74 322 315 74 193 32.8 kg
SVA (5) in. 3.54 20.71 17.48 21.18 17.95 2.91 12.68 12.40 2.91 7.60 72.3 lb
SVA 150 mm 90 572 483 594 505 91 370 315 74 219 60.0 kg
SVA (6) in. 3.54 22.52 19.02 23.39 19.88 3.58 14.57 12.40 2.91 8.62 132.3 lb
SVA 200 mm 90 692 579 726 613 117 464 400 86 276 111.5kg
SVA (8) in. 3.54 27.24 22.80 28.58 24.13 4.61 18.27 15.75 3.39 10.87 245.8 lb
SVA-LT, Butt-weld
SVA 80 mm 76 365 321 367 323 48 216 200 58 129 10.9 kg
SVA (3) in. 3.00 14.37 12.64 14.45 12.72 1.89 8.50 7.87 2.28 5.08 24.0 lb
SVA 100 mm 90 435 367 443 375 60 264 250 58 156 18.2 kg
SVA (4) in. 3.54 17.13 14.45 17.44 14.76 2.36 10.39 9.84 2.28 6.14 40.1 lb
SVA 125 mm 90 526 444 538 456 74 322 315 74 193 32.8 kg
SVA (5) in. 3.54 20.71 17.48 21.18 17.95 2.91 12.68 12.40 2.91 7.60 72.3 lb
SVA 150 mm 90 572 483 594 505 91 370 315 74 219 60.0 kg
SVA (6) in. 3.54 22.52 19.02 23.39 19.88 3.58 14.57 12.40 2.91 8.62 132.3 lb
SVA 200 mm 90 692 579 726 613 117 464 400 86 276 111.5kg
SVA (8) in. 3.54 27.24 22.80 28.58 24.13 4.61 18.27 15.75 3.39 10.87 245.8 lb

Ordering Please note that the type codes only serve to

identify the valves, some of which may not
form part of the standard product range. For
further information please contact your local
Danfoss Sales Company.
Type codes
Valve type SVA Stop Valve
Nominal size in mm Available connections
A/D SOC FPT
(valve size measured 15 DN 15 (1/2) x x x
on the connection 20 DN 20 (3/4) x x x
diameter) 25 DN 25 (1) x x x
32 DN 32 (11/4) x x x
40 DN 40 (11/2) x x
50 DN 50 (2) x x
65 DN 65 (21/2) x
80 DN 80 (3) x
100 DN 100 (4) x
125 DN 125 (5) x
150 DN 150 (6) x
200 DN 200 (8) x
Connections A Butt-weld connection: ANSI B 36.10 schedule 80, DN 15 - 40 (1/2 - 11/2 in.)
Butt-weld connection: ANSI B 36.10 schedule 40, DN 50 - 200 (2 - 8 in.)
D Butt-weld connection: DIN 2448
SOC Socket weld: ANSI B 16.11
FPT Female Pipe Thread NPT: ANSI/ASME B 1.20.1
Valve housing ANG Angle flow
STR Globe flow
Other equipment H-WHEEL Handwheel
CAP Seal cap
Important!
Where products need to be certified according
to specific certification societies or where
higher pressures are required, the relevant
information should be included at the time of
order.

Ordering The table below is used to identify the valve

(cont.) required.
Standard version Standard version
Example: Angle Globe
SVA-ST 20, Butt-weld, ANSI, Size Size
Type Code number Type Code number
angle with handwheel = mm in. mm in.
148B3451 DIN DIN
15 ½ SVA-ST 15 D ANG H-WHEEL 148B3361 15 ½ SVA-ST 15 D STR H-WHEEL 148B3401
Important! 15 ½ SVA-ST 15 D ANG CAP 148B3362 15 ½ SVA-ST 15 D STR CAP 148B3402
20 ¾ SVA-ST 20 D ANG H-WHEEL 148B3441 20 ¾ SVA-ST 20 D STR H-WHEEL 148B3481
Where products need to be
20 ¾ SVA-ST 20 D ANG CAP 148B3442 20 ¾ SVA-ST 20 D STR CAP 148B3482
certified according to specific 25 1 SVA-ST 25 D ANG H-WHEEL 148B3521 25 1 SVA-ST 25 D STR H-WHEEL 148B3561
certification societies or where 25 1 SVA-ST 25 D ANG CAP 148B3522 25 1 SVA-ST 25 D STR CAP 148B3562
higher pressures are required, 32 1¼ SVA-ST 32 D ANG H-WHEEL 148B3601 32 1¼ SVA-ST 32 D STR H-WHEEL 148B3641
the relevant information should 32 1¼ SVA-ST 32 D ANG CAP 148B3602 32 1¼ SVA-ST 32 D STR CAP 148B3642
40 1½ SVA-ST 40 D ANG H-WHEEL 148B3681 40 1½ SVA-ST 40 D STR H-WHEEL 148B3711
be included at the time of order. 148B3682
40 1½ SVA-ST 40 D ANG CAP 40 1½ SVA-ST 40 D STR CAP 148B3712
50 2 SVA-ST 50 D ANG H-WHEEL 148B3032 50 2 SVA-ST 50 D STR H-WHEEL 148B3038
50 2 SVA-ST 50 D ANG CAP 148B3033 50 2 SVA-ST 50 D STR CAP 148B3039
65 2½ SVA-ST 65 D ANG H-WHEEL 148B3044 65 2½ SVA-ST 65 D STR H-WHEEL 148B3050
65 2½ SVA-ST 65 D ANG CAP 148B3045 65 2½ SVA-ST 65 D STR CAP 148B3051
ANSI ANSI
15 ½ SVA-ST 15 A ANG H-WHEEL 148B3371 15 ½ SVA-ST 15 A STR H-WHEEL 148B3411
15 ½ SVA-ST 15 A ANG CAP 148B3372 15 ½ SVA-ST 15 A STR CAP 148B3412
20 ¾ SVA-ST 20 A ANG H-WHEEL 148B3451 20 ¾ SVA-ST 20 A STR H-WHEEL 148B3491
20 ¾ SVA-ST 20 A ANG CAP 148B3452 20 ¾ SVA-ST 20 A STR CAP 148B3492
25 1 SVA-ST 25 A ANG H-WHEEL 148B3531 25 1 SVA-ST 25 A STR H-WHEEL 148B3571
25 1 SVA-ST 25 A ANG CAP 148B3532 25 1 SVA-ST 25 A STR CAP 148B3572
32 1¼ SVA-ST 32 A ANG H-WHEEL 148B3611 32 1¼ SVA-ST 32 A STR H-WHEEL 148B3651
32 1¼ SVA-ST 32 A ANG CAP 148B3612 32 1¼ SVA-ST 32 A STR CAP 148B3652
40 1½ SVA-ST 40 A ANG H-WHEEL 148B3691 40 1½ SVA-ST 40 A STR H-WHEEL 148B3721
40 1½ SVA-ST 40 A ANG CAP 148B3692 40 1½ SVA-ST 40 A STR CAP 148B3722
65 2½ SVA-ST 65 A ANG H-WHEEL 148B3046 65 2½ SVA-ST 65 A STR H-WHEEL 148B3052
65 2½ SVA-ST 65 A ANG CAP 148B3047 65 2½ SVA-ST 65 A STR CAP 148B3053
SOC SOC
15 ½ SVA-ST 15 SOC ANG H-WHEEL 148B3381 15 ½ SVA-ST 15 SOC STR H-WHEEL 148B3421
15 ½ SVA-ST 15 SOC ANG CAP 148B3382 15 ½ SVA-ST 15 SOC STR CAP 148B3422
20 ¾ SVA-ST 20 SOC ANG H-WHEEL 148B3461 20 ¾ SVA-ST 20 SOC STR H-WHEEL 148B3501
20 ¾ SVA-ST 20 SOC ANG CAP 148B3462 20 ¾ SVA-ST 20 SOC STR CAP 148B3502
25 1 SVA-ST 25 SOC ANG H-WHEEL 148B3541 25 1 SVA-ST 25 SOC STR H-WHEEL 148B3581
25 1 SVA-ST 25 SOC ANG CAP 148B3542 25 1 SVA-ST 25 SOC STR CAP 148B3582
32 1¼ SVA-ST 32 SOC ANG H-WHEEL 148B3621 32 1¼ SVA-ST 32 SOC STR H-WHEEL 148B3661
32 1¼ SVA-ST 32 SOC ANG CAP 148B3622 32 1¼ SVA-ST 32 SOC STR CAP 148B3662
40 1½ SVA-ST 40 SOC ANG H-WHEEL 148B3701 40 1½ SVA-ST 40 SOC STR H-WHEEL 148B3731
D = Butt-weld DIN
40 1½ SVA-ST 40 SOC ANG CAP 148B3702 40 1½ SVA-ST 40 SOC STR CAP 148B3732
A = Butt-weld ANSI 50 2 SVA-ST 50 SOC ANG H-WHEEL 148B3036 50 2 SVA-ST 50 SOC STR H-WHEEL 148B3042
SOC = Socket welding 50 2 SVA-ST 50 SOC ANG CAP 148B3037 50 2 SVA-ST 50 SOC STR CAP 148B3043
FPT = Inside pipe thread FPT FPT
15 ½ SVA-ST 15 FPT ANG H-WHEEL 148B3391 15 ½ SVA-ST 15 FPT STR H-WHEEL 148B3431
15 ½ SVA-ST 15 FPT ANG CAP 148B3392 15 ½ SVA-ST 15 FPT STR CAP 148B3432
ANG = Angle 20 ¾ SVA-ST 20 FPT ANG H-WHEEL 148B3471 20 ¾ SVA-ST 20 FPT STR H-WHEEL 148B3511
STR = Globe 20 ¾ SVA-ST 20 FPT ANG CAP 148B3472 20 ¾ SVA-ST 20 FPT STR CAP 148B3512
25 1 SVA-ST 25 FPT ANG H-WHEEL 148B3551 25 1 SVA-ST 25 FPT STR H-WHEEL 148B3591
25 1 SVA-ST 25 FPT ANG CAP 148B3552 25 1 SVA-ST 25 FPT STR CAP 148B3592
CAP = Seal cap 32 1¼ SVA-ST 32 FPT ANG H-WHEEL 148B3631 32 1¼ SVA-ST 32 FPT STR H-WHEEL 148B3671
H-WHEEL = Hand wheel 32 1¼ SVA-ST 32 FPT ANG CAP 148B3632 32 1¼ SVA-ST 32 FPT STR CAP 148B3672

Ordering The table below is used to identify the valve

(cont.) required.
Low temperature version Low temperature version
Example: Angle Globe
SVA-LT 20, Butt-weld, ANSI, Size Size
Type Code number Type Code number
angle with cap = 148B3455 mm in. mm in.
DIN DIN
Important! 15 ½ SVA-LT 15 D ANG H-WHEEL 148B3364 15 ½ SVA-LT 15 D STR H-WHEEL 148B3404
Where products need to be 15 ½ SVA-LT 15 D ANG CAP 148B3365 15 ½ SVA-LT 15 D STR CAP 148B3405
20 ¾ SVA-LT 20 D ANG H-WHEEL 148B3444 20 ¾ SVA-LT 20 D STR H-WHEEL 148B3484
certified according to specific 20 ¾ SVA-LT 20 D ANG CAP 148B3445 20 ¾ SVA-LT 20 D STR CAP 148B3485
certification societies or where 25 1 SVA-LT 25 D ANG H-WHEEL 148B3524 25 1 SVA-LT 25 D STR H-WHEEL 148B3564
higher pressures are required, 25 1 SVA-LT 25 D ANG CAP 148B3525 25 1 SVA-LT 25 D STR CAP 148B3565
the relevant information should 32 1¼ SVA-LT 32 D ANG H-WHEEL 148B3604 32 1¼ SVA-LT 32 D STR H-WHEEL 148B3644
be included at the time of order. 32 1¼ SVA-LT 32 D ANG CAP 148B3605 32 1¼ SVA-LT 32 D STR CAP 148B3645
40 1½ SVA-LT 40 D ANG H-WHEEL 148B3684 40 1½ SVA-LT 40 D STR H-WHEEL 148B3714
40 1½ SVA-LT 40 D ANG CAP 148B3685 40 1½ SVA-LT 40 D STR CAP 148B3715
50 2 SVA-LT 50 D ANG H-WHEEL 148B3264 50 2 SVA-LT 50 D STR H-WHEEL 148B3294
50 2 SVA-LT 50 D ANG CAP 148B3265 50 2 SVA-LT 50 D STR CAP 148B3295
65 2½ SVA-LT 65 D ANG H-WHEEL 148B3324 65 2½ SVA-LT 65 D STR H-WHEEL 148B3344
65 2½ SVA-LT 65 D ANG CAP 148B3325 65 2½ SVA-LT 65 D STR CAP 148B3345
ANSI ANSI
15 ½ SVA-LT 15 A ANG H-WHEEL 148B3374 15 ½ SVA-LT 15 A STR H-WHEEL 148B3414
15 ½ SVA-LT 15 A ANG CAP 148B3375 15 ½ SVA-LT 15 A STR CAP 148B3415
20 ¾ SVA-LT 20 A ANG H-WHEEL 148B3454 20 ¾ SVA-LT 20 A STR H-WHEEL 148B3494
20 ¾ SVA-LT 20 A ANG CAP 148B3455 20 ¾ SVA-LT 20 A STR CAP 148B3495
25 1 SVA-LT 25 A ANG H-WHEEL 148B3534 25 1 SVA-LT 25 A STR H-WHEEL 148B3574
25 1 SVA-LT 25 A ANG CAP 148B3535 25 1 SVA-LT 25 A STR CAP 148B3575
32 1¼ SVA-LT 32 A ANG H-WHEEL 148B3614 32 1¼ SVA-LT 32 A STR H-WHEEL 148B3654
32 1¼ SVA-LT 32 A ANG CAP 148B3615 32 1¼ SVA-LT 32 A STR CAP 148B3655
40 1½ SVA-LT 40 A ANG H-WHEEL 148B3694 40 1½ SVA-LT 40 A STR H-WHEEL 148B3724
40 1½ SVA-LT 40 A ANG CAP 148B3695 40 1½ SVA-LT 40 A STR CAP 148B3725
65 2½ SVA-LT 65 A ANG H-WHEEL 148B3334 65 2½ SVA-LT 65 A STR H-WHEEL 148B3354
65 2½ SVA-LT 65 A ANG CAP 148B3335 65 2½ SVA-LT 65 A STR CAP 148B3355
SOC SOC
15 ½ SVA-LT 15 SOC ANG H-WHEEL 148B3384 15 ½ SVA-LT 15 SOC STR H-WHEEL 148B3424
15 ½ SVA-LT 15 SOC ANG CAP 148B3385 15 ½ SVA-LT 15 SOC STR CAP 148B3425
20 ¾ SVA-LT 20 SOC ANG H-WHEEL 148B3464 20 ¾ SVA-LT 20 SOC STR H-WHEEL 148B3504
20 ¾ SVA-LT 20 SOC ANG CAP 148B3465 20 ¾ SVA-LT 20 SOC STR CAP 148B3505
25 1 SVA-LT 25 SOC ANG H-WHEEL 148B3544 25 1 SVA-LT 25 SOC STR H-WHEEL 148B3584
25 1 SVA-LT 25 SOC ANG CAP 148B3545 25 1 SVA-LT 25 SOC STR CAP 148B3585
32 1¼ SVA-LT 32 SOC ANG H-WHEEL 148B3624 32 1¼ SVA-LT 32 SOC STR H-WHEEL 148B3664
32 1¼ SVA-LT 32 SOC ANG CAP 148B3625 32 1¼ SVA-LT 32 SOC STR CAP 148B3665
D = Butt-weld DIN 40 1½ SVA-LT 40 SOC ANG H-WHEEL 148B3704 40 1½ SVA-LT 40 SOC STR H-WHEEL 148B3734
40 1½ SVA-LT 40 SOC ANG CAP 148B3705 40 1½ SVA-LT 40 SOC STR CAP 148B3735
A = Butt-weld ANSI 50 2 SVA-LT 50 SOC ANG H-WHEEL 148B3284 50 2 SVA-LT 50 SOC STR H-WHEEL 148B3314
SOC = Socket welding 50 2 SVA-LT 50 SOC ANG CAP 148B3285 50 2 SVA-LT 50 SOC STR CAP 148B3315
FPT = Inside pipe thread FPT FPT
15 ½ SVA-LT 15 FPT ANG H-WHEEL 148B3394 15 ½ SVA-LT 15 FPT STR H-WHEEL 148B3434
15 ½ SVA-LT 15 FPT ANG CAP 148B3395 15 ½ SVA-LT 15 FPT STR CAP 148B3435
ANG = Angle 20 ¾ SVA-LT 20 FPT ANG H-WHEEL 148B3474 20 ¾ SVA-LT 20 FPT STR H-WHEEL 148B3514
STR = Globe 20 ¾ SVA-LT 20 FPT ANG CAP 148B3475 20 ¾ SVA-LT 20 FPT STR CAP 148B3515
25 1 SVA-LT 25 FPT ANG H-WHEEL 148B3554 25 1 SVA-LT 25 FPT STR H-WHEEL 148B3594
25 1 SVA-LT 25 FPT ANG CAP 148B3555 25 1 SVA-LT 25 FPT STR CAP 148B3595
CAP = Seal cap 32 1¼ SVA-LT 32 FPT ANG H-WHEEL 148B3634 148B3674
32 1¼ SVA-LT 32 FPT STR H-WHEEL
H-WHEEL = Hand wheel 32 1¼ SVA-LT 32 FPT ANG CAP 148B3635 32 1¼ SVA-LT 32 FPT STR CAP 148B3675




Instruction
SVA-ST 10-65 (PS 52 bar / 754 psi)
SVA-SS 15-200 (PS 50 bar / 725 psi)
SVA-ST 80-200 (PS 50 bar / 725 psi)
SVA-SS 80-200 (PS 50 bar/ 725 psi)
148R9526
148R9526
1 2 3 4
DN 10 Nm LB-fod DN 15 - 200
LB-feet
LB-ft
Pieds-
livres
DN 10 10 7.5
Nm LB-fod
LB-feet
LB-ft
Pieds-
livres
DN 15-20 22 16
DN 25-32-40-50 44 32
DN 65 75 53
DN 80 44 32
DN 100 75 53
DN 125-150 183 135
DN 200 370 272
5a 5b 5c 5a 5b
6 7 8
Nm LB-fod
LB-feet
LB-ft
Pieds-
livres
DN 15-20 50 37
DN 25-40 70 52
DN 50-65-80-100 60 45
9 DN 125-150-200 80 60 10
© Danfoss A/S (AC-DSL / MWA), 11 - 2006 DKRCI.PI.KD0.B3.52 / 520H1293

DANSK Topdækslet kan blive siddende, forudsat at: Sådan fjernes pakdåsen (fig. 8)
Temperaturen i området mellem Håndhjul og pakdåse kan nu fjernes.
ventilhuset og topdækslet under
Installation svejsningen ikke overstiger +150°C/+302°F. Afmontering af ventilen (fig. 9)
Denne temperatur afhænger af Fjern ikke topdækslet, mens ventilen stadig
Kølemidler svejsemetoden samt af eventuel køling er under tryk.
Alle almindelige ikke-brændbare af ventilhuset under selve svejsningen. - Kontroller, at O-ringen (pos. A) ikke er
kølemidler, inklusive R717 og ikke- (Kølingen kan for ekstempel foregå ved, beskadiget.
korroderende gasser/væsker afhængigt af at der svøbes en våd klud om ventilhuset.) - Kontroller, at spindlen ikke har ridser og
forseglingsmaterialets kompatibilitet. Sørg for, at der ikke kommer svejserester stødmærker.
Brændbare kulbrinter kan ikke anbefales. etc. ind i ventilen under svejsningen. - Skift hele kegleenheden ud, hvis teflon-
Ventilen bør kun anvendes i lukkede kegleringen er beskadiget.
kredsløb. Kontakt venligst Danfoss for Pas på ikke at beskadige teflon-kegle-
yderligere information. ringen. Udskiftning af keglen (fig. 9)
Løsn kegleskruen (pos. B) med en
Temperaturområde Ventilhuset skal være frit for spændinger unbrakonøgle.
SVA-ST: –50/+150°C (–58/+302°F) (eksterne belastninger) efter installation. SVA 10....................................................2.0 mm A/F
SVA-SS: –60/+150°C (–76/+302°F) SVA 15-40.............................................2.0 mm A/F
Stopventiler må ikke monteres i systemer, SVA 50-65.............................................2.5 mm A/F
Tryk hvor ventilens udgangsside er åben til SVA 80-100.............................................. 4 mm A/F
SVA 10-65: Ventilerne er konstrueret til et omgivelserne. Udgangssiden af ventilen SVA 125-150........................................... 5 mm A/F
maksimalt arbejdstryk på 52 bar g (754 psig). skal altid være forbundet til systemet eller SVA 200.................................................... 6 mm A/F
SVA 80-200: Ventilerne er konstrueret til et korrekt dækket til for eksempel med et
maksimalt arbejdstryk på 50 bar g (725 psig). påsvejset endestykke. (Der følger en unbrakonøgle med
pakningssættet fra Danfoss Industrial
Installation Montering Refrigeration).
Ventilen skal installeres med spindlen Fjern svejserester og støv fra rørene og Fjern kuglerne (pos. C).
i vertikal eller horisontal position (fig. ventilhuset, før det påmonteres. Kontroller,
1). Ventilerne bør åbnes manuelt uden at keglen er skruet helt tilbage mod Antal kugler i pos. C:
anvendelse af værktøj eller andet udstyr topdækslet før genmontering i ventilhuset SVA 10................................................................ 6 stk.
(fig. 3). Ventilen er designet til at modstå (fig. 5a). SVA 10-20.......................................................10 stk.
et højt internt tryk. Rørsystemet bør dog SVA 25-65.......................................................14 stk.
være konstrueret med henblik på at undgå Tilspænding SVA 80-200.....................................................13 stk.
væskefælder og reducere risikoen for, at der Spænd topdækslet med en momentnøgle,
dannes hydraulisk tryk på grund af termisk indtil værdierne indikeret i tabellen er nået Keglen kan nu fjernes. Sæt den nye kegle
udvidelse. Der skal sørges for, at ventilen (fig. 5b). på spindlen, og sæt kuglerne i igen. Skru
er beskyttet mod kortvarige tryk såsom kegleskruen i igen, og brug Loctite nr. 648
væskeslag i systemet. Farver og identifikation til at sikre, at skruen sidder godt fast.
SVA-ventilerne er fra fabrikkens side
Bemærk! malet med rød oxidgrunder. Ventilen Montering
SVA er stopventiler og skal altid være helt identificeres præcist ved hjælp af ID- Fjern eventuelt snavs fra ventilhuset, før
lukket eller helt åbne. Halvåbne positioner ringen på topdækslet samt prægningen på ventilen samles. Kontroller, at keglen er
er ikke tilladt. Hvis ventilen monteres tæt ventilhuset. Ventilhusets udvendige flader skruet helt tilbage mod topdækslet, før den
på kompressoren (economizer-ledninger, skal have en passende rustbeskyttelse efter igen anbringes i ventilhuset (fig. 5a).
olieledninger etc.) eller på andre ledninger, installation og montering.
der udsættes for kraftige vibrationer og Tilspænding
pulsationer, er det nødvendigt at montere Det anbefales, at ID-ringen beskyttes, når Spænd topdækslet med en momentnøgle,
særlige låseskiver på ventilen. Yderligere ventilen skal males. indtil værdierne indikeret i tabellen er
oplysninger kan findes i kataloget. SVA-SS-ventiler er ikke malet og kræver nået (fig. 5b). Spænd topdækslet med en
ingen beskyttende behandling. momentnøgle, indtil værdierne indikeret i
Anbefalet strømretning tabellen er nået (fig. 10).
Optimale strømningsbetingelser opnås ved Vedligeholdelse
at montere ventilen med strømretning mod Brug kun originale Danfoss-dele – det
ventilkeglen som anvist med pilen på siden Pakdåse gælder også O-ringe og pakdåser – ved
af ventilhuset (fig. 2). Strømning i den I forbindelse med eftersyn og udskiftning. Materialer til nye dele er
modsatte retning kan også accepteres (fig. vedligeholdelse udskiftes altid hele godkendt til det aktuelle kølemedie.
2), men betyder en let reduktion af kv- / Cv- pakdåsen, der fås som reservedel. Generelt
værdien. må pakdåsen ikke fjernes, hvis der er tryk Kontakt venligst Danfoss i tvivlstilfælde.
indvendigt i ventilen. Hvis man overholder Danfoss påtager sig intet ansvar for fejl eller
Svejsning følgende sikkerhedsregler, kan pakdåsen udeladelser. Danfoss forbeholder sig ret til
Topdækslet bør fjernes før svejsning (fig. dog fjernes, mens ventilen stadig er under at ændre produkter og specifikationer uden
4) for at undgå skader på O-ringene i tryk: forudgående varsel.
tætningsbøsningen og mellem ventilhuset
og topdækslet samt på teflonpakningen Spindeltætningsfunktion (fig. 6)
i ventilsædet. Kun materialer og Drej spindlen mod uret, indtil ventilen er
svejsemetoder, der er kompatible med helt åben, for at aktivere spindeltætnings-
ventilhusets materialer, må bruges til funktionen.
at svejse ventilen. Ventilen bør renses
indvendigt for at fjerne svejserester, efter Trykudligning (fig. 7)
svejsning og inden samling. I nogle tilfælde dannes der tryk bag
pakdåsen. Derfor bør der monteres et
Undgå svejserester og smuds i gevindet på håndhjul eller lignende på spindlen, mens
hus og topdæksel. trykket udlignes. Trykket kan udlignes ved
langsomt at skrue pakdåsen af.
DKRCI.PI.KD0.B3.52 / 520H1293 © Danfoss A/S (AC-DSL / MWA), 11 - 2006

ENGLISH packing gland. Hence a handwheel or
Removing the bonnet can be omitted similar should be fastened on top of the
provided that: spindle while the pressure is equalized.
Installation The temperature in the area between the The pressure can be equalized by slowly
valve body and bonnet during welding screwing out the gland.
Refrigerants does not exceed +150°C/+302°F. This
Applicable to all common non-flammable temperature depends on the welding Removal of packing gland (fig. 8)
refrigerants, including R717 and non- method as well as on any cooling of the Handwheel and packing gland can now be
corrosive gases/liquids dependent on valve body during the welding itself. removed.
sealing material compatability. (Cooling can be ensured by, for example,
Flammable hydrocarbons are not recom- wrapping a wet cloth around the valve Dismantling the valve (fig. 9)
mended. The valve is only recommended body.) Make sure that no dirt, welding Do not remove the bonnet while the valve
for use in closed circuits. For further debris etc. get into the valve during the is still under pressure.
information please contact Danfoss. welding procedure. - Check that the O-ring (pos. A) has not
been damaged.
Temperature range Be careful not to damage the teflon cone - Check that the spindle is free of
SVA-ST: –50/+150°C (–58/+302°F) ring. scratches and impact marks.
SVA-SS: –60/+150°C (–76/+302°F) - If the teflon cone ring has been
The valve housing must be free from damaged, the whole cone assembly
Pressure stresses (external loads) after installation. must be replaced.
SVA 10-65: The valves are designed for a max.
working pressure of 52 bar g (754 psi g). Stop valves must not be mounted in Replacement of the cone (fig. 9)
SVA 80-200: The valves are designed for a systems where the outlet side of the valve Unscrew the cone screw (pos. B) with an
max. working pressure of 50 bar g (725 psi is open to atmosphere. The outlet side of Allen key.
g). the valve must always be connected to the SVA 10....................................................2.0 mm A/F
system or properly capped off, for example SVA 15-40.............................................2.0 mm A/F
Installation with a welded-on end plate. SVA 50-65.............................................2.5 mm A/F
The valve must be installed with the spindle SVA 80-100.............................................. 4 mm A/F
vertically upwards or in horizontal position Assembly SVA 125-150........................................... 5 mm A/F
(fig. 1). Valves should be opened by hand Remove welding debris and any dirt from SVA 200.................................................... 6 mm A/F
without the use of tools or other devices pipes and valve body before assembly.
(fig. 3). The valve is designed to withstand Check that the cone has been fully screwed (An Allen key is included in the Danfoss
a high internal pressure. However, the back towards the bonnet before it is Industrial Refrigeration gasket set).
piping system should be designed to avoid replaced in the valve body (fig. 5a). Remove the bolts (pos. C).
liquid traps and reduce the risk of hydraulic
pressure caused by thermal expansion. It Tightening Number of bolts in pos. C:
must be ensured that the valve is protected Thighten the bonnet with a torque wrench, SVA 10................................................................6 pcs.
from pressure transients like “liquid to the values indicated in the table (fig. 5b). SVA 10-20...................................................... 10 pcs.
hammer” in the system. SVA 25-65...................................................... 14 pcs.
Colours and identification SVA 80-200.................................................... 13 pcs.
Attention! The SVA valves are painted with a red oxide
SVA are shut off valves and must always primer in the factory. Precise identification The cone can then be removed. Place the
be either fully closed or fully open. Half of the valve is made via the ID ring at new cone on the spindle and replace the
open positions are not allowed. In case the top of the bonnet, as well as by the bolts. Refit the cone screw in again using
the valve is installed close to compressor stamping on the valve body. The external Loctite No. 648. to ensure that the screw is
(economizer lines, oil lines etc.) or on other surface of the valve housing must be properly fastened.
lines subjected to high vibrations and prevented against corrosion with a suitable
pulsations, it is necessary to install special protective coating after installation and Assembly
lock washers on the valve. Please refer to assembly. Remove any dirt from the body before the
the catalogue for additional information. valve is assembled. Check that the cone
Protection of the ID ring when repainting has been screwed back towards the bonnet
Recommended flow direction the valve is recommended. before it is replaced in the valve body (fig. 5a).
To achieve optimum flow conditions, the SVA-SS valves are not painted and do not
valve should be installed with the flow require any protective coating. Tightening
towards the valve cone as indicated by the Tighten the bonnet with a torque wrench,
arrow on the side of the valve body (fig. 2). Maintenance to the values indicated in the table (fig. 5b).
Flow in the opposite direction is also Tighten the packing gland with a torque
acceptable (fig. 2), but slightly reduces the Packing gland wrench, to the values indicated in the table
kv- / Cv value. When performing service and maintenance, (fig. 10).
replace the complete packing gland only,
Welding which is available as a spare part. As a Use only original Danfoss parts, including
The bonnet should be removed before general rule, the packing gland must not packing glands, O-rings and gaskets for
welding (fig. 4) to prevent damage to the O- be removed if there is internal pressure replacement. Materials of new parts are
rings in the packing gland and between the in the valve. However, if the following certified for the relevant refrigerant.
valve body and bonnet, as well as the teflon precautionary measures are taken, the
gasket in the valve seat. Only materials and packing gland can be removed with the In cases of doubt, please contact Danfoss.
welding methods, compatible with the valve still under pressure: Danfoss accepts no responsibility for
valve housing material, must be welded errors and omissions. Danfoss Industrial
to the valve housing. The valve should be Backseating (fig. 6) Refrigeration reserves the right to make
cleaned internally to remove welding debris To backseat the valve, turn the spindle changes to products and specifications
on completion of welding and before the counter-clockwise until the valve is fully without prior notice.
valve is reassembled. open.
Avoid welding debris and dirt in the threads Pressure equalization (fig. 7)
of the housing and the bonnet. In some cases, pressure forms behind the

DEUTSCH Schweißüberreste und Schmutz in den Druckausgleich (Abb. 7)
Gewinden des Gehäuses und Deckels sind In einigen Fällen baut sich Druck hinter
zu vermeiden. der Stopfbuchse auf. Daher sollte ein
Installation Handrad oder Ähnliches oben an der
Das Entfernen des Ventildeckels kann Spindel befestigt werden, während der
Kältemittel entfallen, wenn: Druck ausgeglichen wird. Der Druck kann
Anwendbar für alle herkömmlichen, nicht durch langsames Herausschrauben der
entflammbaren Kältemittel einschließlich Die Temperatur im Bereich zwischen Stopfbuchse ausgeglichen werden.
R717 und nicht aggressive Gase/Flüssig- Ventilgehäuse und -deckel während
keiten je nach Verträglichkeit mit Dicht- des Schweißens +150 °C nicht über- Ausbau der Stopfbuchse (Abb. 8)
werkstoff. schreitet. Diese Temperatur hängt Das Handrad und die Stopfbuchse können
Der Einsatz mit brennbaren Kohlenwasser- vom Schweißverfahren und auch von jetzt entfernt werden.
stoffen wird untersagt. Das Ventil ist nur Kühlung des Ventilgehäuses während des
für die Verwendung in geschlossenen eigentlichen Schweißens ab. (Kühlung kann Zerlegen des Ventils (Abb. 9)
Kreisläufen empfohlen. Für weitere zum Beispiel sichergestellt werden, indem Den Ventildeckel nicht entfernen, während
Informationen wenden Sie sich bitte an ein nasses Tuch um das Ventilgehäuse das Ventil noch unter Druck steht.
Danfoss. gewickelt wird.) Es ist sicherzustellen, dass - Sicherstellen, dass der O-Ring (Pos. A)
kein Schmutz, keine Schweißüberreste nicht beschädigt wurde.
Temperaturbereich usw. während des Schweißens in das Ventil - Sicherstellen, dass die Spindel frei von
SVA-ST: –50/+150°C (–58/+302°F) gelangt. Kratzern und Stoßspuren ist.
SVA-SS: –60/+150°C (–76/+302°F) - Wenn der Teflon-Kegelring
Sorgfältig darauf achten, den Teflon-Kegel- beschädigt wurde, muss die gesamte
Druck ring nicht zu beschädigen. Kegelbaugruppe ausgetauscht werden.
SVA 10-65: Die Ventile sind für einen max.
Betriebsdruck von 52 bar g (754 psi g) Das Ventilgehäuse muss nach dem Einbau Austausch des Kegels (Abb. 9)
ausgelegt. frei von Beanspruchungen (externen Die Kegelschraube (Pos. B) mit einem
SVA 80-200: Die Ventile sind für einen max. Belastungen) sein. Innensechskantschlüssel lösen.
Betriebsdruck von 50 bar g (725 psi g) SVA 10............................. 2,0 mm Schlüsselweite
ausgelegt. Absperrventile dürfen nicht in Systemen SVA 15-40...................... 2,0 mm Schlüsselweite
eingebaut werden, in denen die SVA 50-65...................... 2,5 mm Schlüsselweite
Installation Auslassseite des Ventils zur Atmosphäre SVA 80-100........................4 mm Schlüsselweite
Das Ventil muss mit der Spindel senkrecht offen ist. Die Auslassseite des Ventils muss SVA 125-150.....................5 mm Schlüsselweite
nach oben oder waagerecht (Abb. 1) ein- immer an das System angeschlossen SVA 200..............................6 mm Schlüsselweite
gebaut werden. Ventile sollten per Hand oder richtig verschlossen werden, wie
ohne Werkzeug oder andere Vorrichtungen zum Beispiel mit einem angeschweißten (Ein Innensechskantschlüssel ist im
geöffnet werden (Abb. 3). Das Ventil ist Endblech. Lieferumfang des Dichtungssatzes von
für einen hohen Innendruck ausgelegt. Danfoss Industrial Refrigeration enthalten.)
Das Verrohrungssystem sollte jedoch Zusammenbau Die Kugeln entfernen (Pos. C).
ausgelegt sein, um Flüssigkeitseinschlüsse Vor dem Zusammenbau Schweißüberreste
zu verhindern und das Risiko von und Schmutz von Rohrleitungen und Anzahl Kugeln in Pos. C:
Hydraulikdruck verursacht durch Wärme- Ventilgehäuse entfernen. Sicherstellen, SVA 10..............................................................6 Stck.
ausdehnung zu senken. Es muss sicher- dass der Kegel vollständig zum Ventildeckel SVA 10-20.................................................... 10 Stck.
gestellt werden, dass das Ventil vor Druck- hin zurückgeschraubt wurde, bevor er im SVA 25-65.................................................... 14 Stck.
stößen wie Wasserschlag im System Ventilgehäuse eingesetzt wird (Abb. 5a). SVA 80-200.................................................. 13 Stck.
geschützt ist.
Anziehen Der Kegel kann dann entfernt werden.
Achtung! Den Ventildeckel mit einem Drehmoment- Den neuen Kegel auf die Spindel setzen
SVA sind Absperrventile und müssen schlüssel auf die Werte in der Tabelle (Abb. und die Kugeln wieder einsetzen. Die
immer entweder vollständig geschlossen 5b) anziehen. Kegelschraube wieder mittels Loctite Nr.
oder vollständig geöffnet sein. Halboffene 648 befestigen, um sicherzustellen, dass die
Stellungen sind nicht erlaubt. Falls das Farben und Kennzeichnungen Schraube richtig fest sitzt.
Ventil nah am Kompressor (Economizer- Die SVA-Ventile werden ab Werk mit
Leitungen, Ölleitungen usw.) oder Rotoxid grundiert. Präzise Kennzeichnung Zusammenbau
an anderen Leitungen, die hohen des Ventils erfolgt über den Kennring Vor dem Zusammenbau des Ventils
Schwingungen und Vibrationen ausgesetzt oben am Ventildeckel sowie die Prägung jeglichen Schmutz vom Gehäuse entfernen.
sind, eingebaut wird, müssen spezielle am Ventilgehäuse. Die Außenfläche des Sicherstellen, dass der Kegel zum
Sicherungsbleche am Ventil montiert Ventilgehäuses muss nach dem Einbau und Ventildeckel hin zurückgeschraubt wurde,
werden. Zusätzliche Informationen dem Zusammenbau mit einer geeigneten bevor er im Ventilgehäuse eingesetzt wird
entnehmen Sie bitte dem Katalog. Schutzbeschichtung gegen Korrosion (Abb. 5a).
geschützt werden.
Empfohlene Durchflussrichtung Anziehen
Das Ventil muss mit dem Durchfluss in Beim Neulackieren des Ventils wird Schutz Den Ventildeckel mit einem
Pfeilrichtung (Seite des Ventilgehäuses) des Kennrings empfohlen. Drehmomentschlüssel auf die Werte in der
zum Ventilkegel eingebaut werden (Abb. SVA-SS-Ventile werden nicht lackiert und Tabelle (Abb. 5b) anziehen. Die Stopfbuchse
2)., um optimale Durchflussbedingungen zu benötigen keine Schutzbeschichtung. mit einem Drehmomentschlüssel auf die
erreichen. Durchfluss in der Werte in der Tabelle (Abb. 10) anziehen.
entgegengesetzten Richtung ist ebenfalls Wartung
zulässig (Abb. 2), reduziert den kv- / Cv-Wert Nur Originalteile von Danfoss einschließlich
jedoch etwas. Stopfbuchse Stopfbuchsen, O-Ringe und Dichtungen
Bei Reparatur und Wartung ist die gesamte zum Austausch verwenden. Werkstoffe
Schweißen Stopfbuchse zu ersetzen, die als Ersatzteil neuer Teile sind für das betreffende
Vor dem Schweißen sollte der Ventildeckel erhältlich ist. Generell darf die Stopfbuchse Kältemittel zertifiziert.
entfernt werden (Abb. 4), um Beschädigung nicht entfernt werden, wenn Innendruck
an den O-Ringen in der Stopfbuchse im Ventil vorliegt. Sofern die folgenden Wenden Sie sich im Zweifelsfall bitte an
und zwischen Ventilgehäuse und - Vorsichtsmaßnahmen ergriffen werden, Danfoss.
deckel sowie der Teflon-Dichtung im kann die Stopfbuchse jedoch entfernt
Ventilsitz zu verhindern. Nur mit dem werden, während das Ventil unter Druck
Ventilgehäusewerkstoff kompatible steht. Danfoss übernimmt keine Verantwortung
Werkstoffe und Schweißverfahren dürfen für Fehler und Auslassungen. Danfoss
beim Schweißen des Ventilgehäuses Auf Rückdichtung setzen (Abb. 6) Industrial Refrigeration behält sich das
verwendet werden. Das Ventil sollte Um das Ventil auf Rückdichtung zu setzen, Recht zu Änderungen an Produkten und
nach dem Schweißen und vor dem die Spindel gegen den Uhrzeigersinn technischen Daten ohne Vorankündigung
Zusammenbau innen gereinigt werden, um drehen, bis das Ventil vollständig geöffnet vor.
Schweißüberreste zu entfernen. ist.

Utiliser exclusivement des pièces de Étanchéité arrière (fig. 6)
FRANÇAIS Pour assurer l’étanchéité arrière de la vanne,
rechange Danfoss d’origine, y compris
pour ce qui est des fouloirs, joints et tourner la tige dans le sens antihoraire
Installation joints toriques. Les pièces de rechange jusqu’à l’ouverture complète de la vanne.
homologuées garantissent que le
Fluides frigorigènes matériau est bien compatible avec le fluide Équilibrage de pression (fig. 7)
Utilisable avec tous les fluides frigorigènes frigorigène concerné. Dans certains cas, la pression se forme
ininflammables courants, y compris le derrière le fouloir. Il est alors nécessaire
R717, mais aussi avec les gaz et liquides Le chapeau peut rester en place de fixer un volant de manoeuvre ou un
non corrosifs, à condition qu’ils soient uniquement si : dispositif similaire au sommet de la tige
compatibles avec les joints. la température dans la zone comprise lors de l’équilibrage de pression. Il suffit de
Les hydrocarbures inflammables sont entre le corps de la vanne et le chapeau dévisser lentement le fouloir pour équilibrer
déconseillés. Cette vanne est préconisée lors de la soudure ne dépasse pas +150 la pression.
uniquement pour les circuits fermés. °C/+302 °F. Cette température dépend de la
Contacter Danfoss pour de plus amples méthode de soudure appliquée, ainsi que Dépose du fouloir (fig. 8)
informations. du refroidissement du corps de la vanne Il est désormais possible de déposer le
pendant la soudure. (Le refroidissement volant de manoeuvre et le fouloir.
Plage de température peut être réalisé, par exemple, en
SVA-ST: –50/+150°C (–58/+302°F) enveloppant le corps de la vanne d’un Démontage de la vanne (fig. 9)
SVA-SS: –60/+150°C (–76/+302°F) chiffon humide.) Veiller à ce qu’aucune Ne jamais déposer le chapeau avec la vanne
salissure, aucun résidu de soudure, etc. toujours sous pression.
Pression ne s’introduise dans la vanne pendant la - Contrôler l’état du joint torique (pos. A).
SVA 10-65 : Ces vannes ont été conçues pour soudure. - Vérifier que la tige est exempte de
une pression de service maximale de 52 bars rayures et de traces d’impact.
g (754 psi g). Veiller à ne pas endommager la bague en - Si la bague en téflon du cône est
SVA 80-200 : Ces vannes ont été conçues téflon du cône. endommagée, l’ensemble du cône doit
pour une pression de service maximale de être remplacé.
50 bars g (725 psi g). Préserver le boîtier de vanne des
contraintes (charges externes) après Remplacement du cône (fig. 9)
Installation l’installation. Desserrer la vis du cône (pos. B) à l’aide
Installer la vanne de sorte que la tige soit d’une clé Allen.
orientée à la verticale vers le haut ou en Les vannes d’arrêt ne doivent en aucun cas SVA 10....................................................2,0 mm A/F
position horizontale (fig. 1). Les vannes être montées dans des circuits où la sortie SVA 15-40.............................................2,0 mm A/F
doivent être ouvertes manuellement, sans de la vanne serait mise à l’atmosphère. La SVA 50-65.............................................2,5 mm A/F
recourir à des outils ou des appareils (fig. sortie de la vanne doit systématiquement SVA 80-100.............................................. 4 mm A/F
3). Cette vanne est conçue pour supporter être raccordée au circuit ou obturée comme SVA 125-150........................................... 5 mm A/F
une pression interne élevée. Toutefois, il il se doit, par exemple à l’aide d’un embout SVA 200.................................................... 6 mm A/F
convient de concevoir le circuit de façon soudé.
à éviter les pièges à liquide et réduire (Une clé Allen est incluse dans le kit de
les risques de formation d’une pression Montage joints Danfoss Industrial Refrigeration).
hydraulique sous l’effet de la dilatation Retirer les résidus de soudure et les Déposer les billes (pos. C).
thermique. Veiller à ce que la vanne soit salissures des conduites et du corps de
protégée des variations de pression au sein la vanne avant de procéder au montage. Nombre de billes à la pos. C :
du circuit comme les « coups de bélier ». Vérifier que le cône est entièrement revissé SVA 10..........................................................6 unités.
au niveau du chapeau avant de le replacer SVA 10-20................................................ 10 unités.
Attention : dans le corps de vanne (fig. 5a). SVA 25-65................................................ 14 unités.
Les vannes SVA sont des vannes d’arrêt SVA 80-200.............................................. 13 unités.
et doivent toujours être complètement Serrage
ouvertes ou fermées. La position semi- Serrer le chapeau avec une clé Le cône peut ensuite être déposé. Placer
ouverte est interdite. Si la vanne est dynamométrique en respectant les valeurs le nouveau cône sur la tige et replacer les
installée à proximité du compresseur prescrites dans le tableau (fig. 5b). billes. Visser de nouveau le cône et assurer
(lignes de l’économiseur, conduits d’huile, la fixation de la vis à l’aide de Loctite n° 648.
etc.) ou sur d’autres lignes soumises à Couleurs et identification
des vibrations et des impulsions de forte Les vannes SVA sont revêtues en usine Montage
intensité, il est nécessaire d’installer des d’une couche primaire d’oxyde rouge. La Retirer toute salissure du corps de vanne
rondelles frein spéciales sur la vanne. Se vanne peut être identifiée précisément à avant de procéder au montage. Vérifier que
reporter au catalogue pour un complément l’aide de la bague d’identification située le cône est revissé au niveau du chapeau
d’informations. au sommet du chapeau, ainsi que par avant de le replacer dans le corps de vanne
l’estampage sur le corps de vanne. La (fig. 5a).
Sens de débit recommandé surface extérieure du boîtier de vanne
Pour obtenir des conditions de débit doit être protégée de la corrosion à l’aide Serrage
optimales, installer la vanne avec le débit d’un revêtement adéquat à l’issue de Serrer le chapeau avec une clé
dirigé vers le cône de vanne tel qu’indiqué l’installation et du montage. dynamométrique en respectant les valeurs
par la flèche située sur le côté du corps de prescrites dans le tableau (fig. 5b). Serrer
vanne (fig. 2). Un débit de sens opposé est Il est préconisé de protéger la bague le fouloir avec une clé dynamométrique
également admis (fig. 2), mais réduit d’identification lors de l’application de la en respectant les valeurs prescrites dans le
légèrement la valeur kv- / Cv. peinture sur la vanne. tableau (fig. 10).
Les vannes SVA-SS ne sont pas peintes
Soudure et ne nécessitent aucun revêtement de
Retirer le chapeau avant de souder (fig. protection. Utiliser exclusivement des pièces de
4) afin de ne pas endommager les joints rechange Danfoss d’origine, y compris
toriques du fouloir, de la partie située entre Maintenance pour ce qui est des fouloirs, joints et
le corps de vanne et le chapeau, ainsi que joints toriques. Les pièces de rechange
le joint en téflon du siège de vanne. Veiller Fouloir homologuées garantissent que le
à faire usage de matériaux et de procédures Lors des interventions de service et de matériau est bien compatible avec le fluide
compatibles avec le matériau du boîtier maintenance, toujours remplacer dans son frigorigène concerné.
de vanne pour effectuer des soudures sur intégralité le fouloir, disponible comme
ce dernier. Nettoyer l’intérieur de la vanne pièce de rechange. En règle générale, le Contacter Danfoss en cas de doute.
pour évacuer les résidus de soudure une fouloir ne doit pas être déposé en cas de
fois le soudage terminé, avant de procéder pression interne de la vanne. Cependant, si Danfoss décline toute responsabilité quant
au remontage. les précautions suivantes sont prises, il est aux éventuelles erreurs et omissions. La
possible de déposer le fouloir avec la vanne société Danfoss Industrial Refrigeration se
Éviter que des résidus de soudure et des toujours sous pression : réserve le droit de modifier les produits et
salissures ne pénètrent dans les filets du spécifications sans préavis.
boîtier et le chapeau.

Declaration of Conformity
The Pressure Equipment Directive 97/23/EC
Name and Address of Manufacturer's Representative within the European Community

Danfoss Industrial Refrigeration A/S
Stormosevej 10
PO Box 60
DK-8361 Hasselager
Denmark
Declaration
We hereby declare that below-mentioned equipment are Classified for Fluid Group I (all refrigerants (toxic, non-toxic,
flammable and non-flammable)), and that all are covered by Article 3, paragraph 3.
For further details / restrictions - see Installation Instruction
Description of Pressure Equipment

Refrigerant stop valve, with straight or angled bonnet arrangement
Type SVA-ST, SVA-HS and SVA-SS
Nominal bore DN ≤ 25 mm (1 in.)
References of other Technical Standards and Specifications used

prEN 12284 DIN 3158
AD-Merkblätter 2000
Authorised Person for the Manufacturer's Representative within the European Community
Name: Michael Breumsø Title: Plant Director
Signature: Date: 07/03/2006
148B9735 – rev. 1

Declaration of Conformity
The Pressure Equipment Directive 97/23/EC
Name and Address of Manufacturer within the European Community

Danfoss Industrial Refrigeration A/S
Stormosevej 10
PO Box 60
DK-8361 Hasselager
Denmark
Description of Pressure Equipment
Refrigerant stop valve, with straight or angled bonnet arrangement

Type SVA-ST, SVA-SS
Nominal bore SVA-ST, DN 32-200 mm (1¼ - 8 in.); SVA-SS DN 32-200 mm (1¼ - 8 in.)
Classified for Fluid Group I (all refrigerants (toxic, nontoxic, flammable and nonflammable)).
For further details / restrictions - see Installation Instruction.
Temperature range SVA-ST –50°C/+150°C (–58°F/+302°F)
SVA-SS –60°C/+150°C (–76°F/+302°F)
Standard applications 40 bar (580 psi)
Maximum allowable High pressure applications 50 bar (725 psi)
working pressure High pressure applications 52 bar (754 psi)
Conformity and Assessment Procedure Followed

Category II III
Module D1 B1 + D
B1: 07 202 0511 Z 0058/1/H-0001
Certificate ID D1: 07 202 0511 Z 0009/1/H-0002
D: 07 202 0511 Z 0009/1/H-0001
Nominal Standard
DN 32-80 mm (1¼ - 3 in.) DN 100-200 mm (4-8 in.)
bore applications
Name and Address of the Notified Body which carried out the Inspection
TÜV-Nord e.V.
Grosse Bahnstrasse 31
22525 Hamburg, Germany (0045)
Name and Address of the Notified Body monitoring the Manufacturer’s Quality Assurance System
TÜV-Nord e.V.
Grosse Bahnstrasse 31
22525 Hamburg, Germany
References of Harmonised Standards used

EN 10028-3 EN 10213-3 EN 10222-4
References of other Technical Standards and Specifications used

prEN 12284 DIN 3158
AD-Merkblätter 2000
Authorised Person for the Manufacturer within the European Community
Name: Michael Breumsø Title: Plant Director
Signature: Date: 07/03/2006
148B9701 - rev. 2

MAKING MODERN LIVING POSSIBLE
Industrial Refrigeration controls

Guide to service and maintenance
REFRIGERATION &
AIR CONDITIONING DIVISION Service guide
Service guide Service and maintenance
Contents Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Mechanical components are subject to wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assuring long lasting performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Maintenance of the stop valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Determining when inspection/service is needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Example - One stage ammonia plant with pump circulation and plate heat condenser (milk plant) . . 8
Inspection guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Spare parts kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Service guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Replacing kit A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Replacing kit B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Replacing the cone HS + ST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Replacing the packing gland (SVA-ST only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Torque overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Other parts and fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
© Danfoss A/S (AC-DSL/???), ?? - 2006 DKRC?.??.???.??.?? / 520H????

Introduction Danfoss components are designed to give a high Danfoss has more than 60 years of experience
level of performance over an extended operating with design and manufacture of refrigeration
life. valves, which assures reliable designs and a long
operating life.
When Danfoss develops its refrigeration
components, deep consideration is given
to functionality, operating performance,
serviceability, and lifetime. Well-designed valves
do not come by coincidence and experience
counts.
Mechanical components Despite the best designs, it is well known that Such contaminants will result in reduced valve
are subject to wear mechanical components experience wear. performance and reduced life expectancy.
Operating conditions have a major influence on
the expected life and performance of mechanical The value of preventive maintenance
components. The use of preventive maintenance procedures
is an effective strategy for maintaing valve
The presence of system contaminants such performance at a high level and assuring a full life
as dirt, metal particles, moisture, and acids in expectancy.
refrigeration systems directly contribute to
accelerated wear in mechanical components. Such procedures can include the appropriate
use and cleaning of system filters and strainers.
Wear can give reduced It can also include the use of moisture indicators
performance and reduced life and driers in systems susceptible to high water
While the effects of normal wear are anticipated concentrations. These two procedures alone are
in valve design and construction, the presence of significant steps towards protecting the system
contaminants take effect depending on the type performance.
and concentration of contaminants over time.
Assuring long Contaminants do not belong in refrigeration systems are completely clean and many have
lasting performance systems. However most refrigeration systems quite a high level of contamination.
have some level of contamination and the level
of contamination is important in determining Danfoss recommends to always follow good
required service intervals. installation practices and to create and use plant
specific service manuals with indication of critical
Water system components and service intervals.
Water is necessary for acid-salts to become
active and aggressive. Strong acids can seriously Such routines keep the need for system service
damage the inside of valves and controls. at a minimum level, and also minimise the cost of
Water in high concentations can freeze and poor system performance and reduce the risk of
clogg nozzles and filters. Water may enter into system breakdowns.
refrigeration systems when the system pressure
is below the atmospheric pressure or when A majority of installed refrigeration systems
system are open during service or installation contain some level of contaminants. While these
procedures. contaminants can be cleaned up and removed
in many cases, it is possible that the refrigeration
Solid Contaminants valves are not working at an optimal level.
Solid contaminants found in refrigeration system
can cause clogging of filters/strainers and Suboptimal valve performance can result in
nozzles. They can damage valve seats and sealing higher system operating costs, lower system
surfaces causing valve leakages. performance, or higher risk of unexpected
failures.
They can even cause valves to fail by damaging
finely machined working surfaces such as As a step in the preventive maintenance
bearings and threads. Contaminants in a procedures, Danfoss recommends periodic valve
refrigeration system may remain from the of inspection to insure optimal performance. The
original installation activities. For example, frequency of the valve inspection should directly
metal particles may be left behind from pipe consider the level of contamination in the system.
grinding before welding or from pipes that This document contains some specific guidelines
were not properly cleaned before installation. for evaluating service intervals.
Contaminants can also result from corrosion
caused by water, acids or other chemicals in Ultimately it is up to the refrigeration mechanic
the system. Experience shows that refrigeration to diagnose the condition of the valves. It is the
systems free from contaminants are more refrigeration mechanic, who has the hands-on
reliable. Ideally all of these contaminants can be knowledge and experience to evaluate the
eliminated or prevented. Reality shows that few condition of a system.

Assuring long The refrigeration mechanic should take the time

lasting performance to identify critical system components, with
(continued) the purpose of making a plant specific service
manual where inspection and service intervals
are clearly defined.
Scheduling Service and Inspection

The ideal frequency of inspections and
preventive maintenance intervals varies from
system to system. However, experience shows
that certain events or conditions influence the
ideal length of time between inspections and
service intervals. These events or conditions are
mentioned below:
3 months following a new system start-up
Immediately prior to re-starting a system that
has been idle for 6 months or more.
Immediately prior to re-starting a system that
has experienced a major component failure.
Periodical inspection: Adjusted according to
plant conditions.
Maintenance That may cause increased wear or damage of

of the stop valves the valve. That’s why it is extremely important
to follow the installation procedures and not to
introduce any dirt in the system while assembling
it.
Danfoss stop valves SVA DN 50-300 have special

Teflon valve seat with carbon. That significantly
reduces the wearing of the seat and increases
service intervals.
It is a must in any plant that stop valves operate

reliably. In this manual we give suggestions, how
to estimate service intervals for stop valves, and
what parts should be changed during service in
Despite the robust design of Danfoss industrial order to provide reliable operation.
refrigeration stop valves, the life time and
performance can be reduced by the above
mentioned factors.
Dirt is especially dangerous for the stop valves.

In extremely contaminated systems frequent
operation of the stop valve may allow dirt to
penetrate in to the thread between the bonnet
and the spindle.
DKRC?.??.???.??.?? / 520H???? © Danfoss A/S (AC-DSL/???), ?? - 2006

Service guide Service and maintenance - Stop and regulating valves
Determining when Use the tables below as a guide to determine

inspection/service is the periodic intervals between valve inspections.
needed Please also refer to the inspection guide on issues
to look for inside.
The findings of an inspection will result in a

choice of which service set to use, provided any
is needed.
First the plant conditions table is used to To determine the levels of moisture related to
determine the points. The points from each of the refrigerant, please refer to the moisture
the 5 questions are added. reference table to get an idea of the water
The plant condition points and water content level whether it is low, medium or
content level are then used in the table of high.
recommended intervals together with the
present moisture level.
Table 1 Plant conditions Points Application comment

Vibrations & None or low 0 Dry suction lines, hot gas lines, Wet suction lines.
pulsations High, mounted on unit, but not 4 Compressor discharge lines
mounted directly on compressor Compressor oil lines
High, mounted directly on compressor 6 Economizer lines*
Plant pressures Above atm. pressure 0
Below atm. pressure 2
Filtering Mechanical filtering 1
No filtering - valve position vertical up 3 Note:
Valve position with a spindle down is not allowed
No filtering - valve position horizontal 5
Stand still periods Long >one month 4 Danger of rust formations
Short <one month 2 Sediments occurs
Continuous operation 0 Valves remain quite clean inside
Saturation Dry gas 0 e.g. dry suction line, hot gas line
Pure liquid 1 e.g. liquid line or condensate line, oil lines
Mixture of gas and liquid 2 e.g. wet suction line
Expansion 4 For REG valves only - Not allowed for SVA valves
* 4 points if lock washers are installed.
Table 2 Water content

Moisture reference Low Medium High
R717 [%] < 0.5 0.5 - 1 >1
HFC ppm < 60 60-100 > 100
HCFC ppm < 30 50-100 > 100
CO2 ppm < 15 15-55 > 55
Table 3 Recommended intervals [years] between inspections

Water content
Points
Low Medium High
1-6 10 8 6
Plant Conditions 7-11 8 6 4
12-17 6 4 2
Table 4 Service kits

A Inspection Open/close - set of gaskets
B Maintenance Complete set of gaskets with cone
and a packing gland
C Replacement Valve replacement

Example Refrigerant: NH3

One stage ammonia plant with Suction pressure: –10°C
pump circulation and plate heat
condenser (milk plant) Surge drum temperature: –7°C
Liquid temperature: +45°C
Owner of the plant wants to determine service The plant has mechanical filtering (strainers
intervals of the line components (stop and before regulating valves and pumps). The plant is
regulating valves). For example we’ll take the running continuously during the night with high
most critical components: load, than has standstill periods during the day.
Stop valves in the discharge line.
The compressor has stand still periods to
Regulating valve in the liquid line (expansion). distribute running hours between them. Based
Stop valves in the oil line (no lock washers on this information it is now possible to fill in the
installed on the valve) - See technical leaflet tables as follows:
PD.KD0.A for further information.
There is no water in the system at the initial stage.

We presume that the system runs properly and
no water introduced during system maintenance.
However, water content may build up after a few

years of operation. If no water removal systems
are installed in the plant, it is necessary to
periodically check water content in ammonia.
Stop valve - suction Hand regulating valve Stop valve - oil cooler
Vibrations and pulsations 0 0 4
Plant pressures 2 0 0
Filtering 3 1 1
Stand still 2 2 2
Saturation 0 4 1
Total 7 7 8
According to the selection table and considering

low water content in the system, the valves
should be serviced after 8 years of operation.
Please see table ?? for the spare parts kits.
DKRC?.??.???.??.?? / 520H???? © Danfoss A/S (AC-DSL/???), ?? - 2006

Example (continued)
Tapp_0145
One stage ammonia plant with
Danfoss
02-2007
pump circulation and plate heat 1
condenser (milk plant)
3 4
5
9
10
9 6
1. Compressor 7
2. Oil separator
3. Stop valve 1
4. Condenser
5. Liquid separator
6. Hand regulating valve
7. Surge drum
8. Plate heat evaporator
9. Oil cooler 8
10. Stop valve 3

Inspection guide The table below is useful as a checklist when For example, only the inspection kit is required
performing stop valves inspections. for a valve found with acceptable conditions. On
the other hand a valve found with damage to the
The primary checkpoints are listed along with seat, rebuild kit B is required.
different failures that are known to occur by
experience.
If one of these conditions is observed the

appropriate service kit is shown in the top of the
table.
Inspection guide Table 5

SVA - part Check for : Kit to be used
A B C Remark
Bonnet Rust at the outside thread Light: Heavy
Clean - repaint
Rust at the sealing surface Clean Heavy Top gasket or packing
gland
Damage of the sealing Repair Beyond repair Top gasket or packing
surface gland
Cone Teflon valve plate X X
damaged
Erosion or scoring Light: Heavy Heavy
Increase
inspections
Spindle Thread surface damaged Light: Heavy Look out for particles
Clean in the thread
Increase
inspections
Smooth surface in top Light: Heavy Look out for particles
damaged increase in the packing gland
inspections
Wear on the bottom part Light: Heavy Use Teflon ring if
increase suspicion of cone
inspections spinning REFERENCE
Packing gland Damage to o-rings Type is consistent X X Look out for particles
with temperature in the packing gland
range?
Damage to the top X X Rust or deformation
Housing Rust at the seat Light: Heavy rust - change
use sandpaper house
Cavitation of the seat Light: Find the reason for the
clean cavitation
Inspect the PTFE
valve plate
Rust at the sealing surface Clean Heavy rust - change
house
Rust in the bolt holes Clean Condition of bolts?
Grease
Spare parts kits Inspection set A: Table 6

Size SVA-ST, REG* (6-65) SVA-HS STC SVA-DH/DL
6-10 148B4070
15-20 148B4053 148B4119 148B4296
Consists of: 25-40 148B4008 148B4120 148B4297

– o-ring (flat gasket 50 148B4009 148B4121 148B4009
for SVA HS, DL, DH) for 65 148B4010 148B4122 148B4010
housing/bonnet
80 148B4011 148B4123 148B4011
– gasket for cap
– back sealing (80-200) 100 148B4012 148B4124 148B4012
125 148B4013 148B4125 148B4013
150 148B4014 148B4126 148B4014
200 148B4015 148B4127
250 148B4162
300 148B4163
* SVA 6-10 packing gland includes sealing Al ring.
10 DKRC?.??.???.??.?? / 520H???? © Danfoss A/S (AC-DSL/???), ?? - 2006

Spare parts kits Inspection set B1 for stop valve: Table 7

(continued) Size SVA-ST SVA-HS STC SVA-DH SVA-DL
6-10 148B4069*
+148B4072
15-20 148B4052 148B4110 148B4298
+148B4056 148B4300 148B4309
Consists of ** : 25-40 148B4000 148B4111 148B4299

– o-ring (flat gasket +148B4032 148B4301 148B4310
for SVA HS, DL, DH) for 50 148B4001 148B4112 148B4001
housing/bonnet +148B4033 148B4302 148B4311
– allan key 65 148B4002 148B4113 148B4002
– cone** +148B4033 148B4302 148B4311
– locking screw
80 148B4003 148B4114 148B4003
– balls
+148B4034 148B4303 148B4312
– gasket for cap
– back sealing (80-200) 100 148B4004 148B4115 148B4004
(Kit B1) +148B4034 148B4303 148B4312
– packing gland 125 148B4005 148B4116 148B4005
(including gaskets) +148B4035 148B4304 148B4313
(kit B2) 150 148B4006 148B4117 148B4006
+148B4035 148B4304 148B4313
200 148B4007 148B4118
+148B4036 148B4305
250 148B4167 148B4175
300 148B4168 148B4176
Inspection set B2 for regulating valves: Table 8

Size / 6-10 15-25 25-40 50 65
Cone small medium large
1 2453+035
+148B4072
2 2453+036
+148B4072
3 2453+037
+148B4072
Consists of * : 4 2453+038
– o-ring (flat gasket +148B4056
for SVA HS, DL, DH) for 5 2453+039
housing/bonnet +148B4056
– allan key
6 2453+040
– cone***
+148B4056
– locking screw
– balls (Kit B1) 7 2453+041
– packing gland +148B4056
(including gaskets) 8 2453+042
(kit B2) +148B4032
9 2453+043
+148B4032
10 2453+044
+148B4032
11 148G3197
+148B4033
12 148G3198
+148B4033
REG valves DN 25 can have a medium and a

large housing. Please use 15-25 set for a medium
housing and 25-40 set for a large housing.
* SVA 6-10 packing gland includes sealing Al ring.

** In order to get the complete inspection set B it is necessary to order 2 code numbers (kits B1 and B2). First code number
is a packing gland. Second code number is the rest of the set. It is also possible to order a packing gland or the rest of the set
separately (except for SVA-DH and DL).
*** For SVA-DH/DL valves replaceable Teflon seat is included in the set instead of the complete cone.
© Danfoss A/S (AC-DSL/???), ?? - 2006 DKRC?.??.???.??.?? / 520H???? 11

Exploded view: SVA-DH 250-300 SVA-DL 250-300
Inspection set A:
Gasket for cap
Back seating
Flat gasket
Inspection set B:
+
Packing gland
Insert for distance piece
for SVA-DL
Teflon ring for cone (equalization)
Wearing ring for cone (2 pcs.)
Teflon ring for cone (valve seat)
for SVA-DH
Gasket for cone (u-sleeve – 2 pcs.)
Wearing ring for cone
Teflon ring (valve seat)

Exploded view (continued): SVA-ST 15-40 SVA-HS 15-40 SVA-HS 15-40
Inspection set A:
Gasket for cap
O-ring (SVA-ST, STC)/
flat gasket (SVA-HS) for housing
Inspection set B1:

Valve cone
Balls
Allan (int. hex) screw
O-ring/gasket for valve body/bonnet
Inspection set B2:

Packing gland
Only for SVA-HS:

Conical Teflon rings (2 pcs.)
Washer for the packing gland
Distance piece

Exploded view (continued): SVA-ST/STC 65-200 SVA-HS 65-200
Inspection set A:
Gasket for cap
O-ring (SVA-ST, STC)/
flat gasket (SVA-HS) for housing
Back seating (only for SVA-HS, ST)
Inspection set B1:

Valve cone
Balls
Allan (int. hex) screw
O-ring/gasket for valve body/bonnet
Inspection set B2:

Packing gland
Only for SVA-HS

Conical Teflon rings (2 pcs.)
Washer for the packing gland
Distance piece

Service guide
Replacing kit A
Fig. 1 Fig. 2 Fig. 3
Stop valves with cap or handwheel Open the valve fully rotating anti clockwise Loosen and remove all the bolts.
until full stop. Using a socket wrench is the best solution.

Lift the top vertically up from the housing. Take the-o-ring out. Thoroughly clean tihe a clothe the groove for the o
Do not scratch the steel surface under the o-ring. ring in the housing (use a screw driver to get a better
Put on a new o-ring with some oil. contact)
Fig. 7 Fig. 8
Insert top vertically into the housing, and tighten the Be careful not to damage the valve plate, while inserting
bolts. the top into the housing, otherwise the valve will not be
tight internally.

Service guide (continued)
Replacing kit B
Replacing the cone HS + ST
Please see the service guide for kit A (disassembling and assembling the valve)
Fig. 1 Fig. 2. Fig 3.
Remove the screw. The torque to remove is rather high Remove the balls slightly rotating the cone. Remove the Replace the balls.
due to a mechanical deformation of the cone. old cone when all balls are out, and insert the new cone. Count the balls to be sure that all are in place.
Fig. 4 Fig. 4A Fig 4B

Replace the lock screw. Fix the cone with Loctite Fix the cone with punch mark
Tighten it to the required torque and fix it using one of
the following 2 methods (A and B)
Fig. 5
The punch mark should look like this:
Replacing the packing gland (SVA-ST only)

Please see the service guide for kit A (disassembling and assembling the valve).
The valve must be fully open to avoid leakage of refrigerant.
If a lock washer is installed on the cone, extra force should be applied to backseat the spindle.
Unscrew the packing gland Remove the packing gland, be careful not to scratch Gently put a packing gland back on and tighten it.
the spindle. Please make sure that you also remove the
sealing from the bonnet.

Torque overview Bonnet and packing gland torque overview

Size SVA-ST, REG**, SVA-HS STC
SVA-DH/DL (250-300)
6-10 10
15-20 22 22 80
25 44 44 80
32-40 44 44 100
Bolted bonnet* /
50 44 44 36
Top flange bolts
65 75 75 62
80 44 44 36
100 75 75 62
125-150 183 183 130
200 370 370
250-300 370
6-10 30
15-20 50 40 50
25 70 60 50
32-40 70 60 70
Packing gland 50-65 60 60 70
80-100 60 80 70
125-150 80 80 80
200 80 120
250-300 80
* Bolted bonnet for SVA 6-10, STC 15-40;
** REG valves sizes DN6-65
SVA DH-DL 250-300
SVA-DL, SVA-DH SVA-DL SVA-DH

Nm LB-feet Nm LB-feet Nm LB-feet
DN 250-300 25 18 DN 250-300 25 18 DN 250-300 49 36
Lock screw torques:

Please make sure that both of the following conditions are fulfilled:
1. Minimum tightening torques Mmin are according to the table below
2. Cone rotates freely on the spindle
SVA/STC 6-300, REG 15-40 SVA,STC*, REG** Mmin, Nm
6-10 1
15-40 1
50-65 2
80-100 10
125-150 12
200-300 15
* STC sizes DN 15-150
** REG sizes DN 6-65
Please see the product instruction for

further information.

Other parts and fittings Welding nipples with Al. gaskets and nuts for SVA valves
Code no.
148B4244 * ACCESSORY WELD.NIPPLE DN10 D + UNION NUT G 7/8”
148B4245 * ACCESSORY WELD.NIPPLE DN6 A + UNION NUT G ½”
148B4246 * ACCESSORY WELD.NIPPLE DN10 A + UNION NUT G 7/8”
148B4247 * ACCESSORY WELD.NIPPLE DN15 A + UNION NUT G 7/8”
148B4184 * ACCESSORY WELD.NIPPLE DN6 D + UNION NUT G ½”
148B4185 * ACCESSORY WELD.NIPPLE DN15 D + UNION NUT G 7/8”
2469+008 Weld nipple incl. union nut and O-ring CD 10
2469+056 Blind nut incl. gasket G 1/2
148B4182 CD 6 Cutting ring + union nut
148B4186 CD 10 Cutting ring + union nut CD 10 60 pcs.
148B4183 CD 10 Cutting ring + union nut CD 10 1 pc.
* kit contains 2 nipples, 2 gaskets and 2 nuts
Lock washers for the valves subjected to vibrations/pulsations*

Code no.
148B4238 I-PACK(10) ACC.LOCK WASHER SVA 15-20
148B4243 I-PACK(10) ACC.LOCK WASHER SVA 200
* please check SVA catalogue for applications recommendations
Caps and handwheels

SVA Cap including gasket Handwheel incl. screw and washer
3-10 148B4074 148B4073
15-20 148B4075 148B4060
25-40 148B4076 148B4062
50-65 148B4076 148B4064
80 148B4077 148B4065
100 148B4077 148B4066
125-150 148B4078 148B4067
200 148B4079 148B4068
250 148B4171 148B4169
300 148B4171 148B4170

SOLENOID VALVE BLOCK TYPE S102 WITH FOUNDATION
Grasso CAPACITY CONTROL
Refrigeration Devision
protection caps
CONSTRUCTION; CONNECTIONS
Connection Dimension
oil pressure oil port of oil pump M 16x1,5
G oil return capacity control M 16x1,5
K oil charging capacity control M 16x1,5
part load direction
L oil charging capacity control M 16x1,5
full load direction DBV8
TECHNICAL DATA
Type seat valve
Function currentless closed
Pressure range 0-21 bar
Fluid oil with refrigerant
Viscosity 15°E=120cSt
at 20 °C
Medium temperature -30/ +130 view A
Standard voltage 220 V, AC
Power input 17 Watt
Protective system IP00 with
coupler socket IP65
Electric connection plain connector
6.3x0.8 mm or coupler
socket to DIN 43650
shape A
Electrical installation to VDE 0580 /
EX to VDE 0165
Insulation class H
HYDRAULIC CONNECTION DIAGRAM

1 Solenoid valve Y1
2 Solenoid valve Y2
3 Solenoid valve Y3
4 Solenoid valve Y4
5 Throttle screw DS5
L K
8 Pressure limiting valve DBV8 G
Y1 Y2 Y3 Y4 L
oil
capacity é open closed closed open
capacity ê closed open open closed
G
SPARE PARTS
SV block S102 complete 501298372
Magnetic section 13-36T 220V AC 501298915
Magnetic section 13-36T 24V DC 501298948
Other voltages on request.
08.06.01 633161E.DOC - 1/1

SAFETY PRECAUTIONS SPe
JAN 2005
INTRODUCTION SHUT-OFF VALVES
This is a summary of safety procedures for the proper selection, installation, All valves that could trap liquid when closed must be marked with a
use and maintenance of Hansen refrigeration valves or other products warning against accidental closing. Some liquid refrigerant must be removed
hereafter all called components. Hansen components are only for refrigera- to be replaced by gas before the shut-off valves are closed on both sides
tion systems using ammonia, R22, R134a and other Hansen-approved of a control valve or any other component. Also, liquid must be removed
refrigerants (by the factory in writing). This summary is intended to help you before a shut-off valve is closed at the inlet of a solenoid valve or a regulator
protect your personnel, product, and plant. However, this information must with a positive electric shut-off, or some outlet pressure regulators, or at the
be supplemented by accepted and known industry safety practices and local outlet of a check valve, unless these control valves are manually open. To
code requirements. protect personnel, product, and plant, remove the liquid from the section to
Hansen valves and other components are designed and built to the highest be isolated before shut-off valves are closed. Make sure the control valve
standards of the refrigeration industry. Refrigerant in the system must be seat ports are open when removing the liquid. Shut-off valves leading to the
kept free of any foreign matter such as dirt, grit, rust, impure oil, wax, sludge, atmosphere, even if it is temporary, must be plugged or capped to prevent
water, etc. However, for proper performance, components must be corrosion inside of the valve, as well as leakage due to seat expansion,
correctly chosen, properly installed, and periodically serviced. vibration, dirt, or improper opening; the valve seat should be left cracked
open to prevent hydrostatic expansion between the valve and the plug or cap.
All personnel working on valves or refrigeration components must be One must take care when operating valves or regulators with threaded
qualified to work on refrigeration systems. Any person intending to service bonnets so that the bonnet does not turn. Bonnets must be torqued to factory
a valve or component should completely read this summary and the bulletin specifications after field-servicing. Shut-off valves should be either wide
describing the particular component and its operation before any work open or closed shut in service. Shut-off valve should not be used as a
begins. Do not remove any part unless the interior pressure of the throttling valve. Use hand expansion valves for throttling gas and liquid.
component is below zero. When installing or servicing valves or compo-
nents, bonnets and bolts must be properly torqued. If there are any INSTALLATION
questions, contact Hansen before proceeding with the work. Installation must be done according to all applicable Safety Codes and
Standards, and by personnel qualified to install refrigeration systems. Every
Abnormal sounds and/or vibrations of piping, fans, pumps, pressure actu- segment of a refrigeration system, including control valves, must be field
ated pumping systems and hydraulic pipe pressure surges should be pressure tested before system is insulated and put into use. Make sure that
corrected. correct high and low side pressures are used. Pressure or temperature must
If a component has failed under circumstances which caused, or could have never exceed the limits stated in current bulletins.
caused, injury to personnel or damage to property, a replacement should not Allow proper space for installing any valves. Do not use a valve or component
be installed until the reason for the previous failure is determined and to “stretch” or “align” the pipe. Using flange bolts to close a large gap can
corrected. distort a valve or at least stress it unduly and possibly cause it to malfunction,
Where critical temperatures or products are involved, backup temperature or the bolts may be damaged or stripped. For proper sealing, gaskets should
controls and alarms are required. It is the responsibility of the installer to add be lightly oiled and all bolts must be tightened evenly. Make sure the flange
devices (alarms, safety and limit controls, etc.) that protect against or warn tongues are properly aligned with the grooves in the valve or component
of any operating control failure. Users and operators also must be aware body. Where necessary, support components by brackets or hangers to
that harmful refrigerant properties and pressure could damage products or avoid overstressing.
injure people. Components must not be installed in locations where they can be damaged
As with all electronic and mechanical components, there is a limited life by material handling or other equipment. Trapped ice buildup must be
expectancy. An expected maximum life of seven to ten years is typical for avoided at or between valves and other equipment. Provide reasonable
an electronic component. This should be understood as only a suggested access to all components for maintenance purposes. Individual valves,
replacement time period. Actual condition and performance of electronics control stations, pumps or other components must be provided with isolation
due to ambient conditions, quality of electrical current, voltage, etc. may valves and means for pumping out or safely purging the refrigerant.
necessitate a different replacement schedule. Regardless, all mechanical,
electrical, and electronic components should be inspected at least annually PUMP OUT
and replaced or repaired as necessary to ensure their safe and continuous For the protection of personnel, product, and plant, all refrigerant must be
service. Parts subject to wear should be replaced by factory-original removed from a valve or any other component of the system before any
components. Valves exhibiting excessive rust must be maintained, repaired refrigerant retaining part is loosened. Before opening a valve, make sure all
or replaced as necessary. refrigerant has been removed. In particular, beware of strainers and other
sections of valves or piping which may trap liquid refrigerant which will require
LIQUID EXPANSION a considerable length of time to remove. Pump out as much refrigerant as
Temperature increase in a section with trapped 100% liquid can cause possible before discharging remaining refrigerant in a properly protected
extremely high pressures due to the expanding liquid and possibly rupture manner. During pump out, it is normally advisable that control valves be
a gasket, pipe, or various components. When low temperature liquid lines opened manually whenever possible to avoid trapping refrigerant.
are used, as in a liquid overfeed (recirculation) system, and the lines, valves At times, it may be necessary to discharge some small amount of refrigerant
or other components may be exposed to warm ambient conditions, particular from the isolated section. When this becomes necessary, certain precau-
care must be taken. Liquid expansion can occur very rapidly, even if warmed tions must be observed. Make sure control of discharge rate can be easily
only slightly, with subsequent rupture pressure if not relieved or vented maintained and that a quick shut-off is available. Whenever possible,
properly. refrigerant should be discharged into and disposed of in a proper container
RELIEFDEVICES accepted by applicable safety codes and other standards including environ-
Relief devices must be inspected semiannually for rust, corrosion, and other mental. Discharge of refrigerant to atmosphere must be avoided. Never
factors which may prevent valves from operating properly, and should be discharge any refrigerant into an area without sufficient ventilation, or into
replaced at intervals of no longer than five years. In addition to normal an area where open flame or electrical spark is present. Any oil in the
pressure vessel relief requirements, atmosphere relief devices or relief refrigerant may cause a mist that could cause a fire or explosion. To prevent
methods must be used in all parts of a refrigeration system where liquid can pulling excessive air and moisture into a system, avoid opening the system
be trapped and liquid expansion could take place. Do not use "gas service when it is under noticeable vacuum.
only" relief devices for liquid relief applications. CAUTION
VELOCITY SHOCK Do not attempt to work on any part of a refrigeration system without help
nearby and observing. Disconnect all electric power to components
Systems must be designed and operated to avoid any velocity shock of liquid involved. Use "lock-out/tag-out" for electrical and fluid security. Use safety
being conveyed to valves or components or other equipment. Screw goggles or safety face mask to protect the eyes. Other parts of the body,
compressor side port feed is very severe duty in this regard and design
precautions are necessary. Delayed valve openings or closings or other especially the face, hands, and lungs must also be protected. Protective
methods must be utilized where shock is a potential problem. equipment including breathing apparatus and eye flushing equipment must
be readily available, and all personnel involved must be thoroughly trained
PROBES in its use. Personnel must be especially protected against falling because
When removing housing (electronics) for service, do not rotate or back-out they may be startled by escaping refrigerant. Always make sure that there
the probe itself from the pressurized level column. When removing oil from is a way out and that everyone can leave the area fast. When seal caps cover
level column, follow standard pump out procedure. manual opening or adjusting stems, the cap must be removed with caution
- liquid refrigerant could accumulate under cap. Avoid all possibility of contact
with any refrigerant liquid or gas.
6827 High Grove Boulevard

Burr Ridge, Illinois 60527 USA
Effective 01/01/05 and Expires 12/31/05 Tel: (630) 325-1565 Fax: (630) 325-1572
Bulletin K109f
JAN 2004
Specifications, Applications,
Service Instructions & Parts
REFRIGERANT
PRESSURE-RELIEF
VALVE
l
na
a tio d
N fie
For Ammonia and
& rti
A S ME d C e
r
Halocarbon Gas Service
a
Bo Safety Relief to Atmosphere
Pressure Relief Valve
INTRODUCTION KEY FEATURES

Designed to provide emergency relief from excessive INSTALLATION NEOPRENE O-RING
pressure in refrigerant-containing vessels, they are built DATE TAG HELPS SEAL VALVE
in strict conformance with ASME Boiler and Pressure FROM MOISTURE
Vessel Code requirements for safety relief devices. Each ACCURATELY
valve bears the ASME code symbol of certification FACTORY SET
(UV). Their capacities are rated by the National Board of AND SEALED
Boiler and Pressure Vessel Inspectors. These tamper-
STAINLESS
resistant valves are accurately set and sealed by qualified DUCTILE IRON STEEL SPRING
technicians at the factory. BODY FOR ADDED
STRENGTH
APPLICATIONS STAINLESS STEEL
Hansen pressure-relief valves help meet the requirements PISTON
of ANSI/ASHRAE 15-2001 Safety Standard for PREMIUM GRADE
Refrigeration Systems as well as other worldwide codes. STAINLESS STEEL VIRGIN TEFLON
SEAT INSERT
This standard requires pressure vessels of all refrigeration SEAT DISC
systems to be protected by a pressure relief device or
other approved means to safely relieve pressure in the ORDERING INFORMATION
event of fire or other abnormal conditions. Once installed, THREADED CONNECTIONS (NPT)
a properly selected Hansen pressure-relief valve is ready CAT NO
to vent to atmosphere any temporary excessive BOTTOM INLET SIDE OUTLET
overpressure inside of a vessel. After discharge, these H5600R
1 2
/ " FPT 3 4
/ " FPT
valves will attempt to reseat to minimize loss of refrigerant.
H5600A
However, once any relief valve has discharged, it must
1 2
be replaced as soon as possible because debris may H5601 / " FPT 1" FPT
have settled on the seat during discharge. H5602
Hansen pressure-relief valves should be connected to H5602R 3 4
/ " FPT 1" FPT
the vapor space of refrigerant vessels, heat exchangers,
H5632R
oil pots, oil stills, pilot receivers, and elsewhere as may
be required by various codes. H5613
1" FPT 11/4" FPT
Where dual pressure-relief valves are required, Hansen H5633R
offers the three-way valves and other components H5604
necessary for assembly; see pg 4. Rupture disc 11/4" FPT 11/2" FPT
assemblies are required when using Hansen pressure- H5634R
relief valves for halocarbon applications because the TO ORDER:
high cost of such refrigerants demands extreme tightness, Specify catalog number, inlet/outlet connection size, and
see bulletin K209. pressure setting. For halocarbon applications, a rupture
R-Series capacity valves are designed for use where disc assembly is required. See pg 4 and Hansen Bulletin
inlet piping pressure drop including three-way valves K209.
must be less than 3% of the pressure setting. Standard pressure settings: 150*, 175, 200, 225, 250*,
275, 300*, 325, and 350 psig. (*Stock pressure settings.)
Custom pressure settings available; may require extra
delivery time. The new "R" Series Valves have reduced
capacities, see pg 2.
VALVE SIZING AND SELECTION
Step 1: Use the formula below, per ANSI/ASHRAE 15- Example: To determine the minimum required capacity
2001 Safety Standard for Refrigeration Systems to of a relief valve for a vessel containing ammonia that
calculate the minimum required discharge capacity in measures 16 feet in length and 6 feet in outside diameter,
pounds of air per minute. When selecting a dual pressure- the equation would be as follows: 0.5 x 6 x 16 = 48 lb/
relief valve system, be aware that each individual valve min
must have sufficient capacity to protect the vessel.
Step 2: Determine the pressure setting needed. This
C=fDL should be at or below the design pressure of the vessel.
The relief setting should also be at least 25% above the
C= minimum required discharge capacity of the relief maximum expected operating pressure to avoid "weeping"
device in pounds of air per minute. of relief valves. The setting may be below (never above)
f= factor for ammonia refrigerant is 0.5**, factor for the design pressure of the vessel, but it is sometimes
R-22 and R-134a refrigerants is 1.6**. for other best to match vessel design pressure and relief setting
refrigerants see ANSI/ASHRAE 15 or contact to minimize the likelihood of a discharge.
factory.
D= outside diameter of vessel in feet. Step 3: Refer to the Valve Capacity Ratings below and
select the valve with the required capacity (C) at the
L= length of vessel in feet. desired pressure setting.
** This factor is not suitable when combustible materials are
within 20 feet (6.1 m) of the pressure vessel; refer to relevant
codes for corrected sizing method.
PRESSURE-RELIEF VALVE CAPACITY RATINGS (NATIONAL BOARD CERTIFIED)
AIR STANDARD PRESSURE SETTINGS (psig)

CAT NO
CAPACITY
150 175 200 225 250 275 300 325 350 400
H5600R lb/min 10.5 12.2 13.8 15.4 17.0 18.6 20.2 21.8 23.5 26.7
H5602R scfm 140 162 183 205 226 248 269 290 312 355
lb/min 22 25 29 32 36 39 42 46 49 56
H5632R
scfm 292 337 382 427 472 517 561 606 651 741
lb/min 28 33 37 41 46 50 54 59 63 72
H5633R
scfm 377 435 492 550 608 665 723 781 839 954
lb/min 34 39 44 49 54 60 65 70 75 85
H5634R
scfm 449 518 586 655 724 793 861 930 999 1136
lb/min 31.3 36.1 40.9 45.7 50.5 55.3 60.1 64.9 69.7 79.3
H5600A
scfm 417 480 544 608 672 736 799 863 927 1055
H5601 lb/min 35.8 41.3 46.8 52.2 57.7 63.2 68.6 74.1 79.6
H5602 scfm 476 549 622 695 768 841 913 986 1059
lb/min 53.0 61.1 69.2 77.3 85.4 93.5 101.6 109.7 117.8 134
H5613
scfm 704 812 920 1028 1136 1243 1351 1459 1567 1782
lb/min 72.0 83.0 94.0 105.1 116.1 127.1 138.1 149.1 160.2 182
H5604
scfm 958 1104 1251 1397 1544 1691 1837 1984 2130 2423
IMPORTANT NOTE: These are atmospheric relief valves. Settings equal pressure above atmosphere when outlet is connected
via proper Schedule 40 piping to the atmosphere (outside). (scfm = Standard Cubic Feet per Minute)
INSTALLATION DIMENSIONS
THREADED CONNECTIONS R-Series capacity valves
(NPT) have green installation
CAT NO A B C date tags, while all others
BOTTOM SIDE
INLET OUTLET are blue.
H5600A 3 A
/4" FPT
H5600R 1
/2" FPT
H5601 1" FPT 2.13" 2.75" 1.63"

HANSEN TECHNOLOGIES
CORPORATION
INSTALLATION DATE
H5602 REMOVE KNOCKOUTS TO

INDICATE INSTALLATION DATE
H5602R 3 4
/ " FPT 1" FPT 97 JAN JUL
H5632R 98 FEB AUG

B
99 MAR SEP
H5613
1" FPT 11/4" FPT 00 APR OCT
H5633R
3.00" 4.13" 2.25" 01 MAY NOV
H5604 1 1 C
1 /4" FPT 1 /2" FPT 02 JUN DEC
H5634R
K109f
JAN 2004 2
INSTALLATION stressed. Do not put undue stress on the valve by using
Hansen pressure-relief valves come with an installation it to stretch or align pipe.
date tag to identify the number of years the valve has Pressure test all valves and related piping for leaks.
been in service. R-series capacity valves have green When testing a dual pressure relief system, the three-way
installation date tags, while all others are blue. When valve stem should be in the mid position (only during
installing the pressure-relief valve, remove the knockouts testing), ensuring that all valves are properly leak tested.
corresponding to the current year and month. Use a pen Do not discharge valves prior to installation or when
to push the knockout partially through the tag and tear- pressure testing. Never attempt to reset or change the
away from other side. valve setting. Always replace pressure-relief valves
Pressure-relief valves for ammonia refrigeration are once they have discharged.
subject to preventative inspection and maintenance or SERVICE AND MAINTENANCE
periodic replacement (Risk Management Program RMP).
Normal replacement is five years from installation. These tamper-resistant pressure relief valves are
However, once a valve discharges it must be replaced accurately factory set and do not require any field
as soon as possible. Self-reseating is not dependable adjustments whatsoever. They are intended for one time
because of dirt. over-pressure operation and should be replaced
immediately after discharging because setting or seat
Protect pressure-relief valves from dirt and moisture. tightness may be altered. Every six months, relief valves
Match capacity on valve nameplate to system document shall be visually inspected for corrosion or accumulation
as specified by system designer and based upon protected of scale and for leaks. Normally pressure-relief valves
vessel volume. Mount valve directly at the vapor space should be removed and replaced with new valves at
of pressure vessel or on connecting non-valved vapor least every five years. Even when simply replacing an
piping as close to the vessel as possible. Pressure- existing valve, a review of requirements per current local
relief valves should be installed upright, although and national code is advisable. Valves should not be
horizontal installation is possible. removed unless system has been evacuated to zero
pressure.
MATERIAL SPECIFICATIONS
Body: Ductile iron, ASTM A395 CAUTION
Piston: Stainless steel Hansen pressure-relief valves and three-way dual shut-
Spring: Stainless steel off valves are only for refrigerant gas relief and cannot
Seat Insert: Stainless steel be used for liquid relief. These instructions and related
Seat Discs: Premium grade virgin Teflon® (PTFE) safety precautions must be read and completely
Cap: Steel understood before selecting, using, or servicing these
Cap O-ring: Neoprene valves. Only knowledgeable, trained refrigeration
Maximum Temperature Rating: 240F (115°C) mechanics should install, operate, or service valves.
Safe Working Pressure: 400 psig (27 bar) Stated temperature and pressure limits should not be
Setting Range: 150 to 400 psig (10.4 to 27 bar) exceeded. Valves should not be removed unless system
has been evacuated to zero pressure. See also safety
GENERAL PRECAUTIONS precautions in current List Price Bulletin and Safety
Never expose your face or body to a connected relief Precautions Sheet supplied with product. Escaping
valve exit or piping. refrigerant might cause personal injury, particularly to
eyes and lungs.
Make sure the valve setting and capacity (see Nameplate
Information Section) meet the requirements per system WARRANTY
design in accordance with local and national regulations. Hansen valves are guaranteed against defective materials
Be sure to isolate the valve and related piping from the and workmanship for one year F.O.B. our factory. No
refrigeration system and pump out pressure to zero before consequential damage or field labor is included.
attempting to install or replace any pressure-relief valve.
Avoid residual refrigerant when doing so. NAMEPLATE INFORMATION
The nameplate, located on the side of Hansen pressure-
Remove the shipping caps from both the inlet and outlet
relief valves, contains important information about the
before installation. Install the pressure-relief valve to
valve pressure setting, capacity and date of manufacture.
the pressure vessel at a location above the liquid refrigerant
The serial number traces the month and year the valve
level. These valves are for gas relief only. Do not install
was built. This is a helpful guide in establishing an
shut-off valves in line with pressure-relief valves. Install
approximate date of service. Example: A valve with
valves in locations where they will not be damaged by
Serial No. 05A 99, indicates that it was built in May of
moving equipment such as lift trucks, etc. Install valves
1999. See nameplate below for location of data.
in a manner that enables them to be replaced.
When a dual pressure relief system is being put into
service, the three-way valve stem should be positioned
so that only one valve is exposed to pressure. While the
valve can be either frontseated (front port is closed) or
backseated (back port is closed), the backseated position
is recommended because it takes pressure off the packing
and reduces the possibility of packing leaks.
Vent the relief valve exit to a safe outdoor location in an
approved manner away from people and building
openings. Do not install valves in a refrigerated space
unless precautions are taken to prevent moisture
migration into the valve body or the relief vent line.
Avoid trapped ice build-up between valves and other
equipment.
Only apply thread sealing compound to external pipe
threads and use a modest amount to avoid getting
compound inside the valve. Use brackets or hangers to
support the pipe and prevent the valve from being overly
K109f
3 JAN 2004
DUAL PRESSURE-RELIEF VALVES
In accordance with ANSI/ASHRAE 15-2001 Safety DUAL AND DUAL UNION PRESSURE-RELIEF KITS
Standard for Refrigeration Systems, pressure vessels Hansen’s Dual Pressure-Relief Valve Kit includes one
having 10 cubic feet or more of internal gross volume, (1) three-way dual shut-off valve, two (2) pressure-relief
shall be fitted with dual pressure-relief valves. This is valves, and two (2) nipples; for field assembly. The Dual
typically accomplished using a pair of pressure-relief kit is available ½" to 1¼". The Dual Union Pressure-
valves interconnected via a three-way dual shut-off valve. Relief Valve Kit consists of one (1) three-way dual shut-
Even on smaller vessels this arrangement is often off valve, two (2) pressure-relief valves, four (4) unions
preferred because one valve remains operational, while and a single outlet. Unions at the inlets and outlets of
the other is being replaced; thereby eliminating the need both pressure-relief valves facilitate valve replacement.
to remove refrigerant from the vessel. Hansen can provide The Dual Union kit is only available with ½" & ¾" inlet
any or all the necessary components, in addition to the sizes. Both kits require field assembly. Assembled kits
actual relief valves, as follows: are shown below.
THREE-WAY DUAL SHUT-OFF VALVES
These rugged, forged steel bodied valves facilitate the
parallel installation of pressure-relief valves. Because
three-way valves will not isolate both pressure-relief
valves simultaneously, they are considered the only
acceptable type of shut-off valve for use with refrigerant
relief piping. Their durable metal-to-metal seating and
patented non-leak packing plus o-ring stem seal design
combine for long, trouble-free service. Inlet and outlet
connections are threaded female NPT all the same size.
Shown below is a three-way dual shut-off valve in the
stem out position (backseated). The valve stem should
be positioned so that only one pressure-relief valve is
activated. While the valve can be either frontseated DUAL KIT DUAL UNION KIT
(front port is closed) or backseated (back port is closed),
the backseated position (shown) is recommended for TO ORDER:
normal use because it takes pressure off the packing Add “D” suffix for Dual Kit or “DU” suffix for Dual Union
and reduces the possibility of packing leaks. Kit to pressure-relief valve catalog number. Specify inlet/
outlet connection size and pressure setting.
THREE-WAY DUAL SHUT-OFF VALVE
(SHOWN BACKSEATED) RUPTURE DISC ASSEMBLIES
Hansen rupture disc

assemblies (RDAs) are used
to indicate which pressure-
relief valve has discharged.
A pressure-relief valve will
reseat after discharging.
However, a rupture disc
remains open after bursting.
An installed pressure gauge
or switch (required by code)
provides a visual or electronic
indication that the rupture disc
has burst.
Also, rupture disc assemblies provide a hermetic seal to
help eliminate any possibility of minute losses of
refrigerant via pressure-relief valve seat materials. Rupture
disc assemblies are required when using Hansen
pressure-relief valves in halocarbon applications because
the high cost of such refrigerants demands extreme
CAT CONNECTION DIMENSIONS (INCHES) tightness. For more detailed information, including
NO SIZE
ordering and ASME capacity requirements, see Hansen
A B C D E Bulletin K209.
1
H8021 /2" FPT
3.63" 2.38" 3.38" 1.75" 6.00"
3 4
H8022 / " FPT
H8024 1" FPT
5.88" 3.75" 4.00" 2.00" 8.00"
H8025 11/4" FPT
TO ORDER:
Please specify three-way dual shut-off valve catalog 6827 High Grove Boulevard
number and connection size. Burr Ridge, Illinois 60527 USA
Tel: (630) 325-1565 Fax: (630) 325-1572
Toll: (800) 426-7368 http://www.hantech.com
K109f © 2004 Hansen Technologies Corporation
JAN 2004
Bulletin T479e
JUL 2006
Specifications, Applications,
Service Instructions & Parts
ST
STRAINERS
(FILTERS)
1/2” thru 6”
(13 mm thru 150 mm)
for refrigerants
2” Strainer: ST200
INTRODUCTION TO ORDER
These rugged, refrigerant strainer s (filter s) are Specify catalog number and if strainer will be close-
designed to remove foreign materials, like dirt and coupled to valve or installed as a separate unit. If it
weld slag, from refrigeration systems. Strainers help will be a separate unit, also specify flange connection
prevent damage to valves and other components, style and size.
reducing costly service and downtime. Strainers are
usually close-coupled to solenoid valves, pressure KEY FEATURES
regulators and other flanged valves. DUCTILE IRON CLOSE-COUPLES
OR STEEL BODY TO VALVES
ORDERING INFORMATION
FLANGE ST YLE AND SIZES
FOR VALVE
SIZE CONNECTIONS AVAILABLE
CAT NO
FPT, SW, WN ODS
INCH (MM)
STD ALSO STD
ST050 1/2” (13)

1/2” 1/4” 5/8”
ST050D† 5/32” (4) GENEROUS
FLOW AREA STAINLESS
3/4” (20) 3/4” 1”, 1-1/4” 7/8” STEEL
ST100 SCREEN
ST100HD* 1” (25) 1” 3/4”, 1-1/4” 1-1/8”
ST100/100** DRAIN PLUG EASY IN-LINE
1-1/4” (32) 1-1/4” 3/4”, 1” 1-3/8” SERVICEABILITY
ST200 1-1/2” (40) 1-1/2” 2” 1-5/8” MATERIAL SPECIFICATIONS

ST200/100** 2” (50) 2” 1-1/2” 2-1/8” Body: ½” through 4”: Ductile iron, ASTM A536,
ST250 5” and 6”: Cast steel, ASTM A352
2-1/2” (65) 2-1/2” 3” 2-5/8”
ST250/100**
Bottom Cover: ½”: Steel, ASTM 108
ST300 3” (80) 3” — 3-1/8”
¾” through 1¼”: Ductile iron, ASTM A536
ST400 4” (100) 4” — 4-1/8”
1½” through 6”: Steel, ASTM A36
STW500 5” (125) 5 WN‡ — —
STW600 6” (150) 6 WN ‡ — — Drain Plug: Standard on ¾” through 1¼” (¼” NPT), 1½”
‡ Integral butt weld only
through 4” (½” NPT), 5” & 6” (¾” NPT), ½” optional
†ST050D includes Drain Plug. (¼” NPT)
* includes stainless steel screen with perforated metal backup.
** 100 mesh stainless steel screen. Screen: Stainless steel, 60 mesh (233 micron rating)
or 100 mesh (150 micron rating)
OPTIONS
ST050 has 100 mesh (150 micron rating)
Perforated Metal Strainer Basket: necessary for protection of
compressors in suction side port applications (1½” through Gaskets: Nonasbestos, graphite composite
3”); contact factory. Safe Working Pressure: 400 psig (27 bar)
Cloth Bags: available up to 4” for system start-up.
Filter System: An extra-fine filter system with double the Operating Temperature: – 60°F to +240°F (–50ºC to
cleansing capacity of standard strainers is available. See +115°C)
bulletin T782 for more information.
INSTALLATION DIMENSIONS CAUTION
inches (mm) Hansen strainers are for refrigeration systems only.
Read these instructions and related safety precautions
L1 completely before selecting, using, or servicing these
strainers. Only knowledgeable, trained refrigeration
mechanics should install, operate, or service these
strainers. Stated temperature and pressure limits
should not be exceeded. The bottom cover should
H2 not be removed from strainers unless the system has
been evacuated to zero pressure. See also Safety
Precautions in the current List Price Bulletin and the
Safety Precautions Sheet supplied with the product.
Escaping refrigerant can cause injury, particularly to
the eyes and lungs.
H1
WARRANTY
A l l H a n s e n p r o d u c t s , exc e p t e l e c t r o n i c s , a r e
guaranteed against defective materials or workmanship
L3 R
for one year F.O.B. factory. Electronics are guaranteed
against defective materials or workmanship for 90
days F.O.B. factory. No consequential damages or
field labor is included.
SCREEN
CAT NO H1 H2 L1 L3 R W AREA REPLACEMENT SCREEN KITS
in 2 (cm 2 )
3.32 0.68 2.03 1.38 3.00 2.03 5.40

ST050
(84) (17) (52) (35) (76) (52) (35) PART NO PART NO
DESCRIPTION QTY
3.82 0.68 2.03 1.38 3.00 2.03 5.40 60 MESH 100 MESH
ST050D
(95) (17) (52) (35) (76) (52) (35)
Screen Kit for ST050/ST050D ─ 78-1001
5.15 1.56 3.75 4.59 3.00 4.59 63.00
ST100
(130) (40) (95) (117) (76) (117) (407) Screen Assembly 1 78-0005
5.34 2.79 9.88 4.25 4.00 4.58 84.50 Bottom Cap Gasket 1 78-0016
ST200
(136) (71) (251) (108) (102) (116) (545)
Screen Kit for ST100 (Standard) 78-1003 ─
6.10 3.62 9.88 5.38 4.50 5.62 134.50
ST250
(155) (92) (251) (137) (114) (143) (868) Screen Assembly 1 78-0028
6.56 4.06 12.25 5.38 4.75 6.50 134.50 Bottom Cover Gasket 1 78-0026
ST300
(167) (103) (311) (137) (121) (165) (868)
Screen Kit for ST100HD, ST100/100 78-1013 78-1014
7.38 4.73 14.12 6.75 5.75 8.06 219.00
ST400
(187) (120) (359) (171) (146) (205) (1413) Screen Assembly 1 78-0135 78-0137
14.34 6.40 20.40 12.75 8.00 12.75 536.50
Bottom Cover Gasket 1 78-0026 78-0026
STW500
(364) (163) (518) (324) (203) (324) (3462)
Screen Kit for ST200, ST200/100 78-1005 78-1025
14.34 6.40 20.40 12.75 8.00 12.75 536.50
STW600 Screen Assembly 1 78-0052 78-0198
(364) (163) (518) (324) (203) (324) (3462)
Bottom Cover Gasket 1 75-0196 75-0196
W = Maximum width of strainer body
R = Clearance for screen assembly removal Screen Kit for ST250, ST250/100 78-1006 78-1026
Screen Assembly 1 78-0040 78-0199
SERVICE AND MAINTENANCE Bottom Cover Gasket 1 75-0128 75-0128
Repeated inspection of strainers during system start- Screen Kit for ST300 78-1007 ─
up or repairs is essential for optimum benefit. Before
Screen Assembly 1 78-0054
opening a strainer or any other component, be sure
Bottom Cover Gasket 1 75-0128
it is isolated from the system, and all refrigerant is
removed (pumped out to zero pressure). The ¾” through Screen Kit for ST400 78-1008 ─
6” strainers have a drain plug in the bottom cover for Screen Assembly 1 78-0057
connecting a drain valve and hose for proper and safe Bottom Cover Gasket 1 75-0234
removal of any trapped liquid refrigerant. Screen Kit for STW500/STW600 78-1009 ─
Screen Removal and Cleaning: Be careful to avoid Screen Assembly 1 78-0071
any refrigerant which may still be in the strainer. For Bottom Cover O-Ring, Inner 1 75-0605
the ½” strainer, slowly remove the hex bottom cap, Bottom Cover O-Ring, Outer 1 75-0606
then remove the screen assembly. For ¾” through 6”
strainers, loosen the bottom cover bolts and bottom
cover, check for refrigerant presence, and then remove
the bolts, cover, and screen assembly. Clean the screen
assembly with a good solvent, blow dry, and inspect. If Hansen Technologies Corporation
the screen is damaged or sediment cannot be removed 6827 High Grove Boulevard
from the screen, replace the screen assembly. Carefully Burr Ridge, Illinois 60527 USA
align the screen assembly in the center of the strainer Tel: 630.325.1565 Fax: 630.325.1572 Toll: 800.426.7368
Email: info@hantech.com Web: www.hantech.com
body and replace the bottom cover. Pressure test for
USA ∙ Asia ∙ Europe ∙ India ∙ Latin America ∙ Middle East
leaks before returning to service. © 2006 Hansen Technologies Corporation
T479e
JUL 2006 2
Me echanical Shafft Seal
Installa
ation Proceduure for
Grasso GL Series Compre essors
Introducttion
This proceedure is designned to provide guidance for replacing
r the mechanical
m shaaft seal on GL series compreessors. In som me
cases the replacement
r seeal will differ from
f the OEMM seal originallyy supplied. Thhe difference merely
m represeents an
improvem ment in the seal design.
Required d Tools
In additionn to ordinary hand
h tools, the following item
ms are requiredd for removal ofo the factory seal:
s
1. Two threaded jackiing bolts (M100x50-Models 180GL1 – 565GGL; M12x80-M Models 675GL L-1435GL) inccluded in shaftft
seal replacement
r kiit.
2. Two M12x1.5 Pulll Rods, approxximately 10” loong (Models 675GL 6 – 1435G GL only), Hexx Wrench, Croowbar, Seal hook
Preparation
1. Isollate the compreessor unit fromm the system. Purge the unitt and remove thhe coupling guuard.
2. Remmove the comp a Operating Manual.
pressor hub annd center membber per the insstructions in thhe Installation and
3. Remmove the coupling guard ringg from the com mpressor.
Disassem mbly
1. Remmove the sock ket head screwss from the seall cover/housinng.
2. Usiing the approppriate jacking bolts,
b screw intto the tapped holes
h of the seaal housing covver until they bottom
b out.
Remmove the seal housing coverr. The stationaary seal ring will
w come out with
w the seal hoousing cover.
Jacking boltts
3. Rem
move the statio
onary ring from
m the seal houusing cover.
4. Pulll the mechaniccal shaft seal off

o by hand.
5. Forr the 675GL –1 1435GL comppressors use the two pull rods, in conjunction with pry baars, to remove the seal glandd.
Seal Glland Removal
Page 1 of 2 P
P/N: 037-0000116-000
Revisiion: B
Effective: 10/08
hree oil feed po
Note th orts located at th
he top-center off the seal gland. When replaceed, these must reemain at the topp(see #1 below)
6. Rem
move the lip seeal from the seeal gland (Moddels 675GL annd 800GL onlly)
Assemblyy (for 180GL – 565GL and 1025GL-21100GL Skip to Sttep 3)
Seall Seat Lip Seal
Fitting Cone O-Rings

O Note: jackingg bolts are alsoo included
L Seal
Lip
S
Shaft Seal
Shaaft Seal Replacement Kit

1. Insttall the new lipp seal in the seeal gland.
2. To install the seall gland, oil the outside of thee installation coone. Push the cone onto the shaft until it sttops. Push thee
seall gland over th
he installation cone
c until it sttops and removve the cone.
3. Insttall the mechan nical shaft seall. Lubricate thhe carbon seal face and shaft with clean reffrigeration gradde oil. Push thhe
seall onto the shaft
ft so that the doowel pin hole on o the seal ringg is inserted innto the dowel pin
p located in the
t shaft.
Alignnment hole
Alignment Piin
4. Installl a new O-ring

g on the stationnary ring and insert
i into the seal housing cover.
c Lubricaate the stationaary ring seal faace
with clean refrigeraation oil.
5. Replaace the seal ho

ousing cover O-ring
O and instaall the seal houusing cover. Torque
T the soccket head screw
ws progressiveely
usingg a cross diago
onal pattern as per the table below.
b
Mod
del 180G
GL (P) 2330GL (R) – 14435GL (XD) 1770GL (XE) – 2110G
GL (XF)
Coveer Torque (ft--lb) 6
60 1400 295
6. Presssurize the comp

mpressor to 40 psig
p with refriggerant from thhe system and check
c for leaks. Also, checkk the shaft to seee it
is free to rotate.
7. Installl the coupling
g guard ring onnto the seal houusing cover.
8. Installl the compressor hub and ceenter member per the instrucctions in the Innstallation and Operation Maanual.
9. Installl the coupling
g guard.
10. Resstart the comprressor and cheeck for leaks.
Page 2 of 2 P
P/N: 037-0000116-000
Revisiion: B
Effective: 10/08
ifin Cor
ann po
rH
ra
ke
ISO 9001
tion
Par
CERTIFIED
SAFETY PROCEDURES REFRIGERATING SPECIALTIES DIVISION
io n
Ref
FOR REFRIGERATING SPECIALTIES SAFETY BULLETIN RSBCV
s
r ig
iv i
ra D
e
ti ng S ialties
p ec
REFRIGERATION CONTROL VALVES
INTRODUCTION HAND VALVES
This bulletin is a summary of safety procedures for the proper selection, instal- All hand valves that could trap liquid when closed must be marked with a
lation, use and maintenance of Refrigerating Specialties Division industrial warning against accidental closing. The liquid refrigerant must be removed
refrigerant control valves. Additional free copies are available and should be before the hand valves are closed on both sides of a control valve or any other
distributed to all concerned personnel. This bulletin is intended to help you component. Also, liquid must be removed before a hand valve is closed at the
protect your personnel, product and plant. Because of space limitations, this inlet of a solenoid valve or a regulator with positive electric shut-off, or some
bulletin must be supplemented by accepted and known industry safety prac- outlet pressure regulators, or at the outlet of a check valve, unless these
tices and local code requirements. valves are manually open.
Refrigerating Specialties Division control valves are designed and built to the Caution: To protect personnel, product and plant, remove all liquid from the
highest standards of the refrigeration industry. However, for proper perfor- section to be isolated before hand valves are closed. Make sure the control
mance the valves must be correctly chosen, properly installed and periodically valves are open when removing the liquid. See Service and Maintenance
serviced. Because safe operation is of primary concern, this bulletin empha- Instructions before attempting to take any valve apart.
sizes suggestions for the safe installation and maintenance of Refrigerating
RELIEF DEVICES
Specialties Valves. Read this information carefully before installing a valve or
Relief devices or relief methods should be used in all parts of a refrigeration
working on one already installed; also, use it to review all previous installations.
system where liquid can be trapped and liquid expansion could take place.
All personnel working on valves must be qualified to work on refrigeration Under no circumstances should R/S Pressure Regulators be used as a relief to
systems. Any person intending to service a valve should completely read this the atmosphere, R/S Type H Safety Relief valves should be used instead.
bulletin and the product bulletin describing the particular valve and its opera-
tion before any work begins. If there are any questions, contact Refrigerating SELECTION AND APPLICATION
Specialties before proceeding with the work. A control valve must be selected only by a person having adequate knowl-
edge of the system and of the valve to be chosen. Any Refrigerating Special-
RECEIVING AND UNPACKING
ties Division control valve must be used only as specifically stated in Refriger-
All control valves are packed for maximum protection. Unpack carefully. Flange
ating Specialties Division Catalogs or Bulletins for normal refrigeration applica-
bolts are packed in cotton bags and coils are packed loose. Check the carton
tions unless otherwise approved in writing by Refrigerating Specialties Divi-
to make sure all flanges and other items are unpacked and in agreement with
sion.
the packing slip. Save the enclosed instructions for the installer and eventual
user. Do not remove the protective covering from the inlet and outlet of the The valves are designed to operate with ammonia and/or halocarbon refriger-
control valve until the valve is ready to be installed. ants. Valves using flanges with copper connections must not be used with
ammonia refrigerant. Unless authorized by the factory, Refrigerating Special-
Caution: Do not, at any time, make any alteration or modifications to any
ties valves should not be used for refrigerants or fluids not mentioned on the
Refrigerating Specialties Division valves or regulators without the express and
nameplate or in the pertinent bulletin.
written approval of this company. Threaded parts should not be subjected to
excessive torque by use of an oversized wrench, wrench extension or by INSTALLATION
impacting the wrench handle. Where specified in the individual bulletin, ob- Installation must be done according to all applicable Safety Codes and Stan-
serve the torque requirements for bolts, screws and other threaded parts. dards, and by personnel qualified to install refrigeration systems. Refrigerating
Contact the factory for torque values not furnished in current literature. Specialties Division control valves must be installed according to the
For extensive repairs on valves or regulators, especially those more than three manufacturer’s instructions, this bulletin, and the generally known safety prac-
years old, the valves or regulators should be returned to the factory for thor- tices.
ough inspection and rebuilding. Spare parts should be checked for corrosion
before installation. In addition, part numbers should be checked against the MOUNTING
latest assembly bulletin to be sure current parts are being used. ASTM A307 Grade A square headed bolts should be used to mount flanged
If a valve or regulator has failed under circumstances which caused, or could body valves. They assure the maximum bolt surface and flange engagement.
have caused, injury to personnel or damage to property, a replacement valve For all lug mounted valves, flange bolts should be inserted in a direction
should not be installed until the reason for the previous failure is determined pointing toward the valve body. The bolt should pass first through the mount-
and corrected. Adequate protection should be taken to prevent both liquid ing flange before engaging the valve flange. Allow proper space for installing
shock and suction shock both upstream and downstream of the valve or the valve. Do not use the valve to “stretch” or “align” the pipe. Using flange bolts
regulator. to close a large gap can distort the valve or at least stress it unduly, and
possibly cause it to malfunction, or the bolts may be damaged or stripped.
LIQUID EXPANSION (See table below for proper torque requirements). For proper sealing the
In liquid lines, or lines that might contain substantial amounts of liquid refri- gaskets should be lightly oiled and all bolts must be tightened evenly. Make
gerant, certain precautions must be taken to avoid damage due to liquid sure the flange tongues are properly aligned with the grooves in the valve
expansion when a section of line is isolated by positive shut off valves. This body. Where necessary, support the valve by brackets or hangers to avoid
condition may occur whenever the ambient temperature could be higher than overstressing the pipe or valve.
the liquid temperature. This could even occur in a refrigerant or oil line other When mounting weld-end valves: welding procedures for all steel pipe and
than a “liquid” line. fitting need to conform to all requirements of the ASME IX and other Pressure
Temperature increase in a section with trapped liquid can cause extremely Pipe welding standards. In all cases where valves are installed without disas-
high pressures due to the expanding liquid and possibly rupture a gasket, sembly, they should be manually opened.
pipe, or valve. When low temperature liquid lines are used, as in a liquid
overfeed (recirculation) system, and the lines or control valves may be ex- TORQUE REQUIREMENTS FOR FLANGE BOLTS
posed to warm ambient conditions, particular care must be taken; liquid expan- Bolt Diameter Used on Valve Port Size Torque
sion can occur very rapidly. 7/16" (11 mm)* 5-13 mm (3/16" - 1/2") 3.9 mkg (28 ft. lb.)
CHECK VALVES 20-25 mm (3/4" - 1")
5/8" (16 mm) 11.8 mkg (85 ft. lb.)
Check valves must never be installed at the inlet of either a solenoid valve, or 32-50 mm (1-1/4" - 2")
a regulator with an electric solenoid pilot shut-off feature. Also, the check valve 3/4" (19 mm) 65-75 mm (2-1/2" - 3") 14.5 mkg (105 ft. lb.)
should not be installed at the inlet of an outlet pressure regulator in a system 7/8" (22 mm) 100 mm (4") 22.1 mkg (160 ft. lb.)
where liquid may be trapped between the two valves. If a check valve is
needed, install it on the outlet side of such valves. Most solenoid valves and *All A2 direct operated regulators, and AFR-3 and FFR flow regulators use
regulators will permit reverse flow if the outlet pressure is greater than inlet 7/16" diameter bolts.
pressure. If at any time, such reverse pressure conditions are possible and
reverse flow is unacceptable a check valve should be installed at the control
valve outlet.
Parker Hannifin Corporation • Refrigerating Specialties Division

2445 South 25th Avenue • Broadview, IL 60155-3891
Phone: (708) 681-6300 or 800-506-4261 • Fax: (708) 681-6306 or 800-424-7109 • e-mail: RSD_info@parker.com
LOCATION cal spark is present. Any oil in the refrigerant may cause a mist that could cause
Valves must not be installed in locations where they can be damaged by a fire or explosion.
material handling or other equipment. Trapped ice build-up must be avoided at Halocarbon refrigerant should not be discharged into areas where open flame
or between valves and other equipment. Provide reasonable access to all is present, since toxic gases may form. Ammonia should not be discharged into
control valves for maintenance purposes. occupied areas, or areas containing product affected by ammonia. In the case
INSULATION of ammonia, discharge any vapor left into a container of cold water, making
When it is necessary to insulate the control valves, the insulation must be sure that the discharge hose remains submerged at all times. (Be sure that no
applied to allow access for proper operation and maintenance of the valves. pressure reversals can occur that may pull water into the system.) Water may
The manual opening and adjusting stems should be easily accessible at all have to be refreshed to absorb all the ammonia; about one gallon of fresh
times. In the case of solenoid valves the insulation must not extend to the coil water is needed for one pound of ammonia.
housing or coil burnout may occur. Insulation should be constructed so that To prevent pulling excessive air and moisture into a system, avoid opening the
sections can be easily removed and replaced to allow the valve to be disas- system when it is under vacuum.
sembled. Insulation applied to strainers should provide ready access for clean- Caution: Do not attempt to work on any part of a refrigeration system without
ing the strainer basket. having help nearby and observing. Use safety glasses or a safety face shield
Since most maintenance problems caused by dirt occur at the start-up of a for added safety to protect the eyes. Protective equipment should be readily
system, it is advisable to delay insulating the control valves and strainers until available and all personnel involved should be thoroughly trained in its use.
the system has operated for several days. During that time the strainers should Personnel should be especially protected against falling because they may be
be checked for dirt and cleaned as necesary. Cotton bags are available for startled by escaping refrigerant. Always make sure that there is a way out and
25mm-100mm (1" - 4") Type RSF Strainers to improve their ability to remove that everyone can leave the area fast. When seal caps cover manual opening
small particles of dirt during start-up. or adjusting stems, the caps must be removed with caution because liquid
refrigerant could accumulate under such a cap. Avoid contact with any liquid
PUMP OUT MEANS refrigerant.
Individual valves or control stations should be provided with means for pump-
ing out or safely purging the refrigerant. ELECTRICAL
Before working on any valve or other item having electrical components refer
PRESSURE TESTING to the “ELECTRICAL” paragraph of the “INSTALLATION” section. Be sure the
Every segment of a refrigeration system, including control valves, should be circuits are completely de-energized; just throwing a switch may not be suffi-
field pressure tested before system is insulated and put in use. Make sure that cient. Failure to do this may result in personal injury or damage to solenoid coils
correct high and low side test pressures are used. Use proper refrigerant or gas or other components. Take care to see that the circuits cannot be energized
for pressure testing; that is do not use halocarbons or C02 to test an ammonia accidentally. Never energize the solenoid with the coil housing or plunger
system, nor use ammonia to test halocarbon system. Never use the compres- assembly removed.
sor in a system to build up pressure for testing.
In pressure testing Range V, VA, A, B or D pressure regulators, test pressure DISASSEMBLY
in excess of 21. kg/cm2 (300 psig) may cause setting shift and diaphragm may Be sure that any person working on a valve is familiar with its construction and
deform enough to require replacement after the test. If the above conditions operation by referring to the proper bulletin. Make sure the pressure in the
exist, contact the factory for proper solution. system to be opened is reduced to, and remains, at atmospheric pressure
before valve pressure containment seals are released. A pressure gauge
ELECTRICAL should be connected to the part of the system to be evacuated. Before
Only properly qualified electricians should handle the electrical portions of removing the bonnet of pressure regulators, back out adjusting stem to pre-
control valves and their circuitry. All power supplies and wiring must be ad- vent damage to the diaphragm.
equate to provide the proper voltage and current to the solenoid coils. The
power supply must be capable of providing the proper in-rush current. Never RE-ASSEMBLY
energize the solenoid with the coil housing or plunger assembly removed. Be sure all parts are clean and free of moisture before reassembly. Damaged
parts and gaskets should be replaced. It is advisable to purge the section of air
Inrush Holding Fuse before opening it to the rest of the system. When opening hand valves, ensure
Standard Encapsulated Coil Current Current Size that inital refrigerant flow will be in the normal direction of valve flow; this will
Volts/Hertz (Amps) (Amps) (Amps) avoid backflow and possible damage to the strainer if one is used.
24/60 (Black & White stripe leads) 6.7 2.98 4
120/60 (Blue leads) 1.18 0.46 1 DIRT, CONTAMINATION AND CORROSION
208/60 (Blue and Red leads) 0.63 0.26 1 Protect the valves from foreign material during storage and installation. The
240/60 (Red leads) 0.60 0.23 1 protective plugs on the valve openings should remain in place until the valves
115/50 (Yellow and Blue leads) 1.22 0.21 1 are ready to be installed. Once a section of a system is installed, and before it
230/50 (Yellow leads) 0.65 0.26 1 is put into operation, it is advisable to charge it with appropriate refrigerant or
Other (Contact Factory) suitable inert gas to avoid corrosion. Avoid exposure of R/S valves to haloge-
nated solvents or similar reactive fluids. External corrosion over a long period of
SERVICE AND MAINTENANCE time must be controlled by painting and replacement of corroded parts.
All systems require maintenance and service. The personnel doing the work
STRAINER MAINTENANCE
must be qualified and completely familiar with the system they are to work on
Strainer inspection is of utmost importance, especially the first few hours, days
or all other precautions will be meaningless.
or weeks after the start-up. Foreign material should be removed and the
PUMP OUT screens should be washed with proper solvent. Strainer inspection and clean-
For the protection of personnel, product, and plant, all refrigerant possible ing should be continued until dirt accumulation ceases. Later, any time a valve
must be removed from a valve or any other component of the system, before pressure containment seal is released for service or maintenance, its compan-
any refrigerant retaining part is loosened. Before opening a valve, make sure ion strainer should also be inspected and cleaned. Filter bags are available for
all refrigerant liquid has been removed. In particular, beware of strainers and 25mm-100mm (1” - 4") Type RSF Strainers to improve their ability to remove
other sections of piping which may trap liquid refrigerant which will require a small particles of dirt during start-up. If a strainer filter bag is used in the strainer
considerable length of time to remove. Pump out as much refrigerant as basket, the cloth bag must be checked every few days depending upon the
possible before discharging remaining refrigerant in a properly protected man- amount of system dirt collected. When the cloth bag no longer collects dirt, it
ner. During pump out make sure control valves are opened manually to avoid must be discarded.
trapping refrigerant.All type RSF and RSW Strainers are provided with 3/8"
FPT connection to assist in pump out.
GENERAL SPECIFICATIONS
Refrigerating Specialties refrigerant containing valves and strainers are de-
At times it may be necessary to discharge some small amount of refrigerant
signed for a Maximum Rated Pressure of 21 bar (300 psig) except where
from the isolated section. When this becomes necessary, certain precautions
shown otherwise on the nameplate. They are suitable for use under most
must be observed. Make sure control of discharge rate can be easily main-
temperature conditions encountered in refrigeration systems. Maximum and
tained and that a quick shut-off is available.
minimum fluid temperatures for each valve are published in R/S Condensed
Refrigerant should be discharged into and disposed of in a proper container Catalog CC-11b. If either fluid or ambient temperature is below a valves rated
accepted by applicable safety codes and standards. Discharge of refrigerant minimum, consult the factory. In addition, should fluid temperature exceed the
to atmosphere should be avoided. Never discharge any refrigerant into an rated maximum or should ambient temperatures exceed 125°F, consult the
area without sufficient ventilation, or into an area where open flame or electri- factory.
Refrigerating Specialties Division

050006
DIFFERENTIAL PRESSURE BULLETIN 23-10A
RELIEF REGULATOR Type A4AL
TYPE A4AL
Port Size 3/4"- 4" (20-100mm)
For Ammonia, R-22, R134a, R404a, R507
and other common refrigerants.
FEATURES
• Pilot operated characterized Modulating
Plug for precise control
• Suitable for all common refrigerants and oil
• 400 psig (27.6 bar) Design Pressure
(MRP)
• Flanges for threaded or welded steel pipe
and copper tube (copper not for ammonia)
• Unique Modular construction
• Interchangeable parts
• Easy to Service
• Close coupled strainers, optional
• Many control variations are possible with the
March 2002
use of a few modules and kits.
Installation, Service and Parts Information
• Stainless Steel Diaphragm
• Manual Opening Stem Description:
These compact, heavy duty, pilot operated, iron alloy
(ASTM A126 Class B) Differential Pressure Regulators
are suitable for Ammonia, R22, R134a, R404a, R507 and
other common refrigerants and fluids approved for use in
FLANGE RING TUBE refrigeration systems.
ASSEMBLY
ADJUSTING STEM
All A4AL Regulators are pilot operated using upstream
pressure for the opening force and require a minimum 2
psi (0.14 bar) pressure drop to fully open.
POWER PISTON
These valves are generally ordered with close coupled
upstream strainer to prevent entrance of foreign material
into the valve and the rest of the system.
Purpose:
MODULATING Modulates flow of refrigerant liquid or gas to maintain a
PLUG constant set-for pressure differential between regulator
inlet and regulator outlet.
CLOSING SPRING
Regulator applications are as follows: As a relief valve
from pump outlet to accumulator of a liquid recirculating
MANUAL OPENING STEM pump system to prevent pump overload or dry pumping
when evaporator liquid solenoid valves are closed. Dif-
ferential pressure will not vary despite fluctuating accu-
mulator pressures. As a gas or liquid pressure regulator
whenever it is desired to maintain a set-for pressure
A4AL difference between regulator inlet and outlet.
Fig 1 The fluid temperature range for the A4AL Series of
Regulators is -50F to 220F (-45C to 105C).
Refrigerating Specialties Division 1 I S O 9 0 0 1-2 0 0 0 C E R T I F I E D
050453
A4AL PARTS KITS REFERENCE
ITEM DESCRIPTION PORT SIZE
3/4 1 1-1/4 1-5/8 2 2-1/2 3 4
1, 2 Cap Kit, Seal 202110 202110 202110 202110 202110 202110 202110 202110
3-5 Packing Kit, Stem 202100 202100 202100 202100 202100 202100 202100 202100
4-6 Stem Kit 202120 202120 202120 202120 202120 202120 202120 202120
Spring Stem Kit Rng A 202006 202006 202006 202006 202006 202006 202006 202006
3-5, 6, 12-16
Spring Stem Kit Rng D 202007 202007 202007 202007 202007 202007 202007 202007
8 Bonnet Kit *** *** *** *** *** *** *** ***
Spring Kit Rng A 202481 202481 202481 202481 202481 202481 202481 202481
12-14, 16
Spring Kit Rng D 202482 202482 202482 202482 202482 202482 202482 202482
Diaphragm Kit Rng A 200770 200770 200770 200770 200770 200770 200770 200770
16, 17, 19
Diaphragm Kit Rng D 200771 200771 200771 200771 200771 200771 200771 200771
16-19 Seat Kit 202002 202002 202002 202002 202002 202003 202003 202003
27 Plug Pkg, Pipe 202552 202552 202552 202552 202552 202552 202552 202552
19, 28, 29 Adapter Kit 200703 200703 200700 200725 200725 200685 200713 200716
20, 45 Flange Ring Tube 200439 200439 200441 200443 200443 200445 200447 200449
29, 30 Piston Kit 200760 200760 200767 200389 200389 200391 200393 200227
34-37 Spring Kit, Closing 202300 202300 202301 202302 202302 202303 202304 202305
Plug Kit, Full Capacity 202021 202022 202023 202024 202025 202026 202027 202028
Plug Kit, 50% Capacity 202029 * NA NA NA NA NA NA
33-37, 40-42
Plug Kit, 35% Capacity NA NA 202031 202032 ** 202033 202034 202035
Plug Kit, 17% Capacity 202030 * NA NA NA NA NA
37, 38, 40, 41 Bottom Cover Kit 200761 200761 200761
40-42 Packing Kit, Stem 202100 202100 202100 202100 202100 202100 202101 202101
43, 44 Cap Kit, Seal 202110 202110 202110 202110 202110 202110 202111 202111
Bottom Kit, Full Cap 202010 202011 202012 202013 202014 202015 202016 202017
33-38, 40-44 Bottom Kit, 50% Cap 202347 * NA NA NA NA NA NA
Bottom Kit, 17% Cap 202346 * NA NA NA NA NA NA
(All Seals) Gasket / O-Ring Kit 202112 202112 202113 202114 202114 202115 202116 202117
11 (Qty 8) Bolt Pkg, Bonnet 202246 202246 202246 202246 202246 202246 202246 202246
31 (Qty 8) Bolt Pkg, Adapter 202248 202248 202249 202249 202249 202249 202250 202250
39 (Qty 6) Bolt Pkg, Bottom Cap NA NA NA 202251 202251 202251 202252 202252
(*)
All Plug Kits and Bottom Assembly Kits for 3/4" Port Size Valves can be used in the 1" Port Size
Valves for reducing capacity.
(**)
All Plug Kits and Bottom Assembly Kits for 1-5/8" Port Size Valves can be used in the 2" Port Size
Valves for reducing capacity.
(***)
See Industrial List Price Schedule for PK-1 Pneumatic Bonnet Kit.
Refrigerating Specialties Division 2

Item Description
1 Seal Cap
2 Gasket, Seal Cap
3 Nut, Stuffing Box
4 Packing Ring
5 Packing Washer
6 Adjusting Stem
8 Bonnet
9 Nameplate
10 Screw, Name Plate
11 Screw, Bonnet
12 Spring Rest, Upper
13 Spring, Range
14 Spring Rest, Lower
15 Diaphragm Follower
16 Gasket, Bonnet
17 Diaphragm
18 Seat, Pilot
19 Gasket, Adapter
20 Flg Ring-tube Asm
27 Gauge Port Pipe Plug
28 Adapter, Body
29 Gasket, Body
30 Piston-Stem
31 Screw, Body
32 Body
33 Throttling Plug Asm
34 Spring, Closing
35 Dirt Wiper Retainer
36 Dirt Wiper
37 Seal, Bottom Cap
38 Bottom Cap
39 Screw, Bottom Cap
40 Packing Washer
41 Packing Ring
42 Stuffing Box Nut
43 Gasket, Seal Cap
44 Seal Cap
45 Gasket, Flange
A4AL
Fig 2

Principles of Operation Installation
This is a pilot operated regulator whose main All regulators are packed for maximum protec-
valve is opened by a power piston in response tion. Unpack carefully, check the carton to
to the inlet fluid pressure received from below make sure all flanges and other items are
the regulator diaphragm. The outlet pressure unpacked. Save the enclosed instructions for
is introduced through a sensing tube, which is the installer and eventual user.
part of the Flange Ring-tube Assembly (20),
from the outlet of the regulator into the bonnet Do not remove the protective coverings from
and to the top of the diaphragm, thus allowing the inlet and outlet of the regulator until the
the regulator to maintain a differential pressure regulator is ready to be installed. Protect the
between the inlet and outlet equivalent to the inside of the regulator from moisture, dirt and
spring pressure. chips before and during installation. When
welded or brazed flange connections are used,
After the regulator is set for the desired pres- all slag, scale and loose particles should be
sure differential, the pressure at the inlet of the removed from the flange interior before the
regulator will rise and fall, pound for pound, regulator is installed between the flanges. It is
with the rise and fall of pressure at the regulator advisable to install a close-coupled compan-
outlet, always maintaining the set-for differen- ion strainer (RSF) at the inlet of the regulator to
tial pressure across the regulator. If the differ- help protect it from any foreign material in the
ence between inlet pressure and outlet pres- system.
sure of the regulator is less than the set-for
pressure, the regulator will remain tightly closed. The A4AL series of regulators will give opti-
mum performance if mounted in a horizontal
Manual Opening Stem: line in a vertical position with the manual open-
All Type A4AL Regulators are provided with a ing stem on bottom. Where other positions are
manual opening stem. To open the regulator desired, the factory should be consulted: please
manually, back the stem out (turn counter- give application and piping details. The regu-
clockwise) until it stops. To put the regulator lator must be installed with the arrow on the
into automatic operation, turn the stem in (clock- valve body pointing in the direction of the fluid
wise) until only the flats on the stem protrude flow for the regulator to function properly. Back-
from the packing nut. ward flow through the regulator is uncontrolled
and will vary with valve model and the reverse
Adjustment pressure drop encountered. The regulator is
For adjustment, pressure gauges should be not a check valve.
connected to the gauge port at the regulator
inlet and also downstream of the regulator. Tighten the flange bolts and nuts evenly to
With the system operating, back the adjusting provide proper seating of the flange gasket
stem all the way out to stop (counterclockwise) and to avoid damage to gaskets or flanges.
to give minimum differential, which is about 2 (See Bolt Torque Table). Avoid using the
psi. Gradually turn the adjusting stem in (clock- regulator flange bolts to stretch or align pipe.
wise) until the desired differential pressure is Even the heavy duty body of an A4A can be
reached, assuming the system is capable of distorted, causing the precision parts to bind.
achieving such a differential. Check the differ-
ential setting after the system has been in The regulator should be installed in a location
operation for a while and make any minor where it is easily accessible for adjustment
corrections necessary. and maintenance. The location should be
such that the regulator can not be easily dam-

aged by material handling equipment. When phragm Follower (15). Remove Adapter (28)
it is necessary to insulate the regulator (and by removing Cap Screws (31). Turn the Manual
companion strainer), the insulation should be Opening Stem (33A) all the way in until the
installed to provide access to the regulator flats on the stem barely protrude from the stuff-
(and companion strainer) for adjustment and ing box nut. Push Piston (30) down against the
maintenance. Do not insulate the solenoid spring force. The piston should move freely
coil and coil housing. Proper indicating gauges down and be returned by the spring force. If the
should be installed to be easily visible to the piston is jammed or sticky, remove Bottom
operating engineer for system checking and Cap Assembly, which includes Items (33)
adjusting purposes. through (42), by removing Cap Screws (39) or
unscrewing Bottom Cap, 3/4" through 1-1/4"
Disassembly and Assembly (20mm through 32mm). Using a hard wood
Before disassembling any A4A type regulator, dowel rod inserted through the bottom of the
read the information in this bulletin and Bulle- valve, tap the piston upward and out. Thor-
tin RSB, Safety Procedures for Refrigerating oughly clean all parts. If jamming has taken
Specialties Division Refrigeration Control place and the piston and bore are scored,
Valves. remove all burrs by polishing the piston, bore
and modulating plug with fine crocus cloth.
Before a regulator is removed from the line or Inspect the seating area of the Modulating
disassembled in the line, make sure that all Plug (33) for damage or erosion. If damaged it
refrigerant has been removed from the regula- should be replaced. It would be advisable to
tor, including the bonnet, where applicable, replace the entire bottom cap assembly. In-
and the close-coupled strainer. The regulator spect all gaskets and “o” rings for damage and
must be isolated from the rest of the system in replace where necessary.
a safe manner. When pumping down to re-
move the refrigerant, the manual opening stem Assembly - When reassembling the valve, all
33A must be turned out (counter clockwise) to internal parts should be clean, dry and lightly
make sure the valve is open. oiled with refrigerant oil, except “o” rings. Ap-
ply silicone grease to the “o” rings. Care must
All A4A Regulators be taken especially when the parts are cold
General Procedure since moisture can condense on parts and
The construction of the regulator and the cause rapid rusting. When replacing gaskets,
method of disassembly are relatively simple, they should be oiled very lightly with refriger-
but some procedures must be followed to avoid ant oil before assembly. Items which require
damage. The following describes the proce- several bolts to fasten must be tightened uni-
dure for the basic A4A; special instruction for formly to provide proper alignment and seat-
other styles will be included in other appropri- ing. (See Bolt Torque Table). Install bottom
ate sections. cap assembly first and tighten in place. Care-
fully replace the piston; never try to force it in
Disassembly - Take care when removing Seal place. Align the Adapter Gasket (29) carefully
Caps (1) and (44) in case some refrigerant may with the proper holes in the adapter and the
be trapped inside. Back the Adjusting Stem (6) valve body and fasten adapter in place. Before
all the way out to remove any pressure from assembling the bonnet be sure the adjusting
Range Spring (13) otherwise damage to Dia- Stem (6) is turned all the way out. Place
phragm (17) or Pilot Seat (18) may occur. Gasket (19), Diaphragm (17) and Gasket (16)
Remove Bonnet (8) by carefully removing Cap in Adapter (28). The raised center of the
Screws (11). Take care not to damage Dia- diaphragm must be towards the bonnet. Stack

Diaphragm Follower (15), Lower Spring Rest properly adjusted. Turn adjusting screw slowly
(14), Spring (13) and Upper Spring Rest (12) to see if regulator responds. Check regulator
on top of diaphragm and carefully lower bon- pressure range; if wrong, range spring must be
net in place and tighten Screws (11) in place. replaced.
Tighten Cap Screws (11) evenly. The ideal Check other system components for proper
tightening torque is 11 ft. lbs. (1.5 kg-m). Valve
operation. Check hand valves in the system to
is now ready to be adjusted for normal opera- make sure they are open or closed as required
tion. and the system is receiving liquid or gas as the
case may be.
If close coupled strainer is used, it may be Before disassembly of regulator, make certain
cleaned before putting the valve back in op- that all refrigerant has been removed (pumped
eration. The regulator must be tested for leaks out) from the regulator and it companion strainer
with refrigerant gas or other appropriate gas where one is used. Read Safety Bulletin RSB.
before the system is put into operation.
Safe Operation (See also Bulletin RSB)
After the General Procedure for disassembly, People doing any work on a refrigeration
inspect the Pilot Seat (18) top seating surface system must be qualified and completely
for dirt, wear or damage. Remove seat from familiar with the system and the Refrigerat-
valve body and clean, lap on a flat plate or ing Specialties Division valves involved, or
replace as necessary. Examine the diaphragm all other precautions will be meaningless.
region which contacts the seat surface, look for This includes reading and understanding
dirt, heavy scratches or corrosion. If the dia- pertinent Refrigerating Specialties Division
phragm cannot be easily wiped clean, it should product Bulletins and Safety Bulletin RSB
be replaced. Reassemble the regulator fol- prior to installation or servicing work.
lowing the General Procedure. Where cold refrigerant liquid lines are used, it is
necessary that certain precautions be taken to
Maintenance and Service avoid damage which could result from liquid ex-
General Procedure: pansion. Temperature increase in a piping section
full of solid liquid will cause high pressure due to the
Dirt in the system is the greatest single cause
expanding liquid which can possibly rupture a
of regulator malfunction. All screens or filters
gasket, pipe or valve. All hand valves isolating
must be cleaned or replaced when they be- such sections should be marked, warning against
come dirty. At start up it is especially important accidental closing, and must not be closed until the
that these items are cleaned or changed fre- liquid is removed. Check valves must never be
quently. When the RSF close-coupled com- installed upstream of solenoid valves, or regula-
panion strainers are used, maintain according tors with electric shut-off, nor should hand valve
to instruction in Bulletin 00-10. Moisture in upstream of solenoid valves or downstream of
halocarbon systems in particular can cause check valves be close until the liquid has been
corrosion or form ice, causing the piston to removed. It is advisable to properly install relief
freeze in position. Filter-driers should be used devices in any section where liquid expansion
could take place.
and maintained for halocarbon systems.
Avoid all piping or control arrangements which
Before deciding to disassemble a regulator for
might produce thermal or pressure shock. For the
servicing, the following investigations should protection of people and products, all refrigerant
be made: must be removed from the section to be worked on
Check the manual opening stem; it should be before a valve, strainer, or other device is opened
turned in for automatic operation. or removed. Flanges with ODS connections are
Check the regulator setting to make sure it is not suitable for ammonia service.

Warranty
All Refrigerating Specialties products are war- The express warranty above constitutes the only
ranted against defects in workmanship and mate- warranty of Refrigerating Specialties products,
rials for a period of one year from date of shipment and is in lieu of all other warranties, expressed or
from originating factory. This warranty is in force implied, written or oral, including any warranty of
only when products are properly installed, field merchantability or warranty of fitness for a particu-
assembled, maintained, and operated in use and lar purpose and in no event is Refrigerating Spe-
service as specifically stated in Refrigerating Spe- cialties responsible for any consequential dam-
cialties Catalogs or Bulletins for normal refrigera- ages of any nature whatsoever. No employee,
tion applications, unless otherwise approved in agent, dealer or other person is authorized to give
writing by Refrigerating Specialties Company. any warranties on behalf of Refrigerating Special-
Defective products, or parts thereof returned to the ties nor to assume for Refrigerating Specialties
factory with transportation charges prepaid and any other liability in connection with any of it prod-
found to be defective by factory inspection will be ucts.
replaced or repaired at Refrigerating Specialties
BOLT TORQUE TABLE
option, free of charge F.O.B. factory. Warranty ITEM PORT SIZE TORQUE
does not cover products which have been altered, 7/16" Flange Bolt 1/2" 28 ft lb
or repaired in the field; damaged in transit, acci- 5/8" Flange Bolt 3/4" - 2" 85 ft lb
dents, misuse, or abuse. Products disabled by dirt 3/4" Flange Bolt 2-1/2" - 3" 105 ft lb
or other foreign substances will not be considered 7/8" Flange Bolt 4" 150 ft lb
5/16"-18 Bonnet Bolt 3/4" - 4" 11 ft lb
defective.
5/16"-18 Adapter Bolt 3/4" - 2" 11 ft lb
5/8"-11 Adapter Bolt 3" - 4" 75 ft lb
Bottom Cap 3/4"- 1-1/4" 150 ft lb
1/2"-13 Bottom Cap Bolt 1-5/8" - 2-1/2" 50 ft lb
5/8"-11 Bottom Cap Bolt 3"-4" 75 ft lb

A4AL VALVE DIMENSION TABLE
PORT 20 & 25 MM 32 MM 40 & 50 MM 65 MM 75 MM 100 MM

SIZE 3/4 & 1 1-1/4 1-5/8 & 2 2-1/2 3 4
DIMENSION MM INCH MM INCH MM INCH MM INCH MM INCH MM INCH
A (ALL) 164 6.2 203 8.0 251 9.9 252 9.9 311 12.2 359 14.1
B (ALL) 244 9.3 248 9.6 287 11.3 302 11.9 324 12.8 361 14.2
C (ALL) 392 15.6 410 16.4 464 18.6 483 19.2 597 23.5 563 25.7
FPT 3/4 229 9.0 1-1/4 269 10.6 1-1/2 318 12.5 2-1/2 343 13.5 3 401 15.8 4 462 18.2
D PIPE 1 229 9.0 1-1'2 269 10.6 2 318 12.5
SIZE 1-1/4 229 9.0
SW 3/4 229 9.0 1-1/4 269 10.6 1-1/2 318 12.5 2-1/2 343 13.5 3 401 15.8 4 462 18.2
E PIPE 1 229 9.0 1-1/2 269 10.6 2 318 12.5
SIZE 1-1/4 229 9.0
WN 3/4 267 10.5 1-1/4 312 12.3 1-1/2 376 14.8 2-1/2 414 16.3 3 490 19.3 4 584 23.0
F PIPE 1 274 10.8 1-1/2 318 12.5 2 384 15.1
SIZE 1-1/4 274 10.8
ODS 1-1/8 300 11.8 1-3/8 338 13.3 1-5/8 427 16.8 2-5/8 445 17.5 3-1/8 508 20.0 4-1/8 625 24.6
G TUBE 1-3/8 297 11.7 1-5/8 339 13.8 2-1/8 417 16.4 3-1/8 480 18.9 3-5/8 554 21.8
SIZE 1-5/8 313 12.3 2-1/8 384 15.1 2-5/8 442 17.4
H (ALL) 117 4.6 117 4.8 140 5.5 159 6.3 176 7.0 222 8.8
J (ALL) 98 3.9 178 7.0 251 9.9 314 12.4 314 12.4 363 14.3
Parker Hannifin Corporation Telephone: (708) 681-6300

Refrigerating
Refrigerating SpecialtiesSpecialties
Division Division
FAX: (708) 681-6306
8
2445 South 25th Ave
Broadview, IL 60155
TECHNICAL SERVICE MANUAL SECTION TSM 144
HEAVY-DUTY PUMPS PAGE 1 of 10
SERIES 4195 AND 495
ISSUE D
SIZES GG - AL
CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Information . . . . . . . . . . . . . . . . . . . . 2
Special Information . . . . . . . . . . . . . . . . . . . . 3
Special Mechanical Seals . . . . . . . . . . . . . . . . 3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 7
Thrust Bearing Adjustment . . . . . . . . . . . . . . . . 8 figure 1
Installation of Carbon Graphite Bushings . . . . . . . . 8 GG, HJ and HL4195 SERIES
Pressure Relief Valve Instructions . . . . . . . . . . . 9 Foot Type Unmounted Pump with Tapped Ports
INTRODUCTION
The illustrations used in this manual are for identification
purposes only and cannot be used for ordering parts. Obtain a
parts list from the factory or a Viking® representative. Always
give complete name of part, part number and material with
model number and serial number of pump when ordering
repair parts. The unmounted pump or pump unit model
number and serial number are on the nameplate.
In the Viking model number system, basic size letters are

combined with series number (4195 and 495) are used to
indicate either an unmounted pump or mounted pump unit.
figure 2
AS, AK and AL4195 SERIES
UNMOUNTED PUMP UNITS
Foot Type Unmounted Pump with Tapped Ports
Foot Mounted
GG4195 Units are designated by the
HJ4195 unmounted pump model
numbers followed by a letter(s)
HL4195
indicating drive style.
AS4195
AK4195 D = Direct Drive
AL4195
Flange Mounted figure 3
GG, HJ and HL495 SERIES
GG495 Unmounted Pump with Tapped Ports
HJ495
HL495 M = Horizontal Direct Drive
AS495
AK495
AL495
This manual deals only with Series 4195 and 495 Heavy
Duty Pumps. Refer to Figures 1 through 14 for general
configuration and nomenclature used in this manual. Pump
specifications and recommendations are listed in Catalog figure 4
Section 144, Series 4195 and 495 Heavy Duty Pumps.
AS, AK and AL495 SERIES
Unmounted Pump with Tapped Ports
VIKING PUMP, INC. • A Unit of IDEX Corporation • Cedar Falls, IA 50613 USA
SAFETY INFORMATION AND INSTRUCTIONS
IMPROPER INSTALLATION, OPERATION OR MAINTENANCE OF PUMP MAY CAUSE SERIOUS INJURY
OR DEATH AND/OR RESULT IN DAMAGE TO PUMP AND/OR OTHER EQUIPMENT. VIKING’S WARRANTY
DOES NOT COVER FAILURE DUE TO IMPROPER INSTALLATION, OPERATION OR MAINTENANCE.
THIS INFORMATION MUST BE FULLY READ BEFORE BEGINNING INSTALLATION, OPERATION OR

MAINTENANCE OF PUMP AND MUST BE KEPT WITH PUMP. PUMP MUST BE INSTALLED, OPERATED
AND MAINTAINED ONLY BY SUITABLY TRAINED AND QUALIFIED PERSONS.
THE FOLLOWING SAFETY INSTRUCTIONS MUST BE FOLLOWED AND ADHERED TO AT ALL TIMES.
Warning - In addition to possible serious

Symbol Danger - Failure to follow the indicated injury or death, failure to follow the
WARNING
Legend : ! instruction may result in serious injury
or death.
indicated instruction may cause damage
to pump and/or other equipment.
BEFORE opening any liquid chamber (pumping INSTALL pressure gauges/sensors next to the
WARNING
! chamber, reservoir, relief valve adjusting cap fitting,
etc.) be sure that :
pump suction and discharge connections to monitor
pressures.
● Any pressure in the chamber has been completely
vented through the suction or discharge lines or USE extreme caution when lifting the pump. Suitable
other appropriate openings or connections.
● The pump drive system means (motor, turbine,
! lifting devices should be used when appropriate. Lifting
eyes installed on the pump must be used only to lift
engine, etc.) has been “locked out” or otherwise WARNING the pump, not the pump with drive and/or base plate.
been made non-operational so that it cannot be If the pump is mounted on a base plate, the base plate
started while work is being done on the pump. must be used for all lifting purposes. If slings are used
for lifting, they must be safely and securely attached.
● You know what material the pump has been
For weight of the pump alone (which does not include
handling, have obtained a material safety data
the drive and/or base plate) refer to the Viking Pump
sheet (MSDS) for the material, and understand
product catalog.
and follow all precautions appropriate for the safe
handling of the material.
DO NOT attempt to dismantle a pressure relief valve
BEFORE operating the pump, be sure all drive guards ! that has not had the spring pressure relieved or is
mounted on a pump that is operating.
! are in place.
AVOID contact with hot areas of the pump and/or

DO NOT operate pump if the suction or discharge
! piping is not connected. ! drive. Certain operating conditions, temperature
control devices (jackets, heat-tracing, etc.), improper
installation, improper operation, and improper
DO NOT place fingers into the pumping chamber or maintenance can all cause high temperatures on the
! its connection ports or into any part of the drive train
if there is any possibility of the pump shafts being
pump and/or drive.
rotated.
THE PUMP must be provided with pressure protection.
DO NOT exceed the pumps rated pressure, speed, and

! This may be provided through a relief valve mounted
directly on the pump, an in-line pressure relief valve,
! temperature, or change the system/duty parameters
from those the pump was originally supplied, without
WARNING a torque limiting device, or a rupture disk. If pump
rotation may be reversed during operation, pressure
WARNING confirming its suitability for the new service. protection must be provided on both sides of pump.
Relief valve adjusting screw caps must always point
towards suction side of the pump. If pump rotation is
BEFORE operating the pump, be sure that:
reversed, position of the relief valve must be changed.
! ● It is clean and free from debris Pressure relief valves cannot be used to control pump
● all valves in the suction and discharge pipelines flow or regulate discharge pressure. For additional
WARNING
are fully opened. information, refer to Viking Pump’s Technical Service
● All piping connected to the pump is fully supported Manual TSM 000 and Engineering Service Bulletin
and correctly aligned with the pump. ESB-31.
● Pump rotation is correct for the desired direction

of flow. THE PUMP must be installed in a matter that allows
! safe access for routine maintenance and for inspection
during operation to check for leakage and monitor
WARNING pump operation.
SECTION TSM 144 ISSUE D PAGE OF 10

SPECIAL INFORMATION SPECIAL MECHANICAL SEALS:
This bulletin illustrates the mechanical seal which is
standard in the catalog pump. A Seal Installation Drawing
DANGER ! will be furnished with a pump fitted with a non-standard
mechanical seal. Consult this Seal Installation Drawing
Before opening any Viking pump liquid before disassembling pump.
chamber (pumping chamber, reservoir,
relief valve adjusting cap fitting, etc.) Modifications are required to install PTFE mechanical seals
in these pumps. Contact the factory for specific information.
Be sure:
1. That any pressure in the chamber has relief valve adjusting screw cap
been completely vented through the
suction or discharge lines or other
appropriate openings or connections.
2. That the driving means (motor, turbine,
engine, etc.) has been “locked out”
suction discharge
or made non-operational so that it
cannot be started while work is being
done on pump.
3. That you know what liquid the pump
has been handling and the precautions
necessary to safely handle the liquid. FIGURE 5
Obtain a material safety data sheet
(MSDS) for the liquid to be sure these MAINTENANCE
precautions are understood. Series 4195 and 495 pumps are designed for long, trouble-
free service life under a wide variety of application conditions
Failure to follow above listed with a minimum of maintenance. The points listed below will
precautionary measures may result in help provide long service life.
serious injury or death. CLEANING PUMP: Keep the pump as clean as possible.
This will facilitate inspection, adjustment and repair work
and help prevent overlooking a dirt covered grease fitting.
ROTATION: Viking pumps operate equally well in a clockwise
STORAGE: If the pump is to be stored, or not used for six
or counterclockwise rotation. Shaft rotation determines which
months or more, the pump must be drained and a light coat of
port is suction and which is discharge. Suction Port is where
non-detergent SAE 30 weight oil must be applied to all internal
pumping elements (gear teeth) come out of mesh.
pump parts. Lubricate the fittings and apply grease to the pump
PRESSURE RELIEF VALVES: shaft extension. Viking suggests rotating pump shaft by hand
one complete revolution every 30 days to circulate the oil.
1. Viking pumps are positive displacement pumps and
must be provided with some sort of pressure protection. SUGGESTED REPAIR TOOLS: The following tools must
This may be a relief valve mounted directly on the pump, be available to properly repair Series 4195 and 495 pumps.
an inline pressure relief valve, a torque limiting device or These tools are in addition to standard mechanics’ tools such
a rupture disk. as open end wrenches, pliers, screw drivers, etc. Most of the
items can be obtained from an industrial supply house.
2. There are relief valve options available on those pump
models designed to accept a relief valve. Options may 1. Soft Headed hammer
include a return to tank relief valve. Pumps equipped 2. Allen wrenches (set screws & special mechanical seals)
with a jacketed head plate are generally not available
3. Snap Ring Pliers
with a relief valve.
INTERNAL – Viking Part No. 2-810-047-999
3. If pump rotation is reversed during operation, pressure GG-HJ-HL 4195-495
protection must be provided on both sides of the pump. EXTERNAL – Viking Part No. 2-810-029-375
4. The relief valve adjusting screw cap must always point GG-HJ-HL 4195-495
towards the suction side of the pump. If pump rotation is 4. Mechanical Seal Installation Sleeve
reversed, remove the pressure relief valve and turn end 2-751-001-730 for 0.75 inch seal; GG 4195-495
for end. Refer to Figure 5. 2-751-004-730 for 1.25 inch seal; AS-AL 4195-495
5. Pressure relief valves should not be used to control flow 5. Bearing Locknut Spanner Wrench – 2-810-043-375
or regulate discharge pressure.
6. Spanner Wrench, adjustable pin type for use on bearing
For additional information on pressure relief valves, refer housing end cap. – 2-810-008-375
to Technical Service Manual TSM 000 and Engineering
7. Brass bar
Service Bulletin ESB-31.
8. Arbor press
9. Standard 5/16” 12 point socket

DISASSEMBLY 1. Refer to Figures 7 & 8, page 5 for model to be
disassembled and name of parts. Models 4195 & 495
are disassembled and assembled in the same manner.
DANGER ! The difference between these models is the casings.
2. Mark the head and casing before disassembly to insure
Before opening any Viking pump liquid proper reassembly.
relief valve adjusting cap fitting, etc.) 3. NOTE: The four valve capscrews, valve and gasket
must be removed from the GG4195-495 model before
Be sure:
the six head capscrews are removed.
1. That any pressure in the chamber has Remove the head capscrews.
been completely vented through the 4. Tilt the top of the head back when removing to prevent
suction or discharge lines or other the idler from falling off the idler pin.
5. Remove the idler and bushing assembly. If the idler
2. That the driving means (motor, turbine, bushing needs replacing, see “Installation of Carbon
engine, etc.) has been “locked out” Graphite Bushings,” page 8.
or made non-operational so that it 6. Insert a brass bar or piece of hardwood in the port
cannot be started while work is being opening and between the rotor teeth to keep the shaft
done on pump. from turning. Turn the locknut counterclockwise and
remove locknut. See Figure 9 or 10, page 6.
3. That you know what liquid the pump 7. Loosen the two setscrews in the face of the bearing
has been handling and the precautions housing and turn the thrust bearing assembly
necessary to safely handle the liquid. counterclockwise and remove from casing. See Figure
Obtain a material safety data sheet 9 or 10, page 6.
(MSDS) for the liquid to be sure these 8. GG, HJ, HL: Remove the snap ring from the shaft.
precautions are understood. See Figure 9, page 6.
Failure to follow above listed AS, AK, AL: Remove the bearing spacer from the shaft.
precautionary measures may result in See Figure 10, page 6.
serious injury or death. 9. Remove the brass bar or piece of hardwood from the
port opening.
Mechanical seal
ROTOR
IDLER
HEAD ball bearings
Pressure relief valve
SHAFT
snap rings
casing
IDLER PIN
head gasket
FIGURE 6
cutaway for models gg, hj and hl4195

CASING
Modifications to the pump casing and rotor are required for installation
of optional PTFE mechanical seal. Consult the factory.
figure 7 - exploded view for models gg, hj and hl 4195 and 495
ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART

1 Locknut 8 Casing (4195) 14 Head O-Ring
2 Snap Ring (Outer) 8A Casing (495) 15 Idler Pin
3 Ball Bearing (Outer) 9 Pipe Plug 16 Head and Idler Pin Assembly
4 Snap Ring for Shaft * 10 Mechanical Seal 17 Capscrew for Head
5 Bearing Housing 11 Rotor and Shaft Assembly 18 Gasket for Relief Valve
6 Snap Ring (Inner) 12 Idler Bushing 19 Relief Valve
7 Ball Bearing (Inner) 13 Idler and Bushing Assembly 20 Capscrew for Valve
* Not used on “GG” size pumps.
Modifications to the pump casing and rotor are required for installation
of optional PTFE mechanical seal. Consult the factory.
figure 8 - exploded view for models as, aK and al 4195 and 495
ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART

1 Locknut 9 Bearing Retainer Washer 16 Mechanical Seal
2 Bearing Spacer Collar 10 Casing (4195) 17 Idler Bushing
3 End Cap for Bearing Housing 10A Casing (495) 18 Idler and Bushing Assembly
4 Lip Seal for Bearing Housing 11 O-Rings for Relief Valve 19 Head O-Ring
5 Ball Bearing (Outer) 12 Relief Valve 20 Idler Pin
6 Bearing Housing 13 Pipe Plug 21 Check Valve
7 Bearing Spacer 14 Capscrew for Valve 22 Head and Idler Pin Assembly
8 Ball Bearing (Inner) 15 Rotor and Shaft Assembly 23 Capscrew for Head

inner ball bearing
outer ball bearing
inner snap ring
outer snap ring
LOCKNUT
SHAFT shaft snap ring
bearing housing
setscrew
figure 9 - thrust bearing assembly gg, hj and hl sizes
ball bearing bearing retainer washer
SETSCREW inner BALL BEARING
NYLON INSERT
END CAP
LIP SEAL
SHAFT bearing SPACER
LOCKNUT
bearing spacer collar
bearing housing
SETSCREW
figure 10 - thrust bearing assembly as, ak and al sizes
10. The rotor and shaft can now be removed by tapping on 15. Disassemble the thrust bearing assembly.
the end of the shaft with a lead hammer or, if using a GG, HJ, HL: Remove the outer snap ring from the
regular hammer, use a piece of hardwood between the bearing housing and remove the ball
shaft and hammer. The rotary member of the seal will bearing. See Figure 9.
come out with the rotor and shaft.
AS, AK, AL: Loosen the two setscrews in the flange
11. AS, AK, AL: Remove the bearing retainer washer. The outside diameter. Rotate the end cap and
washer may have stayed with the rotor and lip seal counterclockwise and remove.
shaft when removed or is against the ball Remove the ball bearing. See Figure 10.
bearing. See Figure 10.
The casing should be examined for wear, particularly in the
12. Remove the mechanical seal rotary member and spring area between the ports. All parts should be checked for wear
from the rotor and shaft assembly. before the pump is put together.
13. GG, HJ, HL: Remove the inner snap ring and single row When making major repairs, such as replacing a rotor and
ball bearing from the casing. shaft; it is advisable to also install a new mechanical seal,
AS, AK, AL: Remove the single row ball bearing from head and idler pin, idler and bushing. See “Installation of
the casing. Carbon Graphite Bushings,” page 8.
14. Remove the seal seat or stationary part of the seal from
the casing.

Clean all parts thoroughly and examine for wear or damage. spring mechanical seal
Check the lip seals, ball bearings, bushing and idler pin and (rotary member)
replace if necessary. Check all other parts for nicks, burrs,
excessive wear and replace if necessary.
Wash the bearings in clean solvent. Blow out the bearings
with compressed air. Do not allow the bearings to spin; turn
them slowly by hand. Spinning the bearings will damage
the race and balls. Make sure the bearings are clean, then
lubricate with non-detergent SAE 30 weight oil and check tapered sleeve
for roughness. Roughness can be determined by turning coat with light oil before assembly
the outer race by hand. Replace the bearings if they have FIGURE 11
roughness.
Be sure the shaft is free from nicks, burrs and foreign
particles that might damage the mechanical seal. Scratches
on the shaft in seal area will provide leakage paths under the ROTOR HUB
mechanical seal. Use a fine emery cloth to remove scratches spring
or sharp edges. SHAFT
ASSEMBLY
Standard Mechanical Seal
(Synthetic Rubber Bellows Type)
READ CAREFULLY BEFORE REASSEMBLING PUMP mechanical seal

(rotary member)
The seal used in this pump is simple to install and good
performance will result if care is taken during installation.
The principle of a mechanical seal is contact between the FIGURE 12
rotary and stationary members. These parts are lapped to
a high finish and their sealing effectiveness depends on
complete contact. 6. Slide the rotary member, lapped contact surface facing
away from the spring, over installation sleeve on shaft
Prior to installing the rotary portion of the mechanical until just contacting the spring. Do not compress the
seal, prepare and organize the rotor shaft, head and idler spring. Remove the installation sleeve.
assemblies and appropriate gaskets for quick assembly.
7. Coat the rotor shaft with non-detergent SAE 30 weight
Once the rotary portion of the mechanical seal is installed oil. Install the rotor and shaft into the casing, slowly
on the rotor shaft, it is necessary to assemble the parts as pushing until the ends of the rotor teeth are just below
quickly as possible to insure the seal does not stick to the the face of the casing. Take care not to damage the seal
shaft in the wrong axial position. The seat will stick to the seat.
shaft after several minutes setting time.
8. Leave the rotor in this position. Withdrawal of the rotor
Never touch the sealing faces with anything except clean and shaft may displace the carbon seal rotating face and
hands or clean cloth. Minute particles can scratch the seal result in damage to the seal.
faces and cause leakage.
9. Place the O-ring or gasket on the head and install the
1. Coat the idler pin with non-detergent SAE 30 weight oil head and idler assembly on pump. The pump head
and place idler and bushing on idler pin in the head. If and casing were marked before disassembly to insure
replacing a carbon graphite bushing, refer to “Installation proper reassembly. If not, be sure the idler pin, which
of Carbon Graphite Bushings,” page 8. is offset in the pump head, is positioned up and equal
2. Clean the rotor hub and casing seal housing bore. Make distance between port connections to allow for proper
sure both are free from dirt and grit. Coat the outer flow of liquid through the pump.
diameter of seal seat and inner diameter of seal housing 10. Tighten the head capscrews evenly.
bore with non-detergent SAE 30 weight oil.
11. If the pump was equipped with a relief valve and was
3. Start the seal seat in the seal housing bore. If force is removed during disassembly, install on the head with
necessary protect the seal face with a clean cardboard new O-Rings or gaskets. The relief valve adjusting screw
disc and gently tap it in place with a piece of wood. Be cap must always point towards the suction port. Refer to
sure the seal seat is completely seated in the bore. Figure 5, page 3. For relief valve repair or adjustments,
4. Place a tapered installation sleeve on the shaft, refer to see “Pressure Relief Valve Instructions,” Page 9.
Figure 11. The sleeve is furnished with GG, AS, AK and 12. In 2005, the use of single seal bearings were phased
AL replacement mechanical seals. Coat the rotor shaft, out. Pumps now use “Sealed for Life” bearings that
tapered installation sleeve and inner diameter of the have seals on both sides. The new bearings can be
mechanical seal rotary member with a generous amount installed either side first and do not need to be packed
of non-detergent SAE 30 weight oil. Petrolatum may be with grease. For older models with single seal bearings,
used but grease is not recommended. pack the inner ball bearing with multi-purpose grease,
5. Place the seal spring on the shaft against the rotor hub. NLGI #2.
Refer to Figure 12.
GG, HJ, HL: Drive the bearing into the bore. Tap the THRUST BEARING ADJUSTMENT
inner race with a brass bar and lead
hammer to position bearing. Install the See Figures 9 and 10.
inner snap ring. Loosen the two screws in the face of the thrust bearing
AS, AK, AL: Install the bearing retainer washer over assembly.
the shaft before installing the ball bearing. If the shaft cannot be rotated freely, turn the thrust bearing
Install the ball bearing in the casing with assembly counterclockwise until the shaft can be turned
sealed side towards head end of the easily.
pump. Drive the bearing into the bore. Tap
the inner race with a brass bar and lead To set end clearance:
hammer to position the bearing. 1. While turning the rotor shaft, rotate the thrust bearing
13. GG, HJ, HL: Install the shaft snap ring in groove in the assembly clockwise until a noticeable drag occurs. This
shaft. See Figure 9, page 6. is zero end clearance.
AS, AK, AL: Install the bearing spacer over the shaft 2. Mark the position of the bearing housing with respect to
and against the single row ball bearing. the casing.
See Figure 10, page 6. 3. Rotate the thrust bearing assembly counterclockwise the
14. Pack the lubrication chamber between the inner ball distance listed below as measured on outside of bearing
bearing and double row ball bearing in the thrust bearing housing.
assembly approximately one-half full of multi-purpose 4. After the adjustment is made, tighten the two setscrews
grease, NLGI #2. The thrust bearing assembly will take in the face of the bearing housing assembly to secure
the remaining space. See Figure 9 and 10, page 6. the position.
15. Pack the double row ball bearing with multi-purpose For viscosities above 2500 SSU, add additional end
grease, NLGI #2. clearance (0.004” for GG, HJ and HL size pumps and
GG, HJ, HL: Install the ball bearing into the bearing 0.005” for AS, AK and AL size pumps).
housing with shield side toward the
coupling end of the shaft. See Figure 9,
page 6. Install the snap ring into bearing
housing to retain ball bearing. This snap DISTANCE IN INCHES STANDARD
PUMP
ring has a tapered edge to fit tapered ON O.D. OF BEARING END
SIZE
groove in bearing housing. The tapered HOUSING CLEARANCE
edge is located away from the ball bearing. GG 0.44” (7/16”) .003
AS, AK, AL: Install the ball bearing into the bearing
housing. Install the lip seal in the bearing HJ , HL 0.56” (9/16”) .003
housing end cap. The lip should face AS , AK , AL 0.5” (1/2”) .003
towards the end of the shaft. Put the bearing
spacer collar in the lip seal and install in
the bearing housing and tighten the set
screws securely. See Figure 10, page 6.
16. Insert a brass bar or piece of hardwood through the port
opening between the rotor teeth to keep the shaft from
turning.
INSTALLATION OF CARBON
17. Start the thrust bearing assembly into casing. Turn by
hand until tight. This forces the rotor against the head. GRAPHITE BUSHINGS
Replace and tighten the locknut or shaft.
When installing the carbon graphite bushings, extreme care
18. Remove the brass bar or hardwood from port opening. must be taken to prevent breaking. Carbon graphite is a brittle
19. Adjust pump end clearance, refer to “Thrust Bearing material and is easily cracked. If cracked, the bushing will
Adjustment”. 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:
DANGER ! 1. A press must be used for installation.
Before starting pump, be sure all drive 2. Be certain the bushing is started straight.
equipment guards are in place. 3. Do not stop pressing the operation until the bushing is in
Failure to properly mount guards may the proper position, as starting and stopping may result
in a cracked bushing.
result in serious injury or death.
4. Check the bushing for cracks after installation.

PRESSURE RELIEF VALVE DISASSEMBLY
INSTRUCTIONS
DANGER !
Before opening any Viking pump liquid
relief valve adjusting cap fitting, etc.)
Be sure:
1. That any pressure in the chamber has
been completely vented through the
suction or discharge lines or other
2. That the driving means (motor, turbine,
engine, etc.) has been “locked out”
or made non-operational so that it
cannot be started while work is being
done on pump.
FIGURE 13
VALVE - GG, HJ and HL SIZES 3. That you know what liquid the pump
has been handling and the precautions
VALVE - LIST OF PARTS necessary to safely handle the liquid.
1. Valve Cap 6. Valve Body Obtain a material safety data sheet
2. Adjusting Screw 7. Valve Spring
(MSDS) for the liquid to be sure these
precautions are understood.
3. Lock Nut 8. Poppet
4. Spring Guide 9. Cap Gasket Failure to follow above listed
5. Bonnet precautionary measures may result in
serious injury or death.
Mark the valve and head before disassembly to ensure

proper reassembly.
1. Remove the valve cap.
2. Measure and record the length of extension of the
adjusting screw. Refer to “A” on Figures 13 and 14.
3. Loosen the locknut and back out the adjusting screw
until spring pressure is released.
4. Remove the bonnet, spring guide, spring and poppet
from the valve body. Clean and inspect all parts for wear
or damage and replace as necessary.
FIGURE 14
VALVE - AS, AK and AL SIZES
ASSEMBLY
Reverse the procedures outlined under “Disassembly.” If
VALVE - LIST OF PARTS
the valve is removed for repairs, be sure to replace in the
1. Valve Cap 6. Valve Body same position. The relief valve adjusting screw cap must
2. Adjusting Screw 7. Valve Spring always point towards suction side of the pump. If the pump
3. Lock Nut 8. Poppet rotation is reversed, remove the relief valve and turn end for
end. Refer to Figure 5, page 3.
4. Spring Guide 9. Cap Gasket
5. Bonnet 10. Bonnet O-Ring

HEAVY-DUTY PUMPS PAGE 10 of 10
SERIES 4195 AND 495
ISSUE D
SIZES GG - AL
DANGER !
Before starting pump, be sure all drive
equipment guards are in place. WARRANTY
Failure to properly mount guards may Viking warrants all products manufactured by it to
be free from defects in workmanship or material for a
result in serious injury or death. period of one (1) year from date of startup, provided
that in no event shall this warranty extend more than
eighteen (18) months from the date of shipment from
Viking. If, during said warranty period, any products
PRESSURE ADJUSTMENT sold by Viking prove to be defective in workmanship
or material under normal use and service, and if such
If a new spring is installed or if the pressure setting of the
products are returned to Viking’s factory at Cedar Falls,
pressure relief valve is to be changed from that which the Iowa, transportation charges prepaid, and if the products
factory has set, the following instructions must be carefully are found by Viking to be defective in workmanship
followed. or material, they will be replaced or repaired free of
charge, FOB. Cedar Falls, Iowa.
1. Carefully remove the valve cap which covers the Viking assumes no liability for consequential
adjusting screw. damages of any kind and the purchaser by acceptance
of delivery assumes all liability for the consequences of
Loosen the locknut which locks the adjusting screw so
the use or misuse of Viking products by the purchaser,
the pressure setting will not change during operation of his employees or others. Viking will assume no field
the pump. expense for service or parts unless authorized by it in
2. Install a pressure gauge in the discharge line for actual advance.
adjustment operation. Equipment and accessories purchased by Viking
from outside sources which are incorporated into any
3. Turn the adjusting screw in to increase the pressure and Viking product are warranted only to the extent of and
out to decrease the pressure. by the original manufacturer’s warranty or guarantee,
4. With discharge line closed at a point beyond pressure if any.
gauge, the gauge will show the maximum pressure the THIS IS VIKING’S SOLE WARRANTY AND IS IN
valve will allow while the pump is in operation. LIEU OF ALL OTHER WARRANTIES, EXPRESSED
OR IMPLIED, WHICH ARE HEREBY EXCLUDED,
INCLUDING IN PARTICULAR ALL WARRANTIES
IMPORTANT OF MERCHANTABILITY OR FITNESS FOR A
When ordering parts for the pressure relief valve, always PARTICULAR PURPOSE. No officer or employee of
give the model number and serial number of the pump IDEX Corporation or Viking Pump, Inc. is authorized to
as it appears on the nameplate and the name of the part alter this warranty.
wanted. When ordering springs, be sure to give the pressure
setting desired.
© 5/2007 Viking Pump Inc.
All rights reserved
INSTALLATION, START UP, TROUBLESHOOTING, PAGE 1 of 8

ISSUE G
PREVENTATIVE MAINTENANCE, DO’S & DON’TS
CONTENTS mesh, point “B”, the liquid is forced out the discharge port.
Reversing the rotation reverses the flow through the pump.
Installation, General Comments . . . . . . . . . . . . . . . . 1 When determining shaft rotation, always look from the shaft end
Safety Information and Instructions . . . . . . . . . . . . . . . 2 of the pump. Unless otherwise specified, rotation is assumed to
Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 be clockwise (CW), which makes the suction port on the right
Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 side of the pump. The idler pin, which is offset in the pump head,
Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 should be properly positioned toward and an equal distance
Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 between the port connections.
Rapid Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 6 discharge b
Preventative Maintenance . . . . . . . . . . . . . . . . . . . 7
Do’s and Don’ts . . . . . . . . . . . . . . . . . . . . . . . . 8 a
INSTALLATION
suction
GENERAL COMMENTS
Before installation is started, a few items of a general nature should
be considered. idler pin
1. Location - always locate the pump as close as possible to the
supply of liquid to be pumped. Locate it below the liquid supply figure 3
if at all practical. Viking pumps are self priming but the better the
suction conditions the better the performance. 5. Pressure Protection - Viking pumps are positive displacement.
2. Accessibility - the pump should be located where it is accessible This means that when the pump is rotated, liquid will be delivered
for inspection, maintenance, and repair. For large pumps, allow to the discharge side of the pump. If there is no place for this
room to remove the rotor and shaft without removing the pump liquid to go - discharge line is blocked or closed - pressure can
from the base. build up until the motor stalls, the drive equipment fails, a pump
part breaks or ruptures, or the piping bursts. Because of this,
3. Port Arrangement - since the pumps have different port
some form of pressure protection must be used with a positive
arrangements depending on the model, port location should
displacement pump. This may be a relief valve mounted directly
be checked before starting the installation. The ports may be
on the pump, an inline relief valve, a torque limiting device or a
upright, opposite or at right angles to each other, see Figure
rupture disk.
1. The right angle ports are normally right-hand, see Figure
2; some models are available with left-hand arrangements; still
other models are available with the right angle ports located in valve body (C) spring (A)
any one of eight positions including right-hand and left-hand. poppet (B) cap (should always
point toward
point (E) suction port)
adjusting
screw (D)
figure 1 liquid inlet liquid outlet
figure 4
left right cutaway of viking internal pressure relief valve
hand hand
The pressure relief valve mounted on Viking pumps and most in-line
pump pump
valves are of the spring loaded poppet design See Figure 4. The
spring (A) holds poppet (B) against the seat in the valve body (C)
figure 2 with a given force determined by the spring size and by how tightly
it is compressed by the adjusting screw (D). The pump discharge
4. Suction/Discharge - shaft rotation will determine which port is pressure pushes against the underside of the poppet at point (E).
suction and which is discharge. A look at Figure 3 will show When the force exerted by the liquid under the poppet exceeds that
how rotation determines which port is which; as the pumping exerted by the spring, the poppet lifts and liquid starts to flow through
elements (gears) come out of mesh, point “A” on Figure 3, the valve. As the discharge pressure builds up, more and more of
liquid is drawn into the suction port; as the gears come into the liquid flows through until a pressure is reached at which all of the
liquid being pumped is going through the valve. This pressure is the
relief valve setting.
SAFETY INFORMATION AND INSTRUCTIONS
IMPROPER INSTALLATION, OPERATION OR MAINTENANCE OF PUMP MAY CAUSE SERIOUS INJURY
OR DEATH AND/OR RESULT IN DAMAGE TO PUMP AND/OR OTHER EQUIPMENT. VIKING’S WARRANTY
DOES NOT COVER FAILURE DUE TO IMPROPER INSTALLATION, OPERATION OR MAINTENANCE.
THIS INFORMATION MUST BE FULLY READ BEFORE BEGINNING INSTALLATION, OPERATION OR

MAINTENANCE OF PUMP AND MUST BE KEPT WITH PUMP. PUMP MUST BE INSTALLED, OPERATED
AND MAINTAINED ONLY BY SUITABLY TRAINED AND QUALIFIED PERSONS.
THE FOLLOWING SAFETY INSTRUCTIONS MUST BE FOLLOWED AND ADHERED TO AT ALL TIMES.
Warning - In addition to possible serious

Symbol Danger - Failure to follow the indicated injury or death, failure to follow the
WARNING
Legend : ! instruction may result in serious injury
or death.
indicated instruction may cause damage
to pump and/or other equipment.
BEFORE opening any liquid chamber (pumping INSTALL pressure gauges/sensors next to the
WARNING
! chamber, reservoir, relief valve adjusting cap fitting,
etc.) be sure that :
pump suction and discharge connections to monitor
pressures.
● Any pressure in the chamber has been completely
vented through the suction or discharge lines or USE extreme caution when lifting the pump. Suitable
other appropriate openings or connections.
● The pump drive system means (motor, turbine,
! lifting devices should be used when appropriate. Lifting
eyes installed on the pump must be used only to lift
engine, etc.) has been “locked out” or otherwise WARNING the pump, not the pump with drive and/or base plate.
been made non-operational so that it cannot be If the pump is mounted on a base plate, the base plate
started while work is being done on the pump. must be used for all lifting purposes. If slings are used
for lifting, they must be safely and securely attached.
● You know what material the pump has been
For weight of the pump alone (which does not include
handling, have obtained a material safety data
the drive and/or base plate) refer to the Viking Pump
sheet (MSDS) for the material, and understand
product catalog.
and follow all precautions appropriate for the safe
handling of the material.
DO NOT attempt to dismantle a pressure relief valve
BEFORE operating the pump, be sure all drive guards ! that has not had the spring pressure relieved or is
mounted on a pump that is operating.
! are in place.
AVOID contact with hot areas of the pump and/or

DO NOT operate pump if the suction or discharge
! piping is not connected. ! drive. Certain operating conditions, temperature
control devices (jackets, heat-tracing, etc.), improper
installation, improper operation, and improper
DO NOT place fingers into the pumping chamber or maintenance can all cause high temperatures on the
! its connection ports or into any part of the drive train
if there is any possibility of the pump shafts being
pump and/or drive.
rotated.
THE PUMP must be provided with pressure protection.
DO NOT exceed the pumps rated pressure, speed, and

! This may be provided through a relief valve mounted
directly on the pump, an in-line pressure relief valve,
! temperature, or change the system/duty parameters
from those the pump was originally supplied, without
WARNING a torque limiting device, or a rupture disk. If pump
rotation may be reversed during operation, pressure
WARNING confirming its suitability for the new service. protection must be provided on both sides of pump.
Relief valve adjusting screw caps must always point
towards suction side of the pump. If pump rotation is
BEFORE operating the pump, be sure that:
reversed, position of the relief valve must be changed.
! ● It is clean and free from debris Pressure relief valves cannot be used to control pump
● all valves in the suction and discharge pipelines flow or regulate discharge pressure. For additional
WARNING
are fully opened. information, refer to Viking Pump’s Technical Service
● All piping connected to the pump is fully supported Manual TSM 000 and Engineering Service Bulletin
and correctly aligned with the pump. ESB-31.
● Pump rotation is correct for the desired direction

of flow. THE PUMP must be installed in a matter that allows
! safe access for routine maintenance and for inspection
during operation to check for leakage and monitor
WARNING pump operation.
SECTION TSM 000 ISSUE G PAGE OF 8

discharge
CAUTION ! pump head
Internal type relief valves mounted on
Viking pumps should always have the
cap or bonnet pointed toward the suction
side of the pump. Return-to-tank-type
relief valves should always be mounted
on the discharge side of the pump. If
valve always
pump rotation is reversed, change the mounts on
relief valve. Turn the internal type end for discharge
end; move the return-to-tank type to the side of pump
other port. If, on a particular installation suction
rotation is reversed, e.g., using one pump figure 5B
to fill a tank and then by use of a reversing return-to-tank pressure relief valve
switch or other means changing the rotation
to permit the same pump to circulate the liquid NOTE: on some models the relief valve is mounted on the pump
through a heater or to load out) then pressure casing instead of the pump head.
protection must be provided on both sides The spring loaded poppet-type valve is strictly a differential valve,
of the pump for both rotations. This may sensing only those pressures on each side of the poppet. It should
not be used as a pressure or flow control device. It is intended
be a combination of relief valves, torque
strictly as a relief valve.
limiting devices or rupture disks.
The pressure at which either the return-to-tank or internal relief
valve bypasses can be changed by turning the adjusting screw.
Do not back the adjusting screw all the way out. Stop when spring
tension is off the screw (the screw starts to turn easily). For details
CAUTION ! on maintenance of the relief valve see Technical Service Manual
Pumps or systems without relief valves covering your model series.
should have some form of pressure 6. Motor - follow local electrical codes when hooking up motors.
protection, e.g. torque limiting devices or
rupture disks.
FOUNDATION
Every pump should have a solid foundation. It may be any structure
Viking pumps can be furnished with either an internal pressure relief
sufficiently strong to hold the pump rigid and to absorb any strain or
valve - one which directs the flow from the valve back to the suction
shock that may be encountered.
side of the pump - or a return-to-tank valve which directs the flow
through piping back to the supply tank. See Figures 5A and 5B. An A certified print of the pumping unit should be used in
inline relief valve mounted in the discharge piping also directs the preparing the foundation. If a separate foundation is provided, make
flow back to the supply tank. This type of valve should be mounted it at least four inches wider and longer than the base of the unit.
close to the pump so that the pressure drop through the piping When the unit is placed on the foundation it should be leveled and
between the pump and the valve is at a minimum. Be sure there are checked for position against the piping layout and then fastened
no shutoff valves between the pump and relief valve. Piping from a down.
return-to-tank or an in-line valve to the supply tank should also be as
short and large as possible.
ALIGNMENT
discharge
CHECK ALIGNMENT AFTER MOUNTING
For detailed coupling alignment procedures see Viking service
pump head bulletin ESB-61.
The pump, drive, and motor were properly aligned at the time they
were assembled. During shipping and mounting the alignment is
often disturbed. BE SURE TO RECHECK ALIGNMENT AFTER
THE PUMP UNIT IS INSTALLED!
1. Check pump ports to be sure they are square and in the proper
position; shim or move the pump as required. Do not force
suction
piping to line up with the ports.
2. If the pump is driven by a flexible coupling(s) either direct
connected to the motor or through a reducer, remove any
coupling guards or covers and check alignment of the coupling
halves. A straightedge (a piece of key stock works nicely) across
the coupling must rest evenly on both rims at the top, bottom,
relief valve adjusting
screw cap (should always and sides. See Figure 6, page 4.
point toward suction port)
figure 5A
internal pressure relief valve
USE A STRAIGHT EDGE. THESE
SURFACES MUST BE PARALLEL.
CHECK WIDTH BETWEEN THESE SURFACES WITH

INSIDE CALIPERS TO BE CERTAIN THE FACES ARE
EQUAL DISTANCE APART AND PARALLEL.
figure 8
figure 6 internal pressure relief valve
3. If the pump is driven by V-belts, check the alignment by using a

long straightedge or tightly drawn string across the face of the
sheaves. See Figure 6A.
DRIVER
SHEAVE DRIVEN STRING
SHEAVE OR
STRAIGHT EDGE
a b C D
figure 9
when sheaves are properly aligned, all points
a, b, c, d will touch string or straight edge.
internal pressure relief valve
figure 6A
PIPING
4. Make a final check on alignment after piping is hooked up.
The cause of many pumping problems can be traced to suction
See item 13 under “Installation - Piping.
piping. It should always be as large and short as practical. For help
Figures 7, 8, and 9 show typical units - direct, gear in selecting the proper size piping, both suction and discharge, refer
reducer and V-belt drive. to Viking General Catalog Section 510.
5. For high temperature applications (those above 300°F) allow the Before starting layout and installation of your piping system, consider
pump to reach operating temperature, then recheck alignment. the following points:
1. Never use piping smaller than the pump port connections.
2. Be sure the inside of the pipe is clean before hooking it up.
3. Foot valve - When pumping a light liquid with a suction lift, a
foot valve at the end of the suction piping or a check valve in
the first horizontal run will hold the liquid in the line and make it
easier for the pump to prime. Be sure the foot or check valve is
big enough so that it doesn’t cause excessive line loss.
4. When approaching an obstacle in the suction or discharge line,
go around the obstacle instead of over it. Going over it creates
an air pocket. See Figure 10.5. Where practical, slope the
piping so no air or liquid pockets will be formed. Air pockets in
the suction line make it hard for the pump to prime.
6. For a suction line with a long horizontal run keep the horizontal
portion below the liquid level if possible. This keeps the pipe
full so the pump does not have to remove so much air when
figure 7
starting; this is most helpful when there is no foot valve. See
internal pressure relief valve Figure 11.
7. When piping a hot or cold system (liquid being handled is at a
temperature different from the air surrounding the pump), be
sure allowance is made for expansion and contraction of the
piping. Loops, expansion joints, or unsecured (this does not
mean unsupported) runs should be used so the pump casing is
not distorted or put into a bind.

permitting air to be drawn in may cause a noisy pump, or a
reduction in capacity.
13. ALIGNMENT - Check the alignment of the drive after the piping
is hooked up. As a final check on pump alignment remove the
head of the pump and with a feeler gauge determine if there
is clearance all the way around between the rotor and casing.
OBSTRUCTION Because of manufacturing tolerances, bushing clearances,
OBSTRUCTION etc., the rotor may not be centered in the casing, but it should
GO AROUND THE
OBSTRUCTION ON not drag; dragging would indicate unit misalignment or casing
THE HORIZONTAL
distortion from piping strain. Making this check is most desirable
on installations involving Q, M and N size standard duty
pumps.
DO THIS NOT THIS
14. The auxiliary piping hooked to jackets, glands, etc. for heating,
figure 10 cooling, quenching, or for other purposes should receive the
same attention as the piping handling the liquid pumped.
15. Provide a pressure relief device in any part of a pump and piping
system that can be valved off and, thus, completely isolated.
This is particularly important:
NOT THIS a). When handling a cold liquid such as refrigeration ammonia
that can warm up to ambient temperatures when the pump
is shut off or
b). When handling a liquid such as asphalt or molasses that
has to be heated before it can be pumped.
The rise in temperature causes the liquid to expand; if there is
no provision for pressure relief in the closed off section, there is
a chance that the pump or piping will rupture.
THIS START UP
Before pushing the “start” button, check the following:
1. Are there vacuum and pressure gauges on or near the pump?
KEEP LONG
These gauges are the quickest and most accurate way of finding
HORIZONTAL LINE out what is happening in the pump.
NEAR LIQUID LEVEL 2. Check alignment - See suggestions under “Installation -
figure 11 Alignment” in this manual.
3. Check piping to be sure there is no strain on the pump casing.
4. Rotate the pump shaft by hand to be sure it turns freely. MAKE
8. STRAINER - It is always good practice to consider a strainer on SURE THE PUMP DRIVER IS LOCKED OUT OR CANNOT
the suction side of a positive displacement pump. The strainer BE ENERGIZED BEFORE DOING THIS.
will keep foreign objects from going into the pump; without a 5. Jog motor to be sure it is turning in the right direction; see
strainer some would go through; others would cause a jammed discussion on pump rotation under “Installation - General
pump, a broken part, or a torn up drive. The strainer basket Comments” item 4 in this manual.
mesh or perforation size should be big enough so that it does 6. Check any relief valves to be sure they are installed correctly. See
not cause excessive pressure drop, but it should be fine enough discussion on relief valves under “Installation - General”.
to protect the pump. When in doubt as to the proper size, check
7. Check suction piping to be sure (a) it is all connected and tight,
with the manufacturer, giving him pipe size, flow rate, and
(b) valves are open, and (c) end of pipe is below liquid level.
viscosity involved. Provision should be made for cleaning the
strainer. If the pump operates continuously, a bypass should be 8. Check discharge piping to be sure (a) it is connected and tight,
built around the strainer or two strainers should be put in parallel (b) valves are open, and (c) there is a place for the liquid to
with proper valving so they can be isolated for cleaning. Use of go.
a strainer is particularly important at start up to help clean the 9. Lubricate any grease fitting on the pump using a good, general
system of weld beads, pipe scale, and other foreign objects. For purpose #2 ball bearing grease. Check any gear reducer, motor,
additional information, refer to TSM640. coupling, etc. for instructions and lubricate as recommended.
9. If the pump is not equipped with a relief valve, consideration See Engineering Service Bulletin ESB-515.
should be given to mounting one in the discharge line. See 10. For packed pumps, loosen packing gland nuts so gland can be
discussion on relief valves under START UP. moved slightly by hand. Adjust gland to reduce leakage only
10. The pump should not be used to support the piping. The weight after pump has run long enough to reach constant temperature.
of the pipe should be carried by hangers, supports, stands, Packing should weep a little to keep it cool and lubricated.
etc. 11. Do not use the Viking pump to flush, pressure test or prove the
11. When fastening the piping to the pump it should not be system with water. Either remove the pump or run piping around
necessary to impose any strain on the pump casing. “Springing” it while flushing or testing. Pumping water, dirty or otherwise,
or “drawing” the piping up to the pump will cause distortion, can do more damage in a few minutes than months of normal
possible misalignment, and probable rapid wear of the pump. service.
Do not use the pump to correct errors in piping layout or 12. Check to be sure all guards are in place.
assembly.
12. All joints of the piping system should be tight; pipe sealer will
help assure leak-free threaded joints. Leaks in the suction line

13. Now you are ready to push the “start” button - gently. If the pump still does not deliver, the cause may be one or more of
If the pump begins to deliver liquid within 60 seconds, you’re the following:
in business. If it does not, push the “stop” button. Do not run the 1. Suction line air leaks; vacuum gauge reading should help
pump longer than one minute without liquid in it; you may damage determine if this is the problem.
it. Review the steps just outlined, consider what the suction and 2. End of suction pipe not submerged deep enough in liquid.
discharge gauges indicate, see page 6; if everything appears to be 3. Suction lift is too great or the suction piping is too small.
in order, put some liquid in the pump, a lubricating liquid is best. This
4. Liquid is vaporizing in the suction line before it gets to the
will help it prime.
pump.
Push the “start” button again. If nothing is flowing within two minutes,
If after consideration of these points it still does not pump,
stop the pump. The pump is not a compressor, it will not build up
suggest you review again all points given under START UP;
much air pressure; it may be necessary to vent the discharge line
read through Troubleshooting in this manual and try again. If it
until liquid begins to flow.
still does not pump, contact your Viking representative.
RAPID WEAR
CAUSE EVIDENCE POSSIBLE SOLUTION
1. ABRASIVES Gouges or marks made by large, hard particles; Flush the system with the pump removed. Install strainer in suction
a rapid wearing away of bushings from very line. Oftentimes after a system has run for a few cycles or a few days,
small abrasives similar to pumice; or anything in the dirt is pretty well cleaned out and if the pump is rebuilt into good
between. condition, it will then last for a long time.
2. CORROSION Rust, pitting or metal appears to be “eaten” away. Check the Viking General Catalog Liquid List for materials of
construction recommendation. Consider weather all of the materials
used in pump construction were attacked; consider other materials
used in the system to determine how they resisted the liquid. Check
to see weather or not the liquid has been contaminated to make it
more corrosive than anticipated.
3. EXCEEDING Noisy operation, broken bushings, twisted shaft, Review General Catalog for operating limits on particular model
OPERATING parts show evidence of high heat (discoloration). involved.
LIMITS
4. INSUFFICIENT Pump may stall. Evidence of heavy contact between Increase end clearance and/or contact you distributor or the factory
EXTRA end of rotor teeth and head or other parts. with details of the application so that information regarding proper
CLEARANCE extra clearance may be provided.
5. LACK OF Noisy bearings, localized heating at bearings or lip Be sure all grease fittings are greased before starting and instructions
LUBRICATION seal, smoke, rapid bushing wear. for lubrication of drive equipment are followed; consider use of
auxiliary lubricating equipment.
6. MISALIGNMENT Wear on only one part of a surface, e.g., one side Double check alignment of drive equipment and piping. Check the
of the casing, one side of the packing gland, only a alignment under conditions as close to operating conditions as
portion of the face of the head. possible.
7. RUN DRY Pump stalls because parts have uneven expansion Be sure there is liquid in the system at the time of start up. Provide
caused by frictional heat; galling between surfaces some kind of automatic alarm or shut-off if supply tank runs dry.
having relative motion; seal seats and idler pins
changing color because of high heat.
TROUBLESHOOTING
A Viking pump that is properly installed and maintained will give long Vacuum Gauge - Suction Port
and satisfactory performance. 1. High reading would indicate -
NOTE: Before making any pump adjustment or opening the pump a) Suction line blocked - foot valve stuck, gate valve closed,
liquid chamber in any manner, make sure that: strainer plugged.
1. any pressure in the pumping chamber has been vented through b) Liquid too viscous to flow through the piping.
the suction or discharge lines or other openings provided for c) Lift too high.
this purpose, d) Line too small.
2. the driver has been “locked out” so that it cannot inadvertently 2. Low reading would indicate -
be started while work is being done on the pump and a) Air leak in suction line.
3. the pump has been allowed to cool down to the point where b) End of pipe not in liquid.
there is no chance of anyone being burned. c) Pump is worn.
If trouble does develop, one of the first steps toward finding the d) Pump is dry - should be primed.
difficulty is to install a vacuum gauge in the suction port and a 3. Fluttering, jumping, or erratic reading -
pressure gauge in the discharge port. Readings on these gauges a) Liquid vaporizing.
often will give a clue as to where to start looking for the trouble. b) Liquid coming to pump in slugs, possibly an air leak
insufficient liquid above the end of the suction pipe.
c) Vibrating from cavitation, misalignment, or damage parts.

Pressure Gauge - Discharge Port 8. Too much end clearance.
1. High reading would indicate - 9. Head position incorrect. See Fig. 3.
a) High viscosity and small and/or long discharge line. E) Pump takes too much power.
b) Gate valve partially closed. 1. Running too fast - Is correct motor speed, reducer ratio,
c) Filter plugged. sheave size, etc. being used?
d) Vertical head did not consider a high specific gravity liquid. 2. Is liquid more viscous than unit sized to handle; heat the
e) Line partially plugged from build up on inside of pipe. liquid, increase the pipe size, slow the pump down, or get a
f) Liquid in pipe not up to temperature. bigger motor.
g) Liquid in pipe has undergone a chemical reaction and has 3. Discharge pressure higher than calculated, check with
solidified. pressure gauge. Increase size or reduce length of pipe,
h) Relief Valve set too high. reduce speed (capacity), or get bigger motor.
2. Low reading would indicate - 4. Packing gland drawn down too tight.
5. Pump misaligned.
a) Relief valve set too low.
6. Extra clearance on pumping elements may not be sufficient
b) Relief valve poppet not seating properly.
for operating conditions. Check parts for evidence of drag or
c) Bypass around the pump partially open.
contact in pump and increase clearance where necessary.
d) Too much extra clearance.
e) Pump worn. F) Rapid Wear.
3. Fluttering, jumping, or erratic reading - On most applications the pump will operate for many months
or years before it gradually loses its ability to deliver capacity or
a) Cavitation.
pressure. Examination of such a pump would show a smooth
b) Liquid coming to pump in slugs.
wear pattern on all parts. Rapid wear, occurring in a few minutes,
c) Air leak in suction line.
hours or days, shows up as heavy grooving, galling, twisting,
d) Vibrating from misalignment or mechanical problems.
breaking or similar severe signs of trouble. SEE CHART, PAGE 7.
Some of the following may also help pinpoint the problem:
A) Pump does not pump.
1. Lost its prime - air leak, low level in tank, foot valve stuck.
2. Suction lift too high.
PREVENTATIVE MAINTENANCE
3. Rotating in wrong direction. Performing a few preventative maintenance procedures will extend
4. Motor does not come up to speed. the life of your pump and reduce the overall cost of ownership.
5. Suction and discharge valves not open. A) Lubrication - Grease all grease fittings after every 500 hours
6. Strainer clogged. of operation or after 60 days, whichever occurs first. If service
7. Bypass valve open, relief valve set too low, relief valve is severe, grease more often. Do it gently with a hand gun.
poppet stuck open. Use a NLGI #2 grease for normal applications. For hot or cold
8. Pump worn out. applications use appropriate grease. See Engineering Service
9. Any changes in the liquid system, or operation that Bulletin ESB-515.
would help explain the trouble, e.g. new source of
B). Packing Adjustment - Occasional packing adjustment may
supply, added more lines, inexperienced operators, etc.
be required to keep leakage to a slight weep; if impossible to
10. Too much end clearance.
reduce leakage by gentle tightening, replace packing or use
11. Head position incorrect. See Fig. 3.
different type. See Technical Service Manual on particular
B) Pump starts, then loses its prime. model series for details on repacking.
1. Supply tank empty. C). End Clearance Adjustment - After long service the running
2. Liquid vaporizing in the suction line. clearance between the end of the rotor teeth and the head
3. Air leaks or air pockets in the suction line; leaking air through may have increased through wear to the point where the pump
packing or mechanical seal. is losing capacity or pressure. Resetting end clearance will
4. Worn out. normally improve pump performance. See TSM on particular
C) Pump is noisy. model series for procedure on adjusting end clearance for
1. Pump is being starved (heavy liquid cannot get to pump fast pump involved.
enough). Increase suction pipe size or reduce length. D). Examine Internal Parts - Periodically remove the head,
2. Pump is cavitating (liquid vaporizing in the suction line). examine idler and bushing and head and pin for wear.
Increase suction pipe size or reduce length; if pump is Replacing a relatively inexpensive idler bushing and idler pin
above the liquid, raise the liquid level closer to the pump; if after only moderate wear will eliminate the need to replace
the liquid is above the pump, increase the head of liquid. more expensive parts at a later date. See TSM on particular
3. Check alignment. model series for procedure in removing head of the pump. Be
4. May have a bent shaft or rotor tooth. Straighten or replace. sure idler does not slide off idler pin as head is removed and
5. Relief valve chatter; increase pressure setting. drop and hurt someone or damage the part.
6. May have to anchor base or piping to eliminate or reduce E). Cleaning the Pump - A clean pump is easier to inspect,
vibration. lubricate, adjust, and runs cooler; plus, it looks better.
7. May be a foreign object trying to get into the pump through
F). Storage - If pump is to be stored, or not used for six months or
the suction port.
more, pump must be drained and a light coat of non-detergent
D). Pump not up to capacity. SAE 30 weight oil must be applied to all internal pump parts.
1. Starving or cavitating - increase suction pipe size or reduce Lubricate fittings and apply grease to pump shaft extension.
length. Viking suggests rotating pump shaft by hand one complete
2. Strainer partially clogged. revolution every 30 days to circulate the oil. Retighten all
3. Air leak in suction piping or along pump shaft. gasketed joints before using the pump.
4. Running too slowly; is motor the correct speed and is it
wired up correctly.
5. Bypass line around pump partially open.
6. Relief valve set too low or stuck open.
7. Pump worn out.

INSTALLATION, START UP, TROUBLESHOOTING, PAGE of 8

ISSUE G
PREVENTATIVE MAINTENANCE, DO’S & DON’TS
DO’S & DON’TS

Do’s and Don’ts for installation, operation, and maintenance of Viking
pumps to assure safe, long, trouble-free operation.
INSTALLATION -
WARRANTY
1. Do install pump as close to supply tank as possible.
Viking warrants all products manufactured by it to
2. Do leave working space around the pumping unit. be free from defects in workmanship or material for a
3. Do use large, short, and straight suction piping. period of one (1) year from date of startup, provided
4. Do install a strainer in the suction line. that in no event shall this warranty extend more than
5. Do double check alignment after the unit is mounted and piping eighteen (18) months from the date of shipment from
is hooked up. Viking. If, during said warranty period, any products
sold by Viking prove to be defective in workmanship
6. Do provide a pressure relief valve for the discharge side of the or material under normal use and service, and if such
pump. products are returned to Viking’s factory at Cedar Falls,
7. Do cut out the center of gaskets used as port covers on flanged Iowa, transportation charges prepaid, and if the products
port pumps. are found by Viking to be defective in workmanship
8. Do record pump model number and serial number and file for or material, they will be replaced or repaired free of
future reference. charge, FOB. Cedar Falls, Iowa.
Viking assumes no liability for consequential
OPERATION -
damages of any kind and the purchaser by acceptance
1. Don’t run pump at speeds faster than shown in the catalog for of delivery assumes all liability for the consequences of
your model. the use or misuse of Viking products by the purchaser,
2. Don’t require pump to develop pressures higher than those his employees or others. Viking will assume no field
shown in the catalog for your model. expense for service or parts unless authorized by it in
3. Don’t operate pumps at temperatures above or below limits advance.
shown in the catalog for your pump. Equipment and accessories purchased by Viking
4. Don’t operate pumps without all guards being in place. from outside sources which are incorporated into any
Viking product are warranted only to the extent of and
5. Don’t operate pump without a relief valve on the pump or in the
by the original manufacturer’s warranty or guarantee,
discharge piping; be sure valve is mounted and set correctly.
if any.
6. Don’t exceed catalog limits for temperature and pressures of
fluids in jacketed areas of pump. THIS IS VIKING’S SOLE WARRANTY AND IS IN
7. Don’t use the pump in a system, which includes a steam blow or LIEU OF ALL OTHER WARRANTIES, EXPRESSED
an air or vapor blow or purge without provision for over-speed OR IMPLIED, WHICH ARE HEREBY EXCLUDED,
shutdown in case the pump starts to act as a turbine and over- INCLUDING IN PARTICULAR ALL WARRANTIES
speeds the drive. OF MERCHANTABILITY OR FITNESS FOR A
8. Don’t operate the pump with all of the liquid bypassing through PARTICULAR PURPOSE. No officer or employee of
a pump mounted internal type relief valve or without any flow IDEX Corporation or Viking Pump, Inc. is authorized to
of liquid going through the pump for more than a couple of alter this warranty.
minutes. Operation under either of these conditions may result
in a heat build-up in the pump, which could cause hazardous
conditions or happenings.
MAINTENANCE - 5. Don’t stick fingers in the ports of a pump! Serious injury may
1. Do make sure any pump that has residual system pressure in result.
it or that has handled high vapor pressure liquids, e.g., LP-gas, 6. Don’t spin the idler on the idler pin! Fingers may be jammed
ammonia, Freons, etc. has been vented through the suction or between teeth and crescent.
discharge lines or other openings provided for this purpose.
7. Do remember that a few simple preventative maintenance
2. Do make sure that if the pump is still hooked to the driver procedures such as periodic lubrication, adjustment of end
while maintenance is being performed that the driver has been clearance, examination of internal parts, etc., will extend the
“locked out” so that it cannot be inadvertently started while work service life of your pump.
is being done on the pump.
8. Do obtain, read and keep maintenance instructions furnished
3. Do make sure any pump that has handled a corrosive, with your pump.
flammable, hot, or toxic liquid has been drained, flushed, vented
9. Do have spare parts, pumps or standby units available,
and/or cooled before it is disassembled.
particularly if the pump is an essential part of a key operation or
4. Don’t drop parts during disassembly, e.g., idler can slip from the process.
pin as the head is removed from the pump; it may drop on your
foot, plus, it may get nicked or gouged.
© 5/2007 Viking Pump Inc.
All rights reserved
Nr.: 024746/2011
WEG Indústrias S.A. Date: 21-FEB-2011
DATA SHEET
Three-phase Induction Motor - Squirrel Cage
Customer : WEG ELECTRIC CORPORATION - WEC

Product code :
Product line : NEMA PREMIUM - ODP
Frame : 445TS
Output : 300 HP (220 kW)
Frequency : 60 Hz
Poles : 2
Rated speed : 3565 rpm
Slip : 0.97 %
Rated voltage : 460V
Rated current : 322 A
L. R. Amperes : 2029 A
Il/In : 6.3 Code F
No load current : 81.0 A
Rated torque : 436 ft.lb
Locked rotor torque : 200 %
Breakdown torque : 260 %
Design : B
Insulation class : F
Temperature rise : 80 K
Locked rotor time : 16 s (hot)
Service factor : 1.15
Duty cycle : S1
Ambient temperature : -20°C to +40°C
Altitude : 1000 m.a.s.l
Enclosure : IP23 (ODP)
Mounting : B3R(D)
Rotation : Both
Aprox. weight* : 2007 lb
Moment of inertia : 33.5 sq.ft.lb
Sound Pressure Level : 85.0 dB(A)
Front Rear Load Power factor Efficiency (%)

Bearing 6314-C3 6314-C3 100% 0.90 95.4
Regreasing int. 14417 h 14417 h 75% 0.89 95.4
Grease amount 27 g 27 g 50% 0.84 94.5
Grease - MOBIL POLYREX EM
Notes: 30036OT3G445TS-RF
The figures given herewith are regarded as guaranteed values and applied to sinusoidal power supplied motors, within permissible
tolerances under NEMA MG 1-20. Noise level with tolerance of +3 dB(A).
Performed Checked Revision Approved

adunn AUTOMATICO Nr.: 0 Date: 21-FEB-2011
*Weight value can be changed without previous notification.

260.02/1199 E
INSTALLATION AND
MAINTENANCE MANUAL
FOR NEMA LOW VOLTAGE
ELECTRIC MOTORS
T he electric motor is the item of equipment
most widely used by man in his pursuit of
progress, as virtually all machines and many
renowned inventions depend upon it.
By virtue of the prominent role the electric motor
plays in the comfort and welfare of mankind, it
must be regarded and treated as a prime power
unit embodying features that merit special
attention, including its installation and
maintenance.
This means that the electric motor should receive
proper attention.
Its installation and routine maintenance require
specific care to ensure perfect operation and
longer life of the unit.
THE WEG ELECTRIC MOTOR INSTALLATION AND
MAINTENANCE MANUAL provides the necessary
information to properly install, maintain and
preserve the most important component of all
equipment:
THE ELECTRIC MOTOR!
WEG
INSTALLATION AND MAINTENANCE MANUAL
FOR NEMA LOW VOLTAGE ELECTRIC MOTORS
Contents
1 - Introduction ..............................................................03
2 - Basic Instructions ......................................................04

2.1 Safety Instructions .................................................04
2.2 Delivery ..............................................................04
2.3 Storage ..............................................................04
2.3.1 Drying the Windings ................................05
3 - Installation ..............................................................06
3.1 Mechanical Aspects ...........................................06
3.1.1 Foundation ..............................................06
3.1.2 Types of bases ........................................06
3.1.3 Alignment ...............................................07
3.1.4 Coupling .................................................08
3.1.5 Bearing Load (Stresses on the bearings) ..11
3.2 Electrical Aspects ...............................................15
3.2.1 Feed System ..........................................15
3.2.2 Starting of Electric Motors .......................15
3.2.3 Motor Protection .....................................17
3.3 Start-up ..............................................................18
3.3.1 Preliminary Inspection ............................18
3.3.2 The First Start-up ....................................20
3.3.3 Operation ...............................................20
3.3.4 Stopping .................................................20
4 - Maintenance ..............................................................24
4.1 Cleanliness ........................................................24
4.2 Lubrication .........................................................24
4.2.1 Periodical Lubrication .............................24
4.2.2 Quality and Quantity of Grease .................24
4.2.3 Lubricating Instructions ...........................24
4.2.4 Replacement of Bearings ........................25
4.3 Air Gap Checking ................................................25
4.4 Explosion Proof Motor Repair Steps .....................26
4.4.1 Objective ................................................26
4.4.2 Repair Procedure and Precautions ...........26
4.4.3 Miscellaneous Recommendations ...........26
5 - Malfunctioning ...........................................................27
5.1 Standard Three-phase Motor Failures ...................27
5.1.1 Short Circuits Between Turns ...................27
5.1.2 Winding Failures .....................................27
5.1.3 Rotor Failures .........................................28
5.1.4 Bearing Failures ......................................28
5.1.5 Shaft Fractures .......................................28
5.1.6 Unbalanced V-Belt Drives ........................28
5.1.7 Damage Arising from Poorly Fitted
Transmission Parts or
Improper Motor Alignment .......................28
5.2 Troubleshooting Chart .........................................29
6 - Spare Parts and Component Terminology.....................30
2
1. Introduction
T his manual covers all the three-phase and

single-phase asynchronous squirrel-cage
induction motors, from 140T to 580T frame sizes.
The motors mentioned in this manual are subject

to continuous improvement, therefore, information
is subject to change without notice.
For further details, please consult WEG.
3
2. Basic Instructions
change rusted bearings. The weight of the rotor in an inactive
motor tends to expel grease from between the bearing
surfaces thereby removing the protective film that impedes
2.1 Safety Instructions metal-to-metal contact.
All personnel involved with electrical installations, either As a preventive measure against the formation of corrosion
handling, lifting, operation and maintenance, should be well- by contact, motors should not be stored near machines which
informed and up-to-dated concerning the safety standard and cause vibrations, and every 3 month their shafts should be
principles that govern the work and carefully follow them. rotated manually.
Before work commences, it is the responsibility of the person
in charge to ascertain that these have been duly complied with Insulation resistance fluctuates widely with temperature and
and to alert his personnel of the inherent hazards of the job in humidity variations and the cleanliness of components. When a
hand. motor is not immediately put into service it should be protected
It is recommended that these tasks be undertaken only by against moist, high temperatures and impurities, thus avoiding
qualified personnel and they should be instructed to: damage to insulation resistance.
· avoid contact with energized circuits or rotating parts, If the motor has been in storage more than six month or has
· avoid by-passing or rendering inoperative any safeguards or been subjected to adverse moisture conditions, it is best to
protective devices, check the insulation resistance of the stator winding with a
· avoid extended exposure in close proximity to machinery megohmeter.
with high noise levels, If the resistance is lower than ten megohms the windings
· use proper care and procedures in handling, lifting, should be dried in one of the two following ways:
installing, operating and maintaining the equipment, and 1) Bake in oven at temperatures not exceeding 194 degree F
· follow consistently any instructions and product until insulation resistance becomes constant.
documentation supplied when they do such work. 2) With rotor locked, apply low voltage and gradually increase
Before initiating maintenance procedures, be sure that all current through windings until temperature measured with
power sources are disconnected from the motor and thermometer reaches 194 degree F. Do not exceed this
accessories to avoid electric shock. temperature.
Fire fighting equipment and notices concerning first aid should If the motor is stored for an extensive period, the rotor must be
not be lacking at the job site; these should be visible and periodically rotated.
accessible at all times. Should the ambient conditions be very humid, a periodical
inspection is recommended during storage. It is difficult to
2.2 Delivery prescribe rules for the true insulation resistance value of a
Prior to shipment, motors are factory-tested and balanced. machine as the resistance vary according to the type, size and
They are packed in boxes or bolted to a wooden base. rated voltage and the state of the insulation material used,
Upon receipt, we recommend careful handling and a physical method of construction and the machines insulation
examination for damage which may have occurred during antecedents. A lot of experience is necessary in order to decide
transportation. when a machine is ready or not to be put into service.
In the event of damage and in order to guaranty insurance Periodical records are useful in making this decision.
coverage, both the nearest WEG sales office and the carrier
should be notified without delay. The following guidelines show the approximate values that can
be expected of a clean and dry motor, at 40°C test voltage in
2.3 Storage applied during one minute.
Motors should be raised by their eyebolts and never by their
shafts. It is important that high rating three-phase motors be Insulation resistance Rm is obtained by the formula:
raised by their eyebolts. Raising and lowering must be steady
and joltless, otherwise bearings may be harmed. Rm = Vn + 1
When motors are not immediately installed, they should be
stored in their normal upright position in a dry even Where: Rm - minimum recommended insulation resistance
temperature place, free of dust, gases and corrosive in M W with winding at 40°C
atmosphere. Vn - rated machine voltage in kV
Other objects should not be placed on or against them.
Motors stored over long periods are subject to loss of In case that the test is carried out at a temperature other than
insulation resistance and oxidations of bearings. 40°C, the value must be corrected to 40°C using a
approximated curve of insulation resistance v.s temperature of
Bearings and the lubricant deserve special attention during the winding with the aid of Figure 2.1; its possible verify that
prolonged periods of storage. Depending on the length and resistance practically doubles every 10°C that insulating
conditions of storage it may be necessary to regrease or temperature is lowered.
4
Example:
Ambient temperature = 50°C

Motor winding resistence at 50°C = 1.02 M W
Correction to 40°C
R 40°C = R 50°C x K 50°C
R 40º C = 1.02 x 1.3
R 40º C = 1.326 M W
The minimum resistence Rm will be:

Rm = Vn + 1
Rm = 0.440 + 1
Rm = 1.440 M W
On new motors, lower values are often attained due to solvents

present in the insulating varnishes that later evaporate during
normal operation. This does not necessarily mean that the
motor is not operational, since insulating resistance will
increase after a period of service.
On motor which have been in service for a period of time much
larger values are often attained. A comparison of the values
recorded in previous tests on the same motor under similar
load, temperature and humidity conditions, serves as a better
indication of insulation condition than that of the value derived
from a single test. Any substantial or sudden reduction is
suspect and the cause determined and corrective action taken.
Insulation resistance is usually measured with a MEGGER.
In the event that insulation resistance be inferior to the values
derived from the above formula, motors should be subjected to
a drying process. Winding Temperature (ºC)
R40 ºC = Rt x Kt 40 ºC
2.3.1 Drying the Windings
This operation should be carried out with maximum care, and Figure 2.1.
by only qualified personnel. The rate of temperature rise should
not exceed 5°C per hour and the temperature of the winding
should not exceed 105°C. An overly high final temperature as
well as a fast temperature increase rate can both generate
vapour harmful to the insulation.
Temperature should be accurately controlled during the drying
process and the insulation resistance measured at regular
intervals.
During the early stages of the drying process, insulation
resistance will decrease as a result of the temperature
increase, but the resistance will increase again when the
insulation becomes dryer.
The drying process should be extended until sucessive
measurements of insulation resistance indicate that a constant
value above the minimum acceptable value has been attained.
It is extremely important that the interior of the motor be well
ventilated during the drying operation to ensure that the
dampness is really removed.
Heat for drying can be obtained from outside sources (an
oven), energization of the space heater (optional), or
introducing a current through the actual winding of the moto be
dried.
5
3. Installation
Where:
F1 and F2 - Lateral stress (Lb)

Electric machines should be installed in order to allow an easy g - Force of gravity (32.18 ft/s2)
access for inspection and maintenance. Should the G - Weight of motor (Lb)
surrounding atmosphere be humid, corrosive or contain Tmax - Maximum torque (Lb . Ft)
flammable substances or particles, it is essential to ensure an A - Obtained from the dimensional drawing of the
adequate degree of protection. motor (in)
The installation of motors in ambients where there are vapours, Sunken bolts or metallic base plates should be used to secure
gases or dusts, flammable or combustible materials, subject to the motor to the base.
fire or explosion, should be undertaken according to
appropriate and governing codes, such as NEC Art. 500 3.1.2 Types of Bases
(National Electrical Code) and UL-674 (Underwriters
Laboratories, Inc.) Standards. a) Slide Rails
Under no circumstances can motors be enclosed in boxes or When motor drive is by pulleys the motor should be mounted
covered with materials which may impede or reduce the free on slide rails and the lower part of the belt should be pulling.
circulation of ventilating air. Machines fitted with external The rail nearest the drive pulley is positioned in such a manner
ventilation should be at least 50cm from the wall to permit the that the adjusting bolt be between the motor and the driven
passage of air. machine. The other rail should be positioned with the bolt in the
The opening for the entry and exit of air flow should never be opposite position, as shown in Figure 3.2.
obstructed or reduced by conductors, pipes or other objects. The motor is bolted to the rails and set on the base. The drive
The place of installation should allow for air renewal at a rate of pulley is aligned such that its center is on a plane with the
700 cubic feet per minute for each 75 HP motor capacity. center of the driven pulley and the motor shaft and that of the
machine be parallel.
3.1 Mechanical Aspects
The belt should not be overly stretched, see Figure 3.11.
3.1.1 Foundation After the alignment, the rails are fixed.
The motor base must be levelled and as far as possible free of
vibrations. A concrete foundation is recommended for motors
over 100 HP. The choice of base will depend upon the nature of
the soil at the place of erection or of the floor capacity in the
case of buildings.
When dimensioning the motor base, keep in mind that the
motor may occasionally be run at a torque above that of the
rated full load torque.
Based upon Figure 3.1, foundation stresses can be calculated
by using the following formula:
F1 = 0.2247 (0.009 x g x G - 213 Tmax )

A
Figure 3.2 - Positioning of slide rails for motor alignment
F2 = 0.2247 (0.009 x g x G + 213 Tmax )
A
Figure 3.1 - Base stresses
6
b) Foundation Studs
Very often, particularly when drive is by flexible coupling the
motor is anchored directly to the base with foundation studs.
It is recommended that shim plates of approximately 0.8
inches be used between the foundation studs and the feet of the
motor for replacement purposes. These shim plates are useful
when exchanging one motor for another of larger shaft height
due to variations allowed by standard tolerances.
Foundation studs should neither be painted nor rusted as both
interfere with to the adherence of the concrete, and bring about
loosening.
After accurate alignment and levelling of the motor, the
foundation studs are cemented and their screws tightened to
secure the motor.
Figure 3.4 - Three-phase motor mounted on a metallic base
3.1.3 Alignment
The electric motor should be accurately aligned with the driven
machine, particularly in cases of direct coupling. An incorrect
alignment can cause bearing failure vibrations and even shaft
rupture.
The best way to ensure correct alignment is to use dial gauges
placed on each coupling half, one reading radially and the other
exially - Figure 3.5.
Figure 3.3 - Motor mounted on a concrete base with

foundations studs
c) Metallic Base
Motor-generator sets are assembled and tested at the factory
prior to delivery. However, before putting into service at site,
coupling alignment should be carefully checked as the metallic
base could have suffered dislocation during transit due to
internal stresses of the material.
The metallic base is susceptible to distortion if secured to a
foundation that is not truly flat.
Machines should not be removed from their common metallic Figure 3.5 - Alignment with dial gauges
base for alignment; the metallic base should be levelled on the
actual foundation with the aid of a spirit level (or similar
instrument). Thus, simultaneous readings are possible and allow for
When a metallic base is used to adjust the height of the motor checking for any parallel (Figure 3.6a) and concentricity
shaft end with the machine shaft end, the latter should be deviations (Figure 3.6b) by rotating the shafts one turn.
levelled on the concrete base. Gauge readings should not exceed 0.02 inches. If the installer
After the base has been levelled, foundation, studs tightened, is sufficiently skilled, he can obtain alignment with feeler
and the coupling checked, the metal base and the studs are gauges and a steel ruler, providing that the couplings are
cemented. perfect and centered - Figure 3.6c.
7
Figure 3.6a - Deviation Perfect gear engagement can be checked by the insertion of a
from parallel strip of paper on which the teeth marks will be traced after a
single rotation.
c) Belt and Pulley Coupling

Belt coupling is most commonly used when a speed ratio is
required.
Assembly of Pulleys: To assemble pulleys on shaft ends with a
keyway and threaded end holes the pulley should be inserted
halfway up the keyway merely by manual pressure.
On shafts without threaded end holes the heating of the pulley
Figure 3.6b - Deviation to about 80°C is recommended, or alternatively, the devices
from concentricity illustrated in Figure 3.8 may be employed.
Figure 3.6c - Alignment

with a steel ruler
Figure 3.8 - Pulley mounting device
3.1.4 Coupling
a) Direct Coupling
Direct coupling is always preferable due to its lower cost,
space economy, no belt slippage and lower accident risk. Figure 3.8a - Pulley extractor
In the case of speed ratio drives, it is also common to use a
direct coupling with a reducer (gear box). Hammers should be avoided during the fitting of pulleys and
bearings. The fitting of bearings with the aid of hammers
CAUTION: Carefully align the shaft ends using, whenever leaves blemishes on the bearing races. These initially small
feasible, a flexible coupling. flaws increase with usage and can develop to a stage that
completely impairs the bearing.
The correct positioning of a pulley is shown in Figure 3.9.
Figure 3.7 - A type of direct coupling
b) Gear Coupling
Poorly aligned gear couplings are the cause of jerking motions
which bring about the vibration of the actual drive and
vibrations within the motor.
Therefore, due care must be given to perfect shaft alignment:
exactly parallel in the case of straight gears, and at the correct
angle for bevel or helical gears. Figure 3.9 - Correct positioning of pulley on the shaft
8
RUNNING: To avoid needless radial stresses on the bearings it Belt tension should be sufficient to avoid slippage during
is imperative that shafts are parallel and the pulleys perfectly operation (Figure 3.11).
aligned. (Figure 3.10). Pulleys that are too small should be avoided; these cause shaft
flexion because belt traction increases in proportion to a
decrease in the pulley size. Table 1 determines minimum
pulley diameters, and Tables 2 and 3 refer to the maximum
stresses acceptable on motor bearings up to frame 580.
Beyond frame size 600, an analysis should be requested from
the WEG engineering.
Figure 3.10 - Correct pulley alignment
Laterally misaligned pulleys, when running, transmit

alternating knocks to the rotor and can damage the bearing
housing. Belt slippage can be avoided by applying a resin
(rosin for example). Figure 3.11 - Belt tensions
Table 1 - Minimum pitch diameter of pulleys
Ball bearings
Frame Size X Inches
Bearing
0.79 1.57 2.36 3.15 3.94 4.72
140 6205-Z 1.7 1.85 2
W 180 6206-Z 3.03 3.23 3.46
180 6307-Z 1.69 1.81 1.93
W 210 6308-Z 2.86 3.00 3.16
210 6308-Z 2.90 3.06 3.22
W 250 6309 C3 4.37 4.54 4.72 4.92
250 6309 C3 4.41 4.59 4.77 4.97
280 6311 C3 5.08 5.19 5.47 5.65
320 6312 C3 7.44 7.76 7.94 8.18
360 6314 C3 8.73 9.00 9.28 9.57
Ball Bearing Roller Bearing
Frame Poles Size X Inches Size X Inches
Bearing Bearing
1.97 3.15 4.33 5.51 1.97 3.15 4.33 5.51 6.69 8.27
II 6314 C3 7.3 7.62 7.94 8.24 - - - - - -
400
IV-VI-VII 6314 C3 NU 316 4.13 4.31 4.49 4.67 4.85 -
II 6314 C3 11.75 12.16 12.61 13.08 - - - - - -
440
IV-VI-VIII 6319 C3 NU 319 4.02 4.17 4.32 4.47 4.62 4.82
II 6314 C3 23.54 24.34 25.12 25.87 - - - - - -
500
IV-VI-VIII 6319 C3 NU 319 6.52 6.73 6.95 7.17 7.39 7.67
II 6314 C3 44.66 45.79 46.98 48.23 - - - - - -
5008
IV-VI-VIII 6322 C3 NU 322 8.73 8.95 9.96 11.34 12.87 14.82
II 6314 C3 57 58 59 60 - - - - - -
580
IV-VI-VIII 6322 C3 NU 322 10.72 10.91 11.11 11.31 11.50 11.76
Important: 1) Peripheral speeds for solid grey cast iron pulleys FC 200 is V = 115 ft/s
2) Use steel pulleys when peripheral speed is higher than 115 ft/s
3) V-belt speed should not exceed 115 ft/s.
9
Table 2 - Maximum acceptable radial load (Lbf)
Nema 56 Motors Saw Arbor Motors

Radial Force (Lbf) 80 LMS II - 355 -
Frame Distance X 80 MMS II - 359 -
Poles
1 1,18 2 80 SMS II - 357 -
II 88 - 59 II 427 -
56A 90 LMS
IV 88 - 59 IV - 555 -
II 88 - 59
56B
IV 86 - 59
II 127 - 70
56D
IV 141 - 70
Table 3 - Maximum acceptable axial load (Lbf)

IP55 Totally Enclosed Motors - 60Hz
Position / Construction Form
F
R
A
M
E
II IV VI VIII II IV VI VIII II IV VI VIII II IV VI VIII

140 103 141 167 187 112 152 185 207 99 132 158 178 105 143 174 198
W 180 108 145 180 202 154 209 255 286 94 130 165 183 141 194 240 269
180 149 207 249 286 269 370 443 500 136 189 229 266 253 352 421 480
W 210 196 264 326 368 329 447 544 610 176 238 297 339 310 421 518 582
210 189 257 315 357 324 443 533 599 160 220 275 310 295 405 493 553
W 250 282 372 443 485 471 620 734 811 240 317 394 414 430 564 685 743
250 273 368 436 485 463 615 727 813 220 310 379 421 410 557 672 749
280 355 480 551 624 621 826 959 1,082 275 388 427 502 540 736 838 961
320 374 498 588 668 703 930 1,091 1,232 266 366 432 511 597 793 937 1,078
360 890 1,181 1,144 1,323 890 1,181 1,375 1,552 745 985 1,144 1,323 745 985 1,144 1,323
400 877 1,148 1,347 1,521 877 1,148 1,347 1,521 705 890 1,060 1,241 705 890 1,060 1,241
440 842 1,303 1,563 1,821 842 1,303 1,563 1,821 568 884 1,109 1,488 568 884 1,109 1,488
500 769 1,250 1,481 1,728 769 1,250 1,481 1,728 355 721 844 1,190 355 721 844 1,109
5008 791 1624 1909 2137 791 1624 1909 2137 728 1548 1808 2029 728 1548 1808 2029
580 679 1,406 1,649 1,865 679 1,406 1,649 1,865 033 474 549 597 033 474 549 597
Open Motors - NEMA 56 Frames - 60Hz

Position / Construction Form
F
R
A
M
E
II IV II IV II IV II IV
56 A 68 90 83 112 63 85 79 108
56 B 66 90 81 110 63 83 77 105
56 D 63 88 105 145 59 81 101 138
10
The maximum radial load for each frame are determined, by

graphs.
INSTRUCTIONS ON HOW TO USE THE GRAPHS
1 - Maximum radial load on shaft.

2 - Maximum radial load on bearings.
Where: X - Half of pulley width (inches)

Fr - Maximum radial load in relation to the diameter
and pulley width.
Example:
Verify whether a 2HP motor, II Pole, 60Hz withstands a radial
load of 110Lb, considering a pulley width of 4 inches.
Frame : 145T
Fr : 110Lb
X : 2 inches
1 - Mark the distance X
2 - Find out line N = 3600 for bearing
Based on the above, this bearing withstands a radial load of

130Lb.
11
12
13
Note: For frames 600 and above, consult your engineering

representative.
14
3.2 Electrical Aspects b) Locate the rated voltage of the motor and the feed network
distance in the upper part of the corresponding table. The point
3.2.1 Feed System of intersection of the distance column and the line referring to
Proper electric power supply is very important. The choice of current will indicate the minimum required gauge of the
motor feed conductors, whether branch or distribution circuits, conductor.
should be based on the rated current of the motors as per
NFPA-70 Standard article 430. Example:
Tables 4, 5 and 6 show minimum conductor gauges sized Size the conductors for a 15 HP, three-phase, 230V, 42A, motor
according to maximum current capacity and maximum voltage located 200 feet from the main supply with cables laid in
drop in relation to the distance from the distribution center to conduits.
the motor, and to the type of installation (Overhead or in ducts). a) Current to be located: 1.25 x 42A = 52.5A
b) Closest value on table 6:55A
To determine the conductor gauge proceed as follows: c) Minimum gauge: 6 AWG
a) Determine the current by multiplying the current indicated on 3.2.2 Starting of Electric Motor
the motor nameplate by 1.25 and then locate the resulting value Induction motors can be started by the following methods:
on the corresponding table.
If the conductor feeds more than one motor, the value to be Direct Starting
sought on the table should be equal 1.25 times the rated current Whenever possible a three-phase motor with a squirrel cage
of the largest motor plus the rated current of the other motors. rotor should be started directly at full supply voltage by means
In the case of variable speed motors, the highest value among of a contactor (Connection diagram a). This method is called
the rated currents should be considered. Direct-on-Line (DoL) starting.
When motor operation is intermittent, the conductors should
have a current carrying capacity equal or greater, to the product
of the motor rated current times the running cycle factor shown
on Table 7.
Table 7 - Running cycle factor
Motor short
time 5min 15min 30 at Conti-
Duty rating 60min nuous
Classification
Short (operating valves, 1.10 1.20 1.50 -

activating contacts etc)
Intermittent (passenger or 0.85 0.85 0.90 1.40

freight elevators, tools,
pumps, rolling bridges etc)
Cyclic (rolling mills, 0.85 0.90 0.95 1.40

mining machines etc)
Variable 1.10 1.20 1.50 2.00
15
Table 4 - Wire and cable gauges for single-phase motor installation (voltage drop < 5%) (in conduits)
Supply Voltage Distance of motor from distribution centre (feet)
115 34 51 69 85 102 137 171 205 240 273 308 342 428 514
230 69 102 138 170 204 274 342 410 480 546 616 684 856 1028
460 138 204 276 340 408 548 684 820 960 1092 1232 1368 1712 2056
575 170 250 338 420 501 670 840 1010 1181 1342 1515 1680 2105 2530
Current (A) Cable gauge (conductor)
5 14 14 14 14 14 14 14 12 12 12 12 10 10 8
10 14 14 14 14 12 12 10 10 10 8 8 8 6 6
15 12 12 12 12 12 10 8 8 6 6 6 6 4 2
20 12 12 12 10 10 8 8 6 6 6 4 4 4 2
30 10 10 10 8 8 6 6 6 4 4 2 2 2 1/0
40 8 8 8 8 6 6 4 4 2 2 2 2 1/0 2/0
55 6 6 6 6 6 4 4 2 2 1/0 1/0 1/0 1/0 2/0
70 4 4 4 4 4 2 2 2 1/0 1/0 2/0 2/0 2/0 2/0
95 2 2 2 2 2 2 1/0 1/0 1/0 2/0 3/0 3/0 4/0 250M
Table 5 - Wire and cable gauges for three-phase motor installation - aerial conductors with 25cm spacing (voltage drop < 5%)
115 51 69 85 102 137 171 205 240 273 308 342 428 514 685
230 102 138 170 204 274 342 410 480 546 616 684 856 1028 1370
460 204 276 340 408 547 684 820 960 1092 1232 1368 1712 2056 2740
575 250 338 420 501 670 840 1010 1181 1342 1515 1680 2105 2530 3350
15 14 14 14 12 12 10 10 10 8 8 8 6 6 4
20 14 14 12 12 10 10 8 8 8 6 6 4 4 2
30 14 12 10 8 8 8 6 6 4 4 4 2 2 1/0
40 12 10 10 8 8 6 4 4 4 2 2 2 1/0 2/0
55 10 10 8 8 6 4 4 2 2 2 1/0 2/0 3/0 --
70 8 8 6 6 4 2 2 2 1/0 1/0 2/0 3/0 -- --
100 6 6 4 4 2 2 1/0 2/0 3/0 4/0 4/0 -- -- --
130 4 4 4 2 1/0 1/0 2/0 4/0 -- -- -- -- -- --
175 2 2 2 1/0 2/0 3/0 -- -- -- -- -- -- -- --
225 1/0 1/0 1/0 2/0 3/0 -- -- -- -- -- -- -- -- --
275 2/0 2/0 2/0 4/0 -- -- -- -- -- -- -- -- -- --
320 3/0 3/0 3/0 4/0 -- -- -- -- -- -- -- -- -- --
Table 6 - Wire and cable gauges for three-phase motor installation (voltage drop < 5%) (in conduits)
115 85 102 120 137 171 205 240 273 308 342 428 514
230 170 204 240 274 342 410 480 546 616 684 856 1028
460 340 408 480 548 684 820 960 1092 1232 1368 1712 2056
575 420 501 590 670 840 1010 1181 1342 1515 1680 2105 2530
15 12 12 12 10 10 8 8 8 6 6 6 4
20 12 10 10 10 8 8 6 6 6 6 4 4
30 10 8 8 8 6 6 6 4 4 4 2 2
40 8 8 6 6 6 4 4 4 2 2 2 1/0
55 6 6 6 4 4 4 2 2 2 1/0 1/0 1/0
70 4 4 4 4 2 2 2 1/0 1/0 1/0 2/0 2/0
95 2 2 2 2 2 1/0 1/0 1/0 1/0 2/0 3/0 4/0
125 1/0 1/0 1/0 1/0 1/0 1/0 2/0 2/0 3/0 3/0 4/0 250M
145 2/0 2/0 2/0 2/0 2/0 2/0 2/0 3/0 3/0 4/0 250M 300M
165 3/0 3/0 3/0 3/0 3/0 3/0 3/0 3/0 4/0 4/0 250M 350M
195 4/0 4/0 4/0 4/0 4/0 4/0 4/0 4/0 250M 250M 300M 350M
215 250M 250M 250M 250M 250M 250M 250M 250M 250M 300M 350M 400M
240 300M 300M 300M 300M 300M 300M 300M 300M 300M 300M 400M 500M
265 350M 350M 350M 350M 350M 350M 350M 350M 350M 350M 500M 500M
280 400M 400M 400M 400M 400M 400M 400M 400M 400M 400M 400M --
320 500M 500M 500M 500M 500M 500M 500M 500M 500M 500M 500M --
Note: The above indicated values are orientative. For guaranteed values, contact the Local Power Company.
16
There are DOL starter assemblies available combining a three- Three-Phase slip ring motors with
pole contactor, a bimetal relay (overload protection device), rheostat starting
and a fuse (short circuit protection on branch circuit). On starting slip ring motors an external rheostat is connected
DOL starting is the simplest method, only feasible however, to the rotor circuit by means of a set of brushes and sliding
when the locked rotor current (LRC) does not influence the rings (connection diagram d). The extra rotor resistance is held
main electric supply lines. in the circuit during the starting cycle to reduce the starting
Initial locked rotor current (LRC) in induction motors reach current and increase torque. Furthermore, it is possible to
values six to eight times the value of the full load current. regulate external resistance so as to have a starting torque
During starting by the DOL method, starting current can reach equal to, or close to the maximum motor torque value.
these high levels. The main electrical supply should be rated
sufficiently, such that during the starting cycle no supply 3.2.3 Motor Protection
disturbance to others on the power network is caused by the Motor circuits have, in principle, two types of protection: motor
voltage drop in the main supply. overload, locked rotor and protection of branch circuit from
This can be achieved under one of the following situations: short circuits. Motors in continuous use should be protected
a) The rated main supply current is high enough for the locked from overloading by means of a device incorporated into the
rotor current not to be proportionally high; motor, or by an independent device, usually a fixed or
b) Motor locked rotor current is low with no effect on the adjustable thermal relay equal or less than to the value derived
networks. from multiplying the rated feed current at full load by:
c) The motor is started under no-load conditions with a short
starting cycle and, consequently, a low locked rotor current - 1.25 for motors with a service factor equal or superior to 1.15;
with a transient voltage drop tolerable to other consumers. or
Starting with a compensating switch - 1.15 for motors with service factor equal to 1.0.
(auto-transformer starting)
Some motors are optionally fitted with overheating protective
Should direct on line starting not be possible, either due to
detectors (in the event of overload, locked rotor, low voltage,
restrictions imposed by the power supply authority or due to
inadequate motor ventilation) such as a thermostat (thermal
the installation itself, reduced voltage indirect starting methods
probe), thermistor (PTC), RTD type resistance which dispense
can be employed to lower the locked rotor current. The single
with independent devices.
line connection diagram (C) shows the basic components of a
compensating switch featuring a transformer (usually an auto-
THERMOSTAT (THERMAL PROBE): bimetallic thermal
transformer) with a series of taps corresponding to the different
detectors with normally closed silver contacts. These open at
values of the reduced voltage. Only three terminals of the
pre-determined temperatures. Thermostats are series
motor are connected to the switch, the other being
connected directly to the contactor coil circuit by two
interconnected as per diagram, for the indicated voltage.
conductors.
Star-Delta starting
THERMISTORS: Semi-conductor heat detectors positive
It is fundamental to star-delta starting that the three-phase
temperature coeficient (PTC) that sharply change their
motor has the necessary numbers of leads for both
resistance upon reaching a set temperature. Thermistors,
connections:
depending upon the type, are series or parallel-connected to a
6 leads for Y/D control unit that cuts out the motor feed, or actuates an alarm
or 12 leads for YY/DD system, in response to the thermistors reaction.
All the connections for the various voltages are made through
terminals in the terminal box in accordance with the wiring
Resistance temperature detectors
diagram that accompanies the motor. This diagram may be (RTD) - PT 100
shown on the nameplate or in the terminal box. The resistance type heat detector (RTD) is a resistance
The star-delta connection is usually used only in low-voltage element usually manufactured of copper or platinum.
motors due to normally available control and protection The RTD operates on the principle that the electrical resistance
devices in this method of starting the locked rotor current is of a metallic conductor varies linearly with the temperature.
approximately 30% of the original LRC, as well as the locked The detector terminals are connected to a control panel,
rotor torque is reduced proporcionally. For this reason, is very usually fitted with a temperature gauge, a test resistance and a
important before the decision to use star-delta starting, to terminal changeover switch.
verify if the reduced locked rotor torque in STAR connection Subject to the desired degree of safety and the clients
is enought to accelerate the load. specification, three (one per phase) or six (two per phase)
protective devices can be fitted to a motor for the alarm
systems, circuit breaker or combined alarm and circuit
breaker, with two leads from the terminal box to the alarm or
17
circuit breaker system and four for the combined system Table 9 - Comparision between motor protection system
(alarm and circuit breaker).
Table 9 compares the two methods of protection.
Current-based Protection
3.3 Start-up protection with
Causes of probe
3.3.1 Preliminary Inspection overheating Fuse and thermistor
Before starting a motor for the first time, it will be necessary to: Fuse only thermal in motor
protector
a) Remove all locking devices and blocks used in transit and
check that the motor rotates freely;
b) Check that the motor is firmly secured and that coupling

elements are correctly mounted and aligned.;
c) Ascertain that voltage and frequency correspond to those

indicated on the nameplate. Motor performance will be
satisfactory with mains supply voltage fluctuation within ten 1. Overload with 1.2
per cent of the value indicated on the nameplate or a times rated current
frequency fluctuation within five per cent or, yet, with a
combined voltage and frequency variance within ten per 2. Duty cycles
cent; S1 to S8
IEC 34, EB 120
d) Check that connections are in accordance with the
connection diagram shown on the nameplate and be sure 3. Brakings, reversals
that all terminal screws and nuts are tight; and frequent starts
e) Check the motor for proper grounding. Providing that there 4. Operating with more
are no specifications calling for ground-insulated than 15 starts p/hour
installation, the motor must be grounded in accordance with
prevalent standard for grounding electrical machines. The 5. Locked rotor
screw identified by the symbol should be used for this
purpose. 6. Fault on one phase
This screw is generally to be found in the terminal box or on
one foot of the frame; 7. Execessive voltage
fluctuation
f) Check that motor leads connecting with the mains, as well
as the control wires and the overload protection device, are 8. Frequency
in accordance with Nema Standards; fluctuation on main
supply
g) If the motor has been stored in a damp place, or has been
stopped for some time, measure the insulating resistance 9. Excessive ambient
as recommended under the item covering storage temperature
instructions;
10. External heating
h) Start the motor uncoupled to ascertain that it is turning in caused by bearings,
the desired direction. To reverse the rotation of a three- belts, pulleys etc.
phase motor, invert two terminal leads of the mains supply.
High voltage motors bearing an arrow on the frame 11. Obstructed
indicating rotation direction can only turn in the direction ventilation
shown;
I) Prior to slip ring motors entering into service the brush Caption: unprotected
holder assembly screws require tightening.
partially protected
The gap between brush holders and slip ring surfaces
totally protected
should be between 0.8 inches and 1.6 inches.
18
CONNECTION DIAGRAMS
a) Direct starting b) Star-Delta starting

POWER NETWORK POWER NETWORK
c) Auto-transformer starting d) Multi-stage automatic starting of

POWER NETWORK
slip ring motors
POWER NETWORK
19
Brush pressure on the slip ring should be in accordance 3.3.3 Operation

with Table 10.
For radial type, brushes, incidence to the contact surface Drive the motor coupled to the load for a period of at least one
should be perpendicular; hour while watching for abnormal noises or signs of
overheating.
j) Bronze slip rings are often supplied with a protective Compare the line current with the value shown on the
coating of varnish. Prior to entering into service this coating nameplate.
should be removed. It is advisable to make sure that all Under continuous running conditions without load fluctuations
surfaces are smooth and clean. this should not exceed the rated current times the service
factor, also shown on the nameplate.
Table 10 - Brush characteristics All measuring and control instruments and apparatus should be
continuously checked for anomalies, and any irregularities
Brush type Brush characteristics Pressure Lb/Inc2 corrected.
High conductivity,
EGO applicable to low voltage 2.6 3.3.4 Stopping
and high current
machines Warning:
CM 1S Copper and 2.0
graphite alloy To touch any moving part of a running motor, even though
CM 3H Bronze graphite 3.0
disconnected, is a danger to life and limb.
alloy
a) Three-phase motor with cage rotor:
Open the stator circuit switch. With the motor at a complete
3.3.2 The First Start-up stop, reset the auto-transformer, if any, to the start
position;
Three-Phase Motor with Cage Rotor
b) Three-phase slip ring motor:
Open the stator circuit switch. When the motor is at a
After careful examination of the motor, follow the normal
complete stop reset the rheostat to the start position.
sequence of starting operations listed in the control
instructions for the initial start-up.
Three-Phase Slip Ring Motor
Before running the motor verify that the starter rheostat is in the
start position, and that the brushes are correctly set against
the slip rings.
If the rheostat tap positions are numbered, the lowest usually
corresponds to the start position, and the highest to the
normal running position.
Next, close the stator circuit switch. The ammeter needle
should deflect sharply and then returning to a fixed lower value
after motor start.
When the needle is almost stationary, the rheostat should be
quickly moved to the next tapping position.
Coincident with speed increases, the rheostat should be moved
to each successive position until normal running position is
reached, stopping at each tapping stage until the current
indication shows no visible current drop.
On motors with brushes in permanent contact, the starter
rheostat remains in the run position while the motor is
running.
Special speed control rheostats designed for permanent
connection to resistance contacts within a given range of
settings are an exception to the above.
20
Table 11 - Bearing specifications by type of motor
NEMA Bearings ODP Motors Bearings

Mounting Nema-T Mounting
Frames Front (D.E.) Rear (O.D.E.) frames Front (D.E.) Rear (O.D.E.)
Open drip proof motors E143/5T 6205 ZZ 6204 ZZ
B48 and C48 6203 Z 6202 Z F143/5T 6205 ZZ 6204 ZZ
ALL FORMS
56 and A56 6203 Z 6202 Z 182 T 6206 ZZ 6205 ZZ
B56 and C56 6203 Z 6202 Z 184 T 6202 ZZ 6205 ZZ
D56 and 6204 Z 6202 Z / 213/5T 6208 ZZ 6206 ZZ
F56H/G56H 6203 Z 254 T 6309 Z-C3 6209 Z-C3
Totally enclosed fan cooled motors 256 T 6309 Z-C3 6209 Z-C3
143 T 6205 ZZ 6204 ZZ 284 T 6311 Z-C3 6211 Z-C3
145 T 6205 ZZ 6204 ZZ 284 TS 6311 Z-C3 6211 Z-C3
HORIZONTAL MOUNTING ONLY

182 T 6307 ZZ 6206 ZZ 286 T 6311 Z-C3 6211 Z-C3
184 T 6307 ZZ 6206 ZZ 286 TS 6311 Z-C3 6211 Z-C3
W 182 T 6206 ZZ 6205 ZZ 324 T 6312 Z-C3 6212 Z-C3
W 184 T 6206 ZZ 6205 ZZ 324 TS 6312 Z-C3 6212 Z-C3
213 T 6308 ZZ 6207 ZZ 326 T 6312 Z-C3 6212 Z-C3
215 T 6308 ZZ 6207 ZZ 326 TS 6312 Z-C3 6212 Z-C3
W 213 T 6308 ZZ 6207 ZZ 364 T 6314 C3 6314 C3
W 215 T 6308 ZZ 6207 ZZ
364 TS 6314 C3 6314 C3
254 T 6309-C3 6209 Z-C3
365 T 6314 C3 6314 C3
256 T 6309-C3 6209 Z-C3
365 TS 6314 C3 6314 C3
W 254 T 6309-C3 6209 Z-C3
W 256 T 6309-C3 6209 Z-C3 404 T NU 316 C3 6314 C3
284 T and TS 6311-C3 6211 Z-C3 404 TS 6314 C3 6314 C3
286 T and TS 6311-C3 6211 Z-C3 405 T NU 316 C3 6314 C3
324 T and TS 6312-C3 6212 Z-C3 405 TS 6314 C3 6314 C3
326 T and TS 6312-C3 6212 Z-C3 444 T NU 319 C3 6316 C3
364 T and TS 6314-C3 6314-C3 444 TS 6314 C3 6314 C3
365 T and TS 6314-C3 6314-C3 445 T NU 319 C3 6316 C3
ALL FORMS
404 T NU 316-C3 6314-C3 445 TS 6314 C3 6314 C3

404 TS 6314-C3 6314-C3
405 T NU 316-C3 6314-C3
405 TS 6314-C3 6414-C3 IEC Bearings
444 T NU 319-C3 6316-C3 Mounting
444 TS 6314-C3 6314-C3 frame Front (D.E.) Rear (O.D.E.)
445 T NU 319-C3 6316-C3 Totally enclosed fan cooled motors
445 TS 6314-C3 6314-C3
63 6201 ZZ 6201 ZZ
447 T NU 319-C3 6316-C3
447 TS 6314-C3 6314-C3 71 6203 ZZ 6202 ZZ
449 T NU 322-C3 6319-C3 80 6204 ZZ 6203 ZZ
449 TS 6314-C3 6314-C3 90 S - L 6205 ZZ 6204 ZZ
504 T NU 319-C3 6316-C3 100 L 6206 ZZ 6205 ZZ
504 TS 6314-C3 6314-C3 112 M 6307 ZZ 6206 ZZ
505 T NU 319-C3 6316-C3 132 S - M 6308 ZZ 6207 ZZ
505 TS 6314-C3 6314-C3 160 M - L 6309-C3 6209 Z-C3
5008 T NU 322-C3 6319-C3 180 M - L B3 6311-C3 6211 Z-C3
5008TS 6314-C3 6314-C3 200 M - L 6312-C3 6212 Z-C3
586 T NU 322-C3 6319-C3 225 S/M 6314-C3 6314-C3
586 TS 6314-C3 6314-C3 250 S/M 6314-C3 6314-C3
587 T NU 322-C3 6319-C3 280 S/M 6314-C3 6314-C3
587 TS 6314-C3 6314-C3 6316-C3 6316-C3
Saw Arbor Bearings 315 S/M 6314-C3 6314-C3
motor Mounting 6319-C3 6316-C3
frame Front (D.E.) Rear (O.D.E.) 355 M/L 6314-C3 6314-C3
NU 322-C3 6319-C3
80 S MS 6307 ZZ 6207 ZZ
80 M MS 6307 ZZ 6207 ZZ
B3
80 L MS 6307 ZZ 6207 ZZ
90 L MS 6308 ZZ 6208 ZZ
21
Table 12 - Bearing lubrication intervals and amount of grease
1 - SINGLE-ROW FIXED BALL BEARINGS

Lubrication intervals (running hours)
Bearings II Pole IV Pole VI Pole VIII Pole X Pole XII Pole
60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz Amount
Characteristics 3600 3000 1800 1500 1200 1000 900 750 720 600 600 500 of grease
Ref. rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm (oz)
6200 12500 13800 0,07
6201 11700 13000 16600 18400 0,07
6202 10500 11900 15400 17100 19500 0,07
6203 9800 11200 14500 16200 18500 0,11
6 6204 8700 10100 13300 14800 17100 19100 > 20000 0,14
2 6205 8000 9400 12600 14100 16200 18200 19300 0,14
6206 7300 8700 12000 13400 15400 17200 18300 0,18
S 6207 6600 8100 11400 12700 14500 16300 17300 19200 0,25
E 6208 5900 7400 10800 12000 13700 15300 16300 18200 0,29
R 6209 5300 6900 10400 11600 13400 15000 16000 17800 0,29
I 6210 4900 6400 9700 11000 12900 14600 15600 17300 0,32
E 6211 4300 5900 9500 10900 12700 14400 15300 17000 0,39
S 6212 3800 5400 9300 10300 12400 14300 15200 16500 0,46
6213 3100 4900 8900 10100 12200 14000 14800 16100 0,50
6214 1100 2000 4100 5000 5900 6500 6900 7600 0,54
6215 1000 1800 4400 5000 5600 6300 6700 7600 0,61
6216 700 1600 4100 4700 5700 6500 6800 7500 0,68
6304 8700 10100 13300 14800 17100 19100 0,14

6305 8000 9400 12600 14100 16200 18200 19300 0,21
6306 7300 8700 12000 13400 15400 17200 18300 > 20000 0,25
6307 6600 8100 11400 12700 14500 16300 17300 19200 0,32
6308 5900 7400 10800 12000 13700 15300 16300 18200 18600 0,39
6 6309 5300 6900 10400 11600 13400 15000 16000 17800 18200 19900 0,46
3 6310 4900 6400 9700 11000 12900 14600 19500 17300 17700 19500 19500 0,54
6311 4300 5900 9500 10900 12700 14400 15300 17000 17400 19000 19000 0,64
S 6312 3800 5400 9300 10300 12400 14300 15200 16500 16800 18200 18200 0,75
E 6313 3100 4900 8900 10100 12200 14000 14800 16100 16400 17900 17900 19700 0,86
R 6314 1100 2000 4100 5000 5900 6500 6900 7600 7700 8600 8600 9600 0,96
I 6315 1000 1800 4400 5000 5600 6300 6700 7600 7900 8900 8900 9900 1,07
E 6316 700 1600 4100 4700 5700 6500 6800 7500 7700 8500 8500 9500 1,22
S 6317 800 1300 3900 4700 5600 6300 6700 7400 7500 8300 8300 9300 1,32
6318 - 1000 3800 4600 5500 6200 6600 7200 7400 8200 8200 9100 1,47
6319 - 800 3700 4500 5400 6100 6500 7100 7300 8000 8000 8900 1,61
6320 - - 3600 4300 5300 6000 6300 7000 7100 7900 7900 8800 1,82
6321 - - 3400 4200 5100 5800 6200 6800 7000 7800 7800 8700 2,00
6322 - - 3100 4000 5000 5700 6100 6700 6900 7700 7700 8600 2,14
1) Lubrication periodicity valid for NLG 1 and lithium based bearing lubricant.
2) Bearings for motors of X and XII poles - Lubrication Intervals > 20,000.
22
Table 13 - Bearing lubrication intervals and amount of grease
2 - CYLINDRICAL ROLLER BEARINGS

Lubrication intervals (running hours)
Bearings II Pole IV Pole VI Pole VIII Pole X Pole XII Pole
60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz Amount
Characteristics 3600 3000 1800 1500 1200 1000 900 750 720 600 600 500 of grease
Ref. rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm (oz)
NU309 2800 4000 8300 9500 10700 11800 12500 14100 14500 16300 16300 18200 0,46
N NU310 2400 3600 7900 9100 10300 11400 12200 13700 14000 15800 15800 17700 0,54
U NU311 2000 3200 7400 8700 10000 11000 11800 13300 13600 15400 15400 17200 0,64
NU312 1600 2700 6900 8300 9600 10700 11400 12800 13200 14900 14900 16800 0,75
3 NU313 1500 2500 6600 8100 9400 10500 11200 12700 13000 14700 14700 16500 0,86
NU314 700 1100 3100 3900 4600 5200 5500 6200 6400 7200 7200 8100 0,96
NU315 - 900 2900 3800 4500 5100 5500 6200 6300 7100 7100 7900 1,07
S NU316 - 800 2800 3600 4400 5000 5400 6100 6200 7000 7000 7800 1,22
E NU317 - 600 2600 3500 4300 4900 5300 6000 6100 6900 6900 7700 1,32
R NU318 - - 2100 3300 4300 4900 5300 5900 6000 6700 6700 7500 1,47
I NU319 - - 2300 3200 4100 4700 5100 5800 6000 6700 6700 7500 1,61
E NU320 - - 2000 3000 4000 4700 5000 5700 5900 6600 6600 7300 1,82
S NU321 - - 1900 2800 4000 4600 4900 5600 5700 6500 6500 7200 2,00
NU322 - - 1900 2600 3900 4400 4800 5500 5600 6400 6400 7100 2,14
1) Lubrication periodicity valid for NLG 1 and 2 lithium based bearing lubricant.
23
4. Maintenance
the type of bearing used in frames 140T to 580T are to be found
in Tables 11, 12 and 13.
Lubrication intervals depend upon the size of the motor, speed,
A well-designed maintenance program for electric motors can working conditions and the type of grease used.
be summed up as: periodical inspection of insulation levels,
temperature rise, wear, bearing lubrication and the occasional 4.2.2 . Quality and Quantity of Grease
checking of fan air flow. Correct lubrication is important!
Inspection cycles depend upon the type of motor and the Grease must be applied correctly and in sufficient quantity as
conditions under which it operates. both insufficient or excessive greasing are harmful.
Excessive greasing causes overheating brought about by the
4.1 Cleanliness greater resistance encountered by the rotating parts and, in
Motors should be kept clean, free of dust, debris and oil. Soft particular, by the compacting of the lubricant and its eventual
brushes or clean cotton rags should be used for cleaning. A jet loss of lubricating qualities.
of compressed air should be used to remove non-abrasive dust This can cause seepage with the grease penetrating the motor
from the fan cover and any accumulated grime from the fan and dripping on the coils.
and cooling fins. A lithium based grease is commonly used for the lubrication of
Oil or damp impregnated impurities can be removed with rags electric motor bearings as it has good mechanical stability,
soaked in a suitable solvent. insoluble in water and has a drip point of approximately 200°C.
Terminal boxes fitted to motors with IP55 protection should be This grease should never be mixed with sodium or calcium
cleaned; their terminals should be free of oxidation, in perfect based greases.
mechanical condition, and all unused space dust-free.
Motors with IPW 55 protection are recommended for use under GREASES FOR MOTOR BEARINGS
unfavourable ambient conditions.
For operating temperatures from - 20 to 130°C
4.2 . Lubrication Supplier Grease F Supplier Grease
Proper lubrication extends bearing life.
Esso Beacon 2 Atlantic Litholine 2
Shell Alvania R3 Texaco Multifak 2
Lubrication Maintenance Includes:
a) Attention to the overall state of the bearings; For use in freezing chambers
b) Cleaning and lubrication; Supplier Grease Temperature range
c) Critical inspection of the bearings.
Esso Unirex N2 -30 to 165 ºC
Motor noise should be measured at regular intervals of one to Molikote BG 20 -45 to 180 ºC
four months. A well-tuned ear is perfectly capable of Unisilkon L5012 -20 to 200 ºC
distinguishing unusual noises, even with rudimentary tools
such as a screw driver, etc., without recourse to sophisticated
listening aids or stethescopes that are available on the market. 4.2.3 Lubricating Instructions
A uniform hum is a sign that a bearing is running perfectly.
Bearing temperature control is also part of routine a) Frame 140T to 210T motors
maintenance. The temperature of bearings lubricated as Frame 140T to 210T size motors are not fitted with grease
recommended under item 4.2.2 should not exceed 70°C. nipples.
Constant temperature control is possible with the aid of Lubrication is carried out during periodical overhauls when the
external thermometers or by embedded thermal elements. motor is taken apart.
WEG motors are normally equipped with grease lubricated ball
or roller bearings. Cleaning and Lubrication of Bearings
Bearings should be lubricated to avoid the metallic contact of
the moving parts, and also for protection against corrosion and With the motor dismantled and without extracting the bearings
wear. Lubricant properties deteriorate in the course of time and from the shaft, all existing grease should be removed and the
mechanical operation and, furthermore, all lubricants are bearings cleaned with Diesel oil, kerosene or other solvent,
subject to contamination under working conditions. until thoroughly clean.
For this reason lubricants must be renewed and any lubricant Refill the spaces between the balls or rollers and the bearing
consumed needs replacing from time to time. cages with grease immediately after washing. Never rotate
bearings in their dry state after washing.
4.2.1 Periodical Lubrication For inspection purposes apply a few drops of machine oil.
WEG motors are supplied with sufficient grease for a long During these operations maximum care and cleanliness is
running period. Lubrication intervals, the amount of grease and recommended to avoid the penetration of any impurities or dust
24
that could harm the bearings. Clean all external parts prior to cotton fabric.
reassembly. 2. With the motor running, add grease with a manual grease
gun until the lubricant commences to be expelled from the
b) Frame 360T to 580T Motors bleeder outlet, or until the quantity of grease recommended
Motors above: 360T frame size are fitted with regreasable in Tables 12 or 13 has been applied.
bearing system. 3. Allow the motor to run long enough to eject all excess of
The lubrication system from this frame size upwards was grease.
designed to allow the removal of all grease from the bearing
races through a bleeder outlet which at the same time impedes 4.2.4 Replacement of Bearings
the entry of dust or other contaminants harmful to the bearing. The opening of a motor to replace a bearing should only be
This outlet also avoids injury to the bearings from the well- carried out by qualified personnel.
known problem of over-greasing. Damage to the core after the removal of the bearing cover is
It is advisable to lubricate while the motor is running, to allow avoided by filling the gap between the rotor and the stator with
the renewal of grease in the bearing case. stiff paper of a proper thickness.
Should this procedure not be possible because of rotating parts Providing suitable tooling is employed, disassembly of a
in the proximity of the nipple (pulleys, coupling sleeves, etc.) bearing is not difficult.
that are hazardous to the maintainer the following procedure The extractor grips should be applied to the sidewall of the
should be followed: inner ring to be stripped, or to an adjacent part.
- Inject about half the estimated amount of grease and run the To ensure perfect functioning and no injury to the bearing parts,
motor at full speed for approximately a minute; switch off the it is essential that the assembly be undertaken under
motor and inject the remaining grease. conditions of complete cleanliness and by competent
The injection of all the grease with the motor at rest could personnel.
cause penetration of a portion of the lubricant through the New bearings should not be removed from their packages until
internal seal of the bearing case and hence into the motor. the moment of assembly.
Prior to fitting a new bearing, ascertain that the shaft has no
rough edges or signs of hammering.
Figure 4.2 - A bearing extractor
During assembly bearings cannot be subjected to direct blows.

The aid used to press or strike the bearing should be applied to
Figure 4.1 - Bearings and lubrication system the inner ring.
Nipples must be clean prior to introduction of grease to avoid 4.3 Air Gap Checking (Large Rating
entry of any alien bodies into the bearing. Open Motors)
For lubricating use only a manual grease gun. Upon the completion of any work on the bearings check of the
gap measurement between the stator and the rotor using the
Bearing Lubrication Steps appropriate gazes.
The gap variation at any two vertically opposite points must be
1. Cleanse the area around the grease nipples with clean less than 10% of the average gap measurement.
25
4.4 Explosion Proof Motor Repair MOUNTING THE TERMINAL BOX

Steps Prior to fitting the terminal box all cable outled on the frame
should be sealed with a sealing compound (Ist layer) and an
4.4.1 Objective Epoxy resin (ISO 340) mixed with ground quartz (2nd layer) in
In view of the heavy liability associated with burning of motors the following proportions:
of this type, this product has been designed and manufactured
to high technical standards, under rigid controls. In addition, in 340A resin 50 parts
many areas it is required that explosion proof motors ONLY be 340B resin 50 parts
repaired by licensed personnel or in licensed facilities Ground quartz 100 parts
recognized to do this type of work.
Drying time for this mixture is two hours during which the
The following general procedures, safeguards, and guidelines frame should not be handled and cable outlets should be
must be followed in order to ensure repaired explosion proof upwards.
motors operate as intended. When dry, see that the outlets and areas around the cables are
perfectly sealed.
4.4.2 Repair Procedure and Mount the terminal box and paint the motor.
Precautions
Dismantle the damaged motor with appropriate tooling without 4.4.3 Miscellaneous
hammering and/or pitting machined surfaces such as Recommendations
enclosure joints, fastening holes and all joints in general. · Any damaged parts (cracks, pittings in machined surfaces,
The position of the fan cover should be suitably marked prior to defective threads) must be replaced and under no
removal so as to facilitate reassembly later on. circumstances should attempts be made to recover them.
Examine the motors general condition and, if necessary,
disassemble all parts and clean them with kerosene. Under no · Upon reassembling explosion proof motors IPW55 the
circumstances should scrapers, emery papers or tools be substitution of all seals is mandatory.
used that could affect the dimensions of any part during
cleaning. · Should any doubts arise, consult WEG.
Protect all machined parts against oxidation by applying a

coating of vaseline or oil immediately after cleaning.
STRIPPING OF WINDINGS
This step requires great care to avoid knocking and/or denting
of enclosure joints and, when removing the sealing compound
from the terminal box, damage or cracking of the frame.
IMPREGNATION
Protect all frame threads by inserting corresponding bolts, and
the joint between terminal box and frame, by coating it with a
non-adhesive varnish (ISO 287 - ISOLASIL).
Protective varnish on machined parts should be removed soon
after treating with impregnating varnish. This operation should
be carried out manually without using tools.
ASSEMBLY
Inspect all parts for defects, such as cracks, joint
incrustations, damaged threads and other potential problems.
Assemble using a rubber headed mallet and a bronze bushing
after ascertaining that all parts are perfect by fitted.
Bolts should be positioned with corresponding spring washers
and evenly tightened.
TESTING
Rotate the shaft by hand while examining for any drag
problems on covers or fastening rings.
Carry out running tests as for standard motors.
26
5. Malfunctioning
This failure arises when a motor runs wired in delta and
current fails in one main conductor.
Current rises from 2 to 2.5 times in the remaining winding with
The greater part of the malfunctions affecting the normal a simultaneous marked fall in speed. If the motor stops, the
running of electric motors can be avoided by maintenance and current will increase from 3.5 to 4 times its rated value.
precautions of a preventive nature. In most instances, this defect is due to the absence of a
Wide ventilation, cleanliness and careful maintenance are the protective switch, or else, the switch has been set too high.
main factors ensuring long motor life. A further essential factor
is the prompt attention to any malfunctioning as signalled by b) Two burnt winding phases
vibrations, shaft knock, declining insulation resistance, smoke This failure arises when current fails in one main conductor
or fire, sparking or unusual slip ring or brush wear, sudden and the motor winding is star-connected. 0ne of the winding
changes of bearing temperatures. phases remains currentless while the others absorb the full
When failures of an electric or mechanical nature arise, the voltage and carry an excessive current.
first step to be taken is to stop the motor and subsequent The slip almost doubles.
examination of all mechanical and electrical parts of the
installation. c) Three burnt winding phases
In the event of fire, the installation should be isolated from the Probable cause 1
mains supply, which is normally done by turning off the Motor only protected by fuses; an overload on the motor will be
respective switches. the cause of the trouble.
In the event of fire within the motor itself, steps should be taken Consequently, progressive carbonizing of the wires and
to restrain and suffocate it by covering the ventilation vents. insulation culminate in a short circuit between turns, or a short
To extinguish a fire, dry chemical or C02 extinguishers should against the frame occurs.
be used - never water. A protective switch placed before the motor would easily solve
this problem.
5.1 Standard Three-Phase
Motor Failures Probable cause 2
Owing to the widespread usage of asynchronous three-phase Motor incorrectly connected. For example: A motor with
motors in industry which are more often repaired in the plant windings designed for 230/400V is connected through a star-
workshops, there follows a summary of possible failures and delta switch to 400V connection.
their probable causes, detection and repairs. The absorted current will be so high that the winding will burn
Motors are generally designed to Class B or F insulation and out in a few seconds if the fuses or a wrongly set protective
for ambient temperatures up to 40°C. switch fail to react promptly.
Most winding defects arise when temperature limits, due to
current overload, are surpassed throughout the winding or even Probable cause 3
in only portions thereof. These defects are identified by the The star-delta switch is not commutated and the motor
darkening or carbonizing of wire insulation. continues to run for a time connected to the star under overload
conditions.
5.1.1 Short Circuits Between Turns As it only develops 1/3 of its torque, the motor cannot reach
A short circuit between turns can be a consequent of two rated speed. The increased slip results in higher ohmic losses
coincident insulation defects, or the result of defects arising arising from the Joule effect. As the stator current, consistent
simultaneously on two adjacent wires. As wires are randomly with the load, may not exceed the rated value for the delta
tested, even the best quality wires can have weak spots. Weak connection, the protective switch will not react.
spots can, on occasion, tolerate a voltage surge of 30% at the Consequent to increased winding and rotor losses the motor
time of testing for shorting between turns, and later fail due to will overheat and the winding burn out.
humidity, dust or vibration.
Depending on the intensity of the short, a magnetic hum Probable cause 4
becomes audible. Failures from this cause arise from thermal overload, due to
In some cases, the three-phase current imbalance can be so too many starts under intermittent operation or to an overly
insignificant that the motor protective device fails to react. A long starting cycle. The perfect functioning of motor operating
short circuit between turns, and phases to ground due to under these conditions is only assured when the following
insulation failure is rare, and even so, it nearly always occurs values are heeded:
during the early stages of operation. a) number of starts per hour;
b) starting with or without load;
5.1.2 Winding Failures c) mechanical brake or current inversion;
d) acceleration of rotating masses connected to motor shaft
a) One burnt winding phase e) load torque vs. speed during acceleration and braking.
27
The continuous effort exerted by the rotor during intermittent As a consequence of alternating bending stress induced by a
starting brings about heavier losses which provoke rotating shaft, fractures travel inwards from the outside of the
overheating. shaft until the point of rupture is reached when resistance of the
Under certain circumstances with the motor idle there is a remaining shaft cross-section no longer suffices.
possibility that the stator winding is subjected to damage as a Avoid additional drilling the shaft (fastening screw holes) as
result of the heating of the motor. In such a case, a slip ring such operations tend to cause stress concentration.
motor is recommended as a large portion of the heat (due to
rotor losses) is dissipated in the rheostat. 5.1.6 Unbalanced V-Belt Drives
The substitution of only one or other of various parallel belts of
5.1.3 Rotor Failures a drive is frequently the cause of shaft fractures, as well as
If a motor running under load conditions produces a noise of being malpractice.
varying intensity and decreasing frequency while the load is Any used, and consequently stretched belts retained on the
increased, the reason, in most cases, will be an drive, especially those closest to the motor, while new and
unsymmetrical rotor winding. unstretched belts are placed on the same drive turning farther
In squirrel-cage motors the cause will nearly always be a from the bearing can augment shaft stress.
break in one or more of the rotor bars; simultaneously,
periodical stator current fluctuations may be recorded. As a 5.1.7 Damage Arising from Poorly
rule, this defect appears only in molded or die cast aluminum Fitted Transmission Parts or
cages. Improper Motor Alignment
Failures due to spot heating in one or another of the bars in the Damage to bearing and fracture in shafts often ensue from
rotor stack are identified by the blue coloration at the affected inadequate fitting of pulleys, couplings or pinions. There parts
points. knock when rotating. The defect is recognized by the
Should there be failures in various contiguous bars, vibrations scratches that appear on the shaft or the eventual scalelike
and shuddering can occur as if due to an unbalance, and are flaking of the shaft end.
often interpreted as such. When the rotor stack acquires a blue Keyways with edges pitted by loosely fitted keys can also
or violet coloration, it is a sign of overloading. bring about shaft failures.
This can be caused by overly high slip, by too many starts or Poorly aligned couplings cause knocks and radial and axial
overlong starting cycles. This failure can also arise from shaking to shaft and bearings.
insufficient main voltage. Within a short while these malpractices cause the deterioration
of the bearings and the enlargement of the bearing cover
5.1.4 Bearing Failures bracket located on the drive end side.
Bearing damage is a result of overloading brought about by an Shaft fracture can occur in more serious cases.
overly taut belt or axial impacts and stresses.
Underestimating the distance between the drive pulley and the
driven pulley is a common occurrence.
The arc of contact of the belt on the drive pulley thus becomes
inadmissibly small and thereby belt tension is insufficient for
torque transmission.
In spite of this it is quite usual to increase belt tension in order
to attain sufficient drive.
Admittably, this is feasible with the latest belt types reinforced
by synthetic materials.
However, this practice fails to consider the load on the bearing
and the result is bearing failure within a short time.
Additionally there is the possibility of the shaft being subjected
to unacceptably high loads when the motor is fitted with a
pulley that is too wide.
5.1.5 Shaft Fractures

Although bearings traditionally constitute the weaker part, and
the shafts are designed with wide safety margins, it is not
beyond the realms of possibility that a shaft may fracture by
fatigue from bending stress brought about by excessive belt
tension.
In most cases, fractures occur right behind the drive end
bearing.
28
5.2 Troubleshooting chart
FAILURE PROBABLE CAUSE CORRECTIVE MEASURES
Motor fails to start 1. No voltage supply · Check feed connections to control system and from
this to motor.
2. Low voltage supply · Check voltage supply and ascertain that voltage remains
within 10% of the rated voltage shown on the motor
nameplate.
3. Wrong control connections · Compare connections with the wiring diagram on the
motor nameplate.
4. Loose connection at some · Tighten all connections.
terminal lug
5. Overload · Try to start motor under no-load conditions. If it starts,
there may be an overload condition or a blocking of
the starting mechanism. Reduce load to rated load level
and increase torque.
High noise level 1. Unbalance · Vibrations can be eliminated by balancing rotor. If load is
coupled directly to motor shaft, the load can be unbalanced.
2. Distorted shaft · Shaft cae bent; check rotor balance and eccentricity.
3. Incorrect alignment · Check motor aligment with machine running.
4. Uneven air gap · Check shaft for warping or bearing wear.
5. Dirt in the air gap · Dismantle motor and remove dirt or dust with jet of dry air.
6. Extraneous matter stuck between · Dismantle motor and clean. Remove trash or debris from
fan and motor casing motor vicinity.
7. Loose motor foundation · Tighten all foundation studs. If necessary, realign motor.
8. Worn bearings · Check lubrication. Replace bearing if noise is excessive
and continuous.
Overheating of bearings 1. Excessive grease · Remove grease bleeder plug and run motor until excess
grease is expelled.
2. Excessive axial or radial strain on belt · Reduce belt tension.
3. Deformed shaft · Have shaft straightened and check rotor balance.
4. Rough bearing surface · Replace bearings before they damage shaft.
5. Loose or pooly fitted motor end · Check end shields for close fit around circumference
shields and tightness.
6. Lack of grease · Add grease to bearing.
7. Hardened grease cause locking of · Replace bearings.
balls
8. Foreign material in grease · Flush out housings and relubricate.
Intense bearing vibration 1. Unbalanced rotor · Balance rotor statically and dynamically.
2. Dirty or worn bearing · If bearing rings are in perfect condition, clean and
relubricate the bearing, otherwise, replace bearing.
3. Bearing rings too tight on shaft · Before altering shaft or housing dimensions, it is advisable
and/or bearing housing to ascertain that bearing dimensions correspond to
manufacturers specifications.
4. Extraneous solid particles in · Take bearing apart and clean. Reassemble only if rotating
bearing and support surfaces are unharmed.
Overheating of motor 1. Obstructed cooling system · Clean and dry motor; inspect air vents and windings periodically.
2. Overload · Check application, measuring voltage and current under
normal running conditions.
3. Incorrect voltages and frequecies · Compare values on motor nameplate with those of mains
supply. Also check voltage at motor terminals under full load.
4. Frequent inversions · Exchange motor for another that meets needs.
5. Rotor dragging on stator · Check bearing wear and shaft curvature.
6. Unbalanced electrical load · Check for unbalanced voltages or operation under
(burnt fuse, incorrect control) single-phase condition.
29
6. Spare Parts and
Component Terminology
THREE-PHASE MOTORS IP55 NEMA - Frames 140T - W180T - 180T - 210T and W210T
Part Nr. Description Part Nr. Description Part Nr. Description

1 Terminal box cover 13 VRing 25 Shaft key
2 Terminal box cover fixing bolt 14 Non-drive end endshield fixing bolt 26 Drive end bearing
3 Terminal box cover gasket 15 Non-drive end endshield washer 27 Drive endshield
4 Terminal box fixing bolt 16 Non-drive endshield 28 Drive endshield washer
5 Terminal box fixing washer 17 Spring washer 29 Drive end endshield fixing bolt
6 Terminal box grounding lug 18 Non-drive bearing 33 VRing
7 Terminal box 19 Fan fixing pin 31 Drain plug
8 Frame grounding lug 20 Wound stator
9 Terminal box oring gasket 21 Rotor / shaft assembly
10 Fan cover 22 Nameplate fixing rivet
11 Fan cover fixing bolt 23 Nameplate
12 Fan 24 Frame
THREE-PHASE MOTORS IP55 NEMA - Frames 250T - W250T - 280T and 320T

1 Terminal box cover 16 Non-drive end endshield fixing 30 Nameplate
2 Terminal box cover fixing bolt bolt 31 Frame
3 Terminal box cover gasket 17 Non-drive end bearing cap washer 32 Shaft key
4 Terminal box fixing bolt 18 Non-drive end grease nipple 33 Drive end bearing cap
5 Terminal box fixing washer 19 Non-drive end grease nipple cover 34 Drive end bearing
6 Terminal box grounding lug 20 Non-drive end endshield washer 35 Drive andshield
7 Terminal box 21 Non-drive endshield 36 Drive end grease nipple cover
8 Frame grounding lug 22 Spring washer 37 Drive endshield washer
9 Terminal box oring gasket 23 Non-drive end bearing 38 Drive end endshield fixing bolt
10 Fan cover 24 Non-drive end bearing cap 39 Drive end bearing cap washer
11 Fan cover washer 25 Fan fixing pin 40 VRing
12 Fan cover fixing bolt 26 Wound stator 41 Drive end bearing cap fixing bolt
13 Fan 27 Rotor and shaft 42 Drain plug
14 Non-drive end bearing cap bolt 28 Eyebolt 43 Non-drive and grease relief
15 VRing 29 Nameplate fixing rivet 44 Drive end grease relief
30
THREE-PHASE MOTORS IP55 NEMA T - Frames 360T - 400T - 440T - 500T and 580T

1 Terminal box cover 18 Fan 34 Shaft key
2 Terminal box cover fixing bolt 19 Non-drive end bearing cap bolt 35 Internal drive end bearing cap
3 Terminal box cover washer 20 VRing 36 Drive end bearing
4 Terminal box cover gasket 21 Non-drive end bearing cap washer 37 Drive endshield
5 Terminal box fixing bolt 22 Non-drive end endshield fixing 38 Drive end grease nipple cover
6 Terminal box fixing washer bolt 39 Drive endshield washer
7 Terminal box grounding lug 23 Non-drive end endshield washer 40 Pre-load spring
8 Terminal box 24 Non-drive end grease nipple 41 Drive end endshield fixing bolt
9 Frame grounding lug 25 Non-drive end grease nipple cover 42 External drive end bearing cap
10 Terminal box oring gasket 26 Non-drive enshield 43 Drive end bearing cap washer
11 Nameplate fixing rivet 27 Bearing cap 44 VRing
12 Nameplate 28 Non-drive bearing 45 Drive end bearing cap fixing bolt
13 Eyebolt 29 Internal non-drive end bearing cap 46 Drain plug
14 Fan cover 30 Fan fixing key 47 External non-drive end bearing cap
15 Fan cover washer 31 Wound stator 48 Non drive end grease relief
16 Fan cover fixing bolt 32 Rotor / shaft assembly 49 Non-drive end grease relief
17 Fan fixing ring 33 Frame
31
THREE-PHASE MOTORS NEMA 56 - Frames A56 - B56 - D56 - F56H and G56H

1 Sticker 8 Non-drive end bearing 14 Fan
2 Terminal box cover fixing bolt 9 Wound stator 15 Drive end bearing fastening
3 Terminal box cover 10 Rotor / shaft assembly washer
4 Grounding lug 11 Frame 16 Drive end bearing
5 Through bolt fastening nut 12 Through bolt 17 Drive endshield
6 Non-drive endshield 13 Shaft key
7 Spring washer
SINGLE-PHASE MOTORS NEMA 56 - Frames B48 - C48 - C56 - A56 - B56 - D56 - F56H - G56H

1 Sticker 12 Stationary switch fastening bolt 23 Drive end bearing fastening
2 Capacitor cover fixing bolt 13 Centrifugal switch washer
3 Terminal box cover fixing bolt 14 Rubber ring for lead passing hole 24 Drive end bearing
4 Terminal box cover to capacitor 25 Drive endshield
5 Grounding lug 15 Capacitor cover 26 Overload thermal protector fixing
6 Through bolt fastening nut 16 Capacitor ring
7 Non-drive endshield 17 Wound stator 27 Overload thermal protector
8 Spring washer 18 Rotor / shaft assembly
9 Non-drive and bearing 19 Frame
10 Non-drive and bearing fastening 20 Through bolt
washer 21 Shaft key
11 Stationary switch 22 Fan
Note: For F56H and G56H frame motors: 1)Part nr. 3 = 3 pieces; 2) Part nr. 4 and 5 = 2 pieces
32
NOTES:
33
YOU MAY NEED TO READ OTHER WEG
INSTALLATION AND MAINTENANCE MANUALS:
For Low and High Voltage Large Motors

Induction, Slip Ring, H Line, M Line, A Line Manual Nr 673
For DC Motors Manual Nr 1005
For Tacho Generator Dynamo Manual Nr 1007
For Generators GTA Line Manual Nr 1035
YOU CAN REQUEST THE ABOVE MANUALS FROM

YOUR NEAREST WEG SALES OFFICE OR
DIRECTLY WITH WEG HEADQUARTER.
WEG INDUSTRIAS S.A.

Av. Pref. Waldemar Grubba, 3000
89256-900 JARAGUÁ DO SUL - SC - BRAZIL
PHONE: (55) (47) 372-4000 PABX
FAX: (55) (47) 372-4060
PLUGSERIES Relays on Sockets
PRZ/PRS PRZ/PRS
DC-Version AC-Version
PRS/PRZ SPDT PRS/PRZ DPDT Type/Version Part No. Type/Version Part No.
Screw connection Screw connection
PRS 12 VDC LD SPDT 8536471001 PRS 24 VAC LD SPDT 8536530000
PRS 12 VDC LD DPDT 8536501001 PRS 24 VAC LD DPDT 8536560000
PRS 24 VDC LD DPDT SGR 282 8596000000
with gold-plated with gold-plated
relay contacts: relay contacts:
PRS 24 VDC LD DPDT AU 8561760000 PRS 120 VAC LD DPDT AU 8595960000
PRS 230 VAC LD DPDT AU 8595990000
Tension clamp connection Tension clamp connection

PRZ 12 VDC LD SPDT 8536571001 PRZ 24 VAC LD SPDT 8536651001
Modular system comprising:
PRZ 12 VDC LD DPDT 8536591001 PRZ 24 VAC LD DPDT 8536681001
- relay socket for mounting rails PRZ 24 VDC LD SPDT 8530691001 PRZ 120 VAC LD SPDT 8530710000
- LED indicator unit/RC combination PRZ 24 VDC LD DPDT 8530701001 PRZ 120 VAC LD DPDT 8530720000
- retainer clip PRZ 115 VDC LD SPDT 8536610000 PRZ 230 VAC LD SPDT 8530731001
- pluggable relays PRZ 115 VDC LD DPDT 8536630000 PRZ 230 VAC LD DPDT 8530741001
PRZ 24 VDC LD DPDT SGR 282 8595970000
Independent connection technology: with gold-plated with gold-plated
screw or tension clamp technology relay contacts: relay contacts:
PRZ 24 VDC LD DPDT AU 8552440000 PRZ 120 VAC LD DPDT AU 8575940000
Compatible with low power relays type PRZ 230 VAC LD DPDT AU 8575950000
RT/Standard with SPDT or DPDT Other variants on request Other variants on request
Technical data Technical data
Coil and root-contacts cross-
Input voltage 12 VDC…24 VDC…115 VDC Input voltage 24 VAC…120 VAC…230 VAC
connectable with cross-connection
Rated consumption, typ 400 mW Rated consumption, typ 760 VA
type ZQV 2.5 N Status indicator pluggable LED-housing, Status indicator pluggable LED-housing,
green LED green LED
Available as complete module or as
Output 1 CO/2 CO contacts Output 1 CO/2 CO contacts
spare parts Contact version SPDT/DPDT Contact version SPDT/DPDT
Max. output voltage 250 VAC/DC Max. output voltage 250 VAC/DC
Max. switching current 16 A/2 x 8 A Max. switching current 16 A/2 x 8 A
Continuous current 10 A Continuous current 10 A
Rated breaking capacity 4 kVA/2 x 2 kVA Rated breaking capacity 4 kVA/2 x 2 kVA
Service life, mech. 30 x 106 Service life, mech. 5 x 106
Input/output Input/output
Clearance and creepage path > 8 mm Clearance and creepage path > 8 mm
Protective separation DIN VDE 0106 T. 101 Protective separation DIN VDE 0106 T. 101
Dielectric strength > 4 kVeff Dielectric strength > 4 kVeff
Insulation coordinates acc. to III/2 Insulation coordinates acc. to III/2
EN 50178 EN 50178
Miscellaneous data Miscellaneous data
Ambient temperature -40°C…+50°C Ambient temperature -40°C…+50°C
Protection class IP 20 Protection class IP 20
Rated cross-section 0.5…2.5 mm2 (20…14 AWG) Rated cross-section 0.5…2.5 mm2 (20…14 AWG)
Flammability V0 Flammability V0
Relay type Schrack RT1/RT2 Relay type Schrack RT1/RT2
Dimensions W/L/H mm (in.) 15.2/85/91 (.60/3.35/3.58) Dimensions W/L/H mm (in.) 15.2/85/91 (.60/3.35/3.58)
Approvals CE, UL recognized, cUL Approvals CE, UL recognized, cUL
Rail mounted TS 35 Rail mounted TS 35
Accessories Accessories
Cross-connection Cross-connection
2-pole black ZQV 2.5N/4-2 SW 1784270000 2-pole black ZQV 2.5N/4-2 SW 1784270000
2-pole red ZQV 2.5N/4-2 RT 1784280000 2-pole red ZQV 2.5N/4-2 RT 1784280000
2-pole blue ZQV 2.5N/4-2 BL 1784290000 2-pole blue ZQV 2.5N/4-2 BL 1784290000
Marking tags Marking tags
WS 10/5 1060860000 WS 10/5 1060860000
WS 15/5 1609880000 WS 15/5 1609880000
136
Accessories
DIGITAL SIGNAL PROCESSING

marking field
retaining-clip
Cross-connection
channel
87 (PXZ35)
87
11/21
95 (PXS35) Cross-connections
channel
A1/A2
92
92
Tension Screw Empty base for rail mounted TS 35 Type Part No.
clamp connection Screw connection PXS35 8533771001
Tension clamp connection PXZ35 8536691001
15,3
15.3 (.60) 15.3 (.60)
mm (in.) mm (in.) Technical data
Rated current 16 A
22 12 22 12 Rated voltage 250 V
(NC) (NC) Dielectric strength coil/contacts > 4 kV
Protection class IP 20
21 11 21 11 Rated cross-section 2.5 mm2
(COM) (COM) Insulation stripping length mm (in.)
24 14 24 14 - Screw connection 8 (.31)
(NO) (NO) - Tension clamp connection 10 (.39)
Ambient temperature -40°C…+60°C
Flammability class UL 94 V0
Holding clamp Type Part No.

PRC 8536700000
Operating indication
LED indicator with free-wheeling diode
A2 A1 A2 A1 6…24 VDC PLED 24 VDC 8536710000
(COIL) (COIL)
6…24 VDC PLED 24 VDC red 8611010000
48…60 VDC PLED 48 VDC 8536720000
115 VDC PLED 115 VDC 8536730000
12…24 VAC PLED 24 VAC 8536750000
115 VAC PLED 120 VAC 8536760000
230 VAC PLED 230 VAC 8536780000
Operating indication 230 VAC PLED 230 VAC red 8611000000
RC combination 120…230 VAC/DC PLRC 200 nF/200Ω 8566530000
DC-Version Pluggable cross-connection

14 12 24 22 2-pole black ZQV 2.5N/4-2SW 1784270000
A1
2-pole red ZQV 2.5N/4-2RT 1784280000
2-pole blue ZQV 2.5N/4-2BL 1784290000
* Marking tags Type Part No.

10 x 5 mm (.39 x .20 in.) WS 10/5 1060860000
A2 11 21 * free wheel WS 15/5 1609880000
diode
AC-Version
14 12 24 22
A1
A2 11 21
137
Pluggable relay types SPDT SCHRACK RT
Print figure/circuit diagram

Relay type RT/SGR
DPDT
Pluggable relay Type Schrack RT Part No.

12 VDC SPDT RT 314012 4058470000
12 VDC DPDT RT 424012 4058560000
24 VDC SPDT RT 314024 4058480000

24 VDC SPDT AU RT 315024 4058490000
24 VDC DPDT RT 424024 4058570000

24 VDC DPDT AU RT 425024 4058580000
48 VDC SPDT RT 314048 4058740000

48 VDC DPDT RT 424048 4058750000
60 VDC DPDT RT 424060 4058760000
110 VDC SPDT RT 314110 4058500000

110 VDC DPDT RT 424110 4058590000
24 VAC SPDT RT 315524 4058510000

24 VAC DPDT RT 424524 4058600000
115 VAC SPDT RT 314615 4058520000

115 VAC SPDT AU RT 315625 4058530000
115 VAC DPDT RT 424615 4058610000
115 VAC DPDT AU RT 425615 4058620000
230 VAC SPDT RT 314730 4058540000

230 VAC SPDT AU RT 315730 4058550000
230 VAC DPDT RT 424730 4058630000
230 VAC DPDT AU RT 425730 4058640000
Technical data
Contact number and type SPDT or DPDT
Contact material AgNi 90/10, AgNi 0.15 htv
Switching current 16 A 1We/2 x 8 A 2We
Switching voltage 250 VAC
Breaking capacity 4 kVA
Min. switching current/breaking capacity 10 mA/100 mW
Min. breaking capacity AU contact 40 µW
Rated consumption 400 mW dc/0.55 VA ac
Dielectric strength coil/contact 5 kV
Response/drop out time: DC coil typ. 7/3 ms
AC coil 9/45 ms
Bounce time NO contact/normally closed contact typ. 1/3 ms
Mechanical service life: DC coil > 30 x 106 switching operations
AC coil > 30 x 106 switching operations
Breaking capacity 1-pole DC 13 1.25 A, L/R = 80 ms 2.3 x 105
2-pole DC 13 1.25 A, L/R = 80 ms 2.8 x 105
2-pole AC 15 1.2 A, cosL/R = 0.3 6050x
Miscellaneous data
Protection class IP 40
Flammability class UL V0
Ambient temperature DC coil -40°C…+85°C
AC coil -40°C…+70°C
Weight 14 g
Approvals UL, CSA, VDE, ÖVE
138
1781, Classic & WRC4 Series Single Point Discrete I/O
SPECIFICATIONS
Relay Output & • To specify the WRC4 package, use the prefix “WRC4” (eg. WRC4-IA5S.)
Watchdog Modules • To specify the slim package, use the “S” suffix with the 1781 prefix (eg. 1781-RO5S/RC5S.)
• To specify the mini package, use the “M” suffix with the 1781 prefix (eg. 1781-RO5M/RC5M.)
• To specify the standard package, use the “Classic” part number (eg. OAC5R or OAC5R5.)
INPUT: WRC4 and 1781 WO5S/WC5S1 & 2 RO5S/RC5S2 ROYS/RCYS2 ROXS/RCXS2
INPUT: CLASSIC OAC5R(5) OAC15R(5) OAC24R(5) Units
Nominal input voltage 5 5 15 24 V dc

Discrete I/O Modules
Min. input volt. @ pin 3 - WRC4 4.5 4.5 10.5 19.5 V dc

Min. input volt. @ pin 3 - 1781 3.0 3.0 9 18.0 V dc
Max. input volt. @ pin 3 - WRC4 5.5 5.5 20 30.5 V dc
Max. input volt. @ pin 3 - 1781 5.5 5.5 20 30.5 V dc
Must turn off voltage — 1.0 2.0 3.0 V dc
Typical input current 0 (4A transient) 1.3 3 2.2 mA dc
Maximum input current 0 (5A transient) 2.2 4 2.5 mA dc
Nominal input resistance 2.2K (series 0.1 uF) 2K 4.7K 10K ohm
Typical V+ supply current 50 50 24 15 mA dc
OUTPUT
Nominal line voltage 5 5 5 5 V dc/ V rms
Maximum line voltage 100/125 100/125 100/125 100/125 V dc/ V rms
Minimum line voltage 0 0 0 0 V dc/ V rms
Max peak off-state voltage 100/125 100/125 100/125 100/125 V dc/ V rms
Max. off-state leakage cur. 0 0 0 0 mA dc
Maximum on-state current 1A, 30 Wdc, 1A, 30 Wdc, 1A, 30 Wdc, 1A, 30 Wdc, Resistive
62.5 VA 62.5 VA 62.5 VA 62.5 VA Load
Minimum on-state current 0 0 0 0 mA
Maximum 1 second surge 2.5 2.5 2.5 2.5 A peak
Peak on-state voltage 0.25 0.25 0.25 0.25 V dc
Maximum turn-on time 2 2 2 2 ms
Maximum turn-on time 1 1 1 1 ms
Fuse rating (WRC4 only) 4A 4A 4A 4A fast-acting
1 Timer Values: xxx = value in millisecs. xxs = value in seconds.

40, 80, 125, 250, 500 ms 4, 8, 16, 32 sec. General specifications
Examples: 1781-WO5S-500 has N.O. contacts & 500 ms watchdog . Operating Temperature Range -30 to +80°C
1781-WC5S-4S has N.C. contacts & 4 sec. watchdog. Isolation Voltage 1000 V rms
2 1781-RO5S/ROXS & 1781-WO5S contacts normally open (N/O)
Capacitance Input to Output 8 pF
1781-RC5S/RCXS & 1781-WC5S contacts normally closed (N/C)
Application notes
• Relay & watchdog modules are rated for resistive loads only.
Classic and
1781-RO_S/RC_S 1781-WO5S/WC5S WRC4-RO_S/RC_S
N.O. N.O.
Contact N.O. Contact Contact
CONTACT
1
N.C.
1 (N.C. CONTACT
1
N.C.
CONTACT Contact)
OUTPUT Contact OUTPUT Contact
OUTPUT
2
2 2
V+
+ V+ 3 V+
+
3 3
WATCHDOG
LOGIC IN – INPUT
(+step/pulse)
4 Watchdog
Circuit LOGIC IN –
(low true) 4 (low true) 4
GND 5
GND 5 GND 5
on.co
kr
m
wrca
TM
Phone: (330) 733-6662 | Fax: (330) 733-6663 | e-mail: sales@wrcakron.com | web site: www.wrcakron.com 12
Engineering Data Sheet
GL Series Compressor Package
JOB NUMBER: 03991-001-1-01-02

JOB NAME: PESQUERA CAPRICORNIO S.A
LOCATION: LIMA, CALLAO, PERU
DATE: June 20, 2012

REVISION:
PROJECT ENGINEER: TIMOTHY ULERY
MODEL: 290GLE
SEPARATOR SIZE: 24"
REFRIGERANT: R-717
TYPE OF COOLING: TSOC
APPLICATION: HIGH STAGE
FIXED VI
TYPE OF CONTROL: GFORCE
OPERATING CONDITIONS:
SAT. SUCTION TEMPERATURE -40.0 °F

SAT. SUCTION PRESSURE 8.7 IN HG
SAT. ECON. SUCTION TEMPERATURE -18.5 °F

SAT. ECON. SUCTION PRESSURE 4.4 PSIG
SAT. DISCHARGE TEMPERATURE 95.0 °F

SAT. DISCHARGE PRESSURE 181.1 PSIG
PACKAGE RATINGS:
CAPACITY 83.3 TONS
POWER 269.9 BHP
OCHR 462.5 MBH @ 100% S.V.
398.1 MBH @ 0% S.V.
Ratings are for the complete package including losses for FES supplied suction and
discharge stop valves. Stop valves supplied by others may have losses slightly greater or
less than those used in the calculation.
FES Job No. 03991-001-1-01-02 Page 1 of 6 Form: E-160

Revision: 1X
Effective: 06-12
DRAWINGS
GENERAL ARRANGEMENT 03991-001-1-01-01-M111

PIPING SCHEMATIC 03991-001-1-01-01-M211
ENCLOSURE ASSEMBLY 03991-001-1-01-02-E301
CONTROL DIAGRAM (Includes Field Wiring) 03991-001-1-01-02-E401

Revision: 1X
Effective: 06-12
COMPRESSOR COMPONENTS
ITEM FES PART NO. QTY. DESCRIPTION/REMARKS
Compressor Model 290GLE 1 Compressor Vi 4.8 (Fixed)
Compressor Motor WEG 1 Hp 300

(Premium Efficiency Frame 445TS
W/Space Heaters) RPM (SYN) 3600
Enclosure ODP
Volt/Ph/Hz 460/3/60
FLA 322
LRA 2029
SF 1.15
Furnished By GEA FES
Mounted By GEA FES
Starter 0 Type SOLID STATE

Overload Type ELECTRONIC
4-20mA Range 0-500
Furnished By OTHERS
Compressor Coupling 010-02092C-003 1 Motor Shaft Dia. 2.375"

Coupling Size 52-262
Suction Check Valve 370-028030-060 1 6"
Suction Strainer 031-01094B-004 1 6"

Screen
Suction Stop Valve 360-005450-060 1 6" Angle

Mounted
Discharge Check 370-028020-020 1 2"

Valve
Discharge Stop Valve 360-005470-030 1 3" Globe

Mounted
Oil Separator (24") 011-02004D-001 1 DWP (psig) 300

Dia. (in.) 24
WSL (in.) 120

Revision: 1X
Effective: 06-12
OIL SYSTEM COMPONENTS
Coalescer 030-00613C-010 6
Manway Gasket 030-00085C-000 1
Oil Pump/Motor 290-003910-022 1 w/External Relief

3 HP, 182TC Frame, TEFC
460/3/60, 1800 RPM (SYN)
Oil Pump Shaft Seal 290-000820-000 1
Oil Pump Relief Valve 290-000920-000 1
Oil Regulator 370-001700-075 1 3/4" Port
Oil Filter Cartridge 030-00097A-000 1
O-Ring Gasket 520-000180-000 1

(For Oil Filter Cover)
Secondary Oil Return

Combo Valve 370-015090-000 1
Shut-off/Drain Valve 370-015130-000 1
Oil Strainer Screen 030-00051B-000 1
O-Ring Gasket 520-000170-000 1

(For Oil Strainer Cover)
Main Injection Oil

Metering Valve 360-003150-002 1
Auxiliary Main Oil 360-003150-002 1

Injection Metering
Valve
Screen, Main Oil 370-007595-110 1

Injection Strainer
OIL COOLER COMPONENTS
Oil Cooler 410-00039C-006 1 Size 807

(TSOC)
Thermostatic Oil 370-006780-000 1 Setting 120°F. Fixed

Temp. Regulating
Valve (Amot)

Revision: 1X
Effective: 06-12
OIL COOLER COMPONENTS (cont’d)
Element, Thermostatic 370-003240-120 1 120°F
O-Ring, Element 370-003230-001 1
O-Ring, Sleeve 370-003290-000 1 Type RF
Hydrostatic Relief 370-006290-100 1 100#

Valve
ECONOMIZER COMPONENTS
Back Pressure 370-007690-125 1 1-1/4" Port w/o Solenoid

Regulator
Check Valve 370-010150-125 1 1-1/4" Port
Strainer 370-007590-125 1 1-1/4" Port
Pressure Gauge 910-000300-000 1 30"-150 PSIG
CONTROLS AND INSTRUMENTATION
Valve Block 390-004200-139 1 Y1, Y2, Y3 & Y4 - Solenoids

4-Way Load/Unload S5, S6 & S7 - Metering Valves
Solenoid Coil 390-004260-B13 4 For load/unload valve
Position Sensor 390-004200-L53 1 Capacity Control 4-20mA
Temperature Probes
Separator Oil 715-005100-001 1 1TE
Inlet Oil 715-005100-006 1 2TE
Discharge 715-005100-003 1 3TE
Suction 715-005100-002 1 4TE
Process 715-00006A-002 0 5TE Installed By:
Pressure Transducers
Suction 745-007000-100 1 1PT, 0-100 psia
Discharge 745-007000-500 1 2PT, 0-500 psig
Inlet Oil 745-007000-500 1 3PT, 0-500 psig
Oil Filter Inlet 745-007000-500 1 4PT, 0-500 psig

Revision: 1X
Effective: 06-12
PACKAGE TRIM
Relief Valve 370-016980-250 2 250# (44#/min Air @ 250 psi)
Oil Heater 715-005000-001 2 NEMA 4

Volts 240
Watts 1200
Package Paint 560-002100-002 1 Standard Indoor - XBlue
Oil Charge (24") 560-000290-055 85 Gallons

(Nominal) Type Iso-Paraffinic
Brand FES No. 1
Supplied By GEA FES
Oil Separator 030-000720-000 3 2" Dia.

Sight Glass

Revision: 1X
Effective: 06-12
Engineering Data Sheet
G & X - Series Compressor Package
GForce Control Panel
JOB NUMBER: 03991-001-1-01-02
MODEL NUMBER: 290GLE
PROGRAM PART NUMBER: 726-06051M-001
VOLTAGE: 240V
FREQUENCY: 60 Hz
LANGUAGE: ENGLISH
ENVIRONMENT: NON-HAZARDOUS
CAPACITY CONTROL: PRESSURE (STD)

Revision: N
Effective: 01-12
CONTROL PANEL OPTIONS
ITEM DESCRIPTION/REMARKS
Two Oil Heaters One Oil Heater standard
Three Oil Heaters
Auxiliary Alarm #1 Input
Alarm Status Output
Alarm Status Isolation Relay
Auxiliary Shutdown #2 Input
Process Temp Control
Compressor Starter Isolation Relay
Oil Pump Starter Isolation Relay
Low Oil Level Switch Input
Remote Control & Sequence Slave I/O
Remote Start/Stop Input
Shutdown Status Standard
Shutdown Status Isolation Relay
IntelliSOC Select one or none

Oil Cooling Output
Compressor VFD Control
4-20mA Output of Motor Current
4-20mA Output of Slide Valve Position
Variable Vi
External Oil Pump
Economizer Output Select one or none

Economizer Output w/Precooler
Subcooler Output
Hot Gas Bypass Output
Division 1 Type X Panel Air Purge
Division 2 Type Z Panel Air Purge

Revision: N
Effective: 01-12
ITEM DESCRIPTION/REMARKS
External Type 4 USB port
External Type 4 Ethernet Port
Second I/O Rack
GComm Interface Master
GComm Interface Slave
Motor Starter Communication
Isolated Controls Ground
VTrac Vibration Monitor
Light Tower

Revision: N
Effective: 01-12
OPERATING PARAMETERS
Parameter Recommended Settings
Suction Pressure
Suction 1 Pressure Setpoint 8.7 “HG
Suction 1 Pressure Upper 1.6 “HG
Suction 1 Pressure Lower 14.3 “HG
Suction 1 Pressure Proportional Band 2.0 PSI
Suction 1 Pressure Dead Band 0.2 PSI
Suction 2 Pressure Setpoint 8.7 “HG
Suction 2 Pressure Proportional Band 2.0 PSI
Suction 2 Pressure Dead Band 0.2 PSI
Low Suction Pressure 0=Shutdown / 1=Cycle 0
Process Temperature
Process 1 Temperature Setpoint 0.0 °F
Process 1 Temperature Upper 0.0 °F
Process 1 Temperature Lower 0.0 °F
Process 1 Temperature Proportional Band 0.0 °F
Process 1 Temperature Dead Band 0.0 °F
Process 2 Temperature Setpoint 0.0 °F
Process 2 Temperature Proportional Band 0.0 °F
Process 2 Temperature Dead Band 0.0 °F
Low Process Temperature 0=Shutdown / 1=Cycle 0
Process Temperature Control Low Suction Setpoint 0.0 PSIG
Process Temperature Control Proportional Band Setpoint 0.0 PSIG
Process Temperature Control Load Adjust Setpoint 0.0 PSIG
Discharge
High Discharge Pressure Shutdown 225.0 PSIG
Discharge Pressure Prop Band 10.0 PSI
Discharge Temperature Upper 225.0 °F
REMOTE SLIDE VALVE1
Remote Slide Valve Control Low Suction PSIG
Remote Slide Valve Control Prop Band PSI
Remote Slide Valve Control Load Adjust PSI
Control
Control Mode 0= Suction Pressure / 1=Temperature / 2=Digital Input/ 3=Slide 0
Valve4 /4= Discharge Pressure
Control Point 0=Digital Input / 1=Point #1 / 2=Point #2 1
Capacity Control Direction 0 = Forward/ 1 = Reverse 0
Capacity Load-Unload Period 4.0 Sec
Slide Valve Position Minimum 0.0 %
Slide Valve Position Maximum 100.0 %

Revision: N
Effective: 01-12
OPERATING PARAMETERS (continued)
Load Limit 0=None / 1=Pulse / 2=Set Point / 3=Slide Valve3 0

Load Pulse During Pulldown2,3 Sec
Allow Normal Loading 0=No/1=Yes2,3
Allow Normal Loading After %SV2,3 Sec
Ramp to Suction Setpoint per Minute2,3 PSIG
Ramp to Max Slide Valve Over2,3 Min
Unload Slide Valve Before Stop 0/No/1=Yes 0
Remote Mode Control Setpoint 0=Control Parameter/1=Communications 0
IntelliSOC Valve Control1
Discharge Temperature Setpoint 150.0 °F
Minimum Position for Valve 10 %
Proportional Constant 250
Integral Constant 50
Derivative Constant 1
Test/Manual Mode 0=No/1=Yes
Test/Manual Mode Percent %
Calibrate Time Before Valve Bleed 30 Sec
Inlet Oil
Oil Filter Pressure Drop Maximum 15.0 PSID
Liquid Injection / IntelliSOC 175.0 °F
Inlet Oil Temperature Upper
External Cooling 155.0 °F
Inlet Oil Temperature Lower 95.0 °F
Lead Oil Pump, Select (1/2)1,3
Oil Separator
Oil Separator Heater Setpoint 115.0 °F
Oil Separator Temperature Upper 225.0 °F
Oil Separator Temperature Lower 75.0 °F
Variable Vi Control1
Compressor Model Selection (Refer to Instruction Manual)
Vi Operating Mode 0=Auto/1=Manual
Manual Vi Control Vi Setting Vi
Compressor Motor
Motor Current Upper (FLA X S.F.) 370.3 Amp
Motor Current Lower (FLA X S.F. X 0.85) 314.8 Amp
Motor Current Dead Band (Nom. 10% FLA) 32.2 Amp
Anti-Recycle Period 20 Min
Accumulated Compressor Runtime6 0.0 hrs
Motor Current Maximum8 500 Amp
Variable Speed Compressor Motor1
VFD Control Mode 0=Local/1 = Remote/ 2=DI
Proportional Constant 250
Integral Constant 50
Derivative Constant 1
Manual Control, 0=No/1=Yes
Manual Control, Percent %

Revision: N
Effective: 01-12
OPERATING PARAMETERS (cont’d)
Variable Speed Drive Range1

Motor Speed at 4 mA 1800 rpm
Motor Speed at 20 mA 3600 rpm
Power Monitoring
Demand Metering Ratio (Motor Current Max.)(Voltage)(.7)(1.732)/10001,8 279.0 kW
kilowatt Hour Sampling Period 5 Min
kWh Input Pulse, Weight1 kW
kilowatt Hours Consumed6 0.0 kWh
Power Failure Reset
Power Fail Reset Enable 0=No/1=Yes
Reset to Mode? 1=Local / 2=Remote3 1
Delay Before Power Fail Reset3 10 Sec
Abort Power Fail Reset After3 10 Min
Economizer
Economizer Solenoid On Above %5 40.0 %
Economizer Solenoid Off Below %5 40.0 %
Hot Gas
Start Hot Gas Below Slide Valve % 10.0 %
Stop Hot Gas Above Slide Valve % 15.0 %
Start Hot Gas Below Suction 37.8 PSIG
Stop Hot Gas Above Suction 41.0 PSIG
Historical Data
Long Term Sampling Period3 1 Min
Units
Temperature 0=°C/1=°F3 1
Pressure 0=kg/cm2/1=kPa/2=Psi/3=Bar3 2
Language 0=English/1=Spanish/2=Chinese/3=German/4=French 0
Network ID
Network ID (1-255) 1

Revision: N
Effective: 01-12
ALARM PARAMETERS
Suction Pressure
Low Suction Aux Safety1 PSIG
Process Temperature
Process Temperature Control Low Suction 0.0 PSIG
Discharge
Discharge Pressure Maximum 200 PSIG
Discharge Temperature Upper 210.0 °F
Remote Slide Valve
Remote Slide Valve Control Low Suction 20 PSIG
Inlet Oil
Oil Filter Pressure Drop Maximum 10.0 PSI
Liquid Injection / IntelliSOC 170.0 °F
Inlet Oil Temperature Upper
External Cooling 150.0 °F
Inlet Oil Temperature Lower 102.0 °F
Oil Separator
Oil Separator Temperature Upper 210.0 °F
Oil Separator Temperature Lower 102.0 °F
Compressor Motor
Motor Current Upper (FLA X S.F. X 0.99) 366.6 Amp
Superheat1
Suction Superheat Maximum °F
Suction Superheat Minimum °F
Discharge Superheat Maximum °F
Discharge Superheat Minimum °F

Revision: N
Effective: 01-12
Notes :
1. Factory configured parameter, may or may not be visible on your machine.
2. Visibility of this parameter is based on the settings of other parameters.
3. This setting is based on operator preference, provided for reference only.
4. Visibility of ‘3=Slide Valve’ selection appears based on factory configuration.
5. Available with Standard Programs, may or may not be available with Custom program.
6. Displays an accumulated value, can be used to preset or clear that value.
7. Some special program modifications include additional parameters. In such cases, recommended
settings for those parameters are included in the GForce Control Panel Addendum.
8. For customer supplied starters, refer to starter documentation for settings.

Revision: N
Effective: 01-12
Refrigerant Saturated
Temperature/Pressure (PSIG) Chart
Deg. F R-22 R-717 R-134a R-507 R-290 R-1270 Deg. F R-22 R-717 R-134a R-507 R-290 R-1270
-60 11.9 18.7 21.6 5.8 10.2 4.4 27 51.2 41.2 23.7 68.7 48.4 63.2
-55 9.2 16.7 20.2 2.2 7.4 0.8 28 52.4 42.4 24.5 70.2 49.5 64.6
-50 6.1 14.4 18.6 0.9 4.3 1.5 29 53.7 43.7 25.3 71.7 50.6 66.0
-45 2.7 11.8 16.7 3.1 0.9 3.6 30 54.9 44.9 26.1 73.3 51.7 67.3
-40 0.6 8.8 14.7 5.5 1.4 5.9 31 56.2 46.1 26.9 74.8 52.9 68.7
-35 2.6 5.5 12.3 8.2 3.4 8.4 32 57.5 47.4 27.8 76.4 54.0 70.1
-30 4.9 1.7 9.7 11.1 5.6 11.1 33 58.8 48.7 28.6 78.0 55.2 71.5
-25 7.5 1.2 6.8 14.9 8.1 14.1 34 60.2 50.0 29.5 79.6 56.4 72.9
-20 10.2 3.5 3.6 17.9 10.7 17.4 35 61.5 51.4 30.4 81.3 57.6 74.3
-18 11.4 4.5 2.2 19.3 11.8 18.8 36 62.9 52.7 31.3 82.9 58.8 75.8
-16 12.6 5.6 0.7 20.9 13.0 20.2 37 64.3 54.1 32.2 84.6 60.0 77.3
-14 13.9 6.7 0.4 22.5 14.1 21.6 38 65.7 55.5 33.1 86.3 61.3 78.8
-12 15.2 7.8 1.2 24.1 15.4 23.2 39 67.1 57.0 34.1 88.1 62.5 80.3
-10 16.5 9.0 2.0 25.9 16.7 24.7 40 68.6 58.4 35.0 89.8 63.8 81.9
-8 17.9 10.2 2.8 27.6 18.0 26.3 41 70.0 59.2 36.0 91.6 65.1 83.5
-6 19.4 11.5 3.7 29.4 19.3 28.0 42 71.5 61.4 37.0 93.3 66.4 85.0
-4 20.9 12.8 4.6 31.3 20.7 29.7 43 73.0 62.9 38.0 95.2 67.8 86.6
-2 22.4 14.2 5.5 33.2 22.2 31.4 44 74.5 64.5 39.0 97.0 69.1 88.2
0 24.0 15.6 6.5 35.3 23.6 33.2 45 76.1 66.1 40.0 98.9 70.5 90.1
1 24.8 16.4 7.0 36.2 24.4 34.1 46 77.6 67.6 41.1 100.8 71.8 91.5
2 25.7 17.1 7.5 37.3 25.2 35.1 47 79.2 69.3 42.2 102.7 73.2 93.2
3 26.5 17.9 8.0 38.3 26.0 36.0 48 80.8 70.9 43.2 104.6 74.6 94.9
4 27.4 18.7 8.6 39.4 26.7 37.0 49 82.4 72.6 44.3 106.6 76.0 96.6
5 28.3 19.5 9.1 40.5 27.6 38.0 50 84.1 74.3 45.4 108.6 77.5 98.3
6 29.1 20.3 9.7 41.6 28.4 39.0 55 92.6 83.2 51.2 118.9 84.9 107.2
7 30.0 21.1 10.2 42.7 29.2 40.0 60 101.6 92.6 57.4 129.8 92.8 116.7
8 31.0 22.0 10.8 43.8 30.0 41.0 65 111.3 102.8 64.0 141.4 101.2 126.7
9 31.9 22.8 11.4 45.0 30.9 42.0 70 121.5 113.8 71.1 153.6 110.0 137.2
10 32.8 23.7 12.0 46.2 31.7 43.1 75 132.2 125.5 78.7 166.6 119.3 148.3
11 33.8 24.6 12.6 47.3 32.6 44.1 80 143.7 138.0 86.7 180.3 129.1 159.9
12 34.8 25.5 13.2 48.5 33.5 45.2 85 155.7 151.4 95.2 194.9 139.4 172.2
13 35.8 26.4 13.8 49.8 34.4 46.3 90 168.4 165.5 104.3 210.2 150.2 185.1
14 36.8 27.4 14.4 51.0 35.3 47.4 95 181.9 180.6 113.9 226.4 161.6 198.6
15 37.8 28.3 15.1 52.3 36.2 48.6 100 196.0 196.7 124.1 243.6 173.6 212.8
16 38.8 29.3 15.7 53.5 37.2 49.7 105 210.8 213.3 134.9 261.6 186.1 227.7
17 39.9 30.3 16.4 54.8 38.1 50.9 110 226.4 231.8 146.4 280.7 199.2 243.2
18 40.9 31.3 17.1 56.1 39.1 52.0 115 242.8 251.0 158.4 300.8 213.0 259.5
19 42.0 32.4 17.7 57.4 40.1 53.2 120 260.0 271.1 171.1 322.0 227.4 276.5
20 43.1 33.4 18.4 58.8 41.1 54.4 125 278.1 292.5 184.5 344.3 242.5 294.2
21 44.2 34.5 19.2 60.1 42.1 55.6 130 297.0 314.9 198.7 367.8 258.2 312.8
22 45.3 35.5 19.9 61.5 43.1 56.9 135 316.8 338.8 213.5 392.7 274.7 332.1
23 46.5 36.6 20.6 62.9 44.1 58.1 140 337.5 363.5 229.2 418.8 291.9 352.3
24 47.6 37.7 21.4 64.3 45.2 59.4 145 359.5 390.2 245.6 446.3 309.8 373.3
25 48.8 38.8 22.1 65.8 46.2 60.6 150 381.7 417.4 262.8 475.3 328.5 395.2
26 50.0 40.0 22.9 67.2 47.3 61.9 155 405.4 447.0 281.0 505.8 348.0 418.1
* BOLD Italics indicate inches of mercury
Page 1 of 1 Document: ENG-225

Revision: New
Effective: 09-00
GL Series Recommended Spare Parts List
Model 290GL
COMPRESSOR PARTS
DESCRIPTION 180GL QTY 230GL / 290GL QTY 340GL QTY 400GL QTY 475GL QTY 565GL QTY
KIT, SHAFT SEAL 391-00420M-000 1 391-00422M-000 1 391-00422M-000 1 391-00424M-000 1 391-00424M-000 1 391-00424M-000 1
KIT INCLUDES:
SEAL, SHAFT 390-004200-052 1 390-004200-052 1 390-004200-052 1 390-004240-052 1 390-004240-052 1 390-004240-052 1
O-RING, SHAFT SEAL COVER 390-004200-065 2 390-004200-066 2 390-004200-066 2 390-004220-066 2 390-004220-066 2 390-004220-066 2
INSTRUCTION, SHAFT SEAL REPLACEMENT 037-000016-000 1 037-000016-000 1 037-000016-000 1 037-000016-000 1 037-000016-000 1 037-000016-000 1
INSTRUCTION, ADDENDUM 037-000017-000 1 037-000017-000 1 037-000017-000 1 037-000017-000 1 037-000017-000 1 037-000017-000 1
KIT, SHAFT SEAL HNBR 391-N0420M-000 1 391-N0422M-000 1 391-N0422M-000 1 391-N0424M-000 1 391-N0424M-000 1 391-N0424M-000 1
SENSOR, POSITION 390-004200-L53 1 390-004200-L53 1 390-004200-L53 1 390-004200-L53 1 390-004200-L53 1 390-004200-L53 1
PACKAGE COMPONENTS
COALESCER, OIL SEPARATOR:
24" VESSEL 030-00613C-010 6 030-00613C-010 6 030-00613C-010 6 N/A N/A N/A
GASKET, MANWAY 030-00085C-000 1 030-00085C-000 1 030-00085C-000 1 030-00085C-000 1 030-00085C-000 1 030-00085C-000 1
CARTRIDGE, OIL FILTER (QTY. PER
H.S. 030-00097A-000 1 030-00097A-000 1 030-00097A-000 1 030-00097A-000 2 030-00097A-000 2 030-00097A-000 2
HOUSING 6 FILTERS PER CARTON)
O-RING, OIL FILTER COVER 520-000180-000 1 520-000180-000 1 520-000180-000 1 520-000180-000 1 520-000180-000 1 520-000180-000 1
KIT, MECHANICAL SHAFT SEAL (OIL PUMP):
HIGH STAGE 291-00010M-000 1 291-00010M-000 1 291-00010M-000 1 291-00010M-000 1 291-00010M-000 1 291-00010M-000 1
1-1/2" 520-001030-015 1 520-001030-015 1 520-001030-015 1 520-001030-015 1 520-001030-015 1 520-001030-015 1
GASKET, OIL PUMP CONNECTION
2" 520-001030-020 1 520-001030-020 1 520-001030-020 1 520-001030-020 1 520-001030-020 1 520-001030-020 1
SCREEN, OIL STRAINER 030-00051B-000 1 030-00051B-000 1 030-00051B-000 1 030-00051B-000 1 030-00051B-000 1 030-00051B-000 1
O-RING, OIL STRAINER COVER 520-000170-000 1 520-000170-000 1 520-000170-000 1 520-000170-000 1 520-000170-000 1 520-000170-000 1
VALVE, BLOCK 4-WAY - LOAD/UNLOAD 390-004200-139 1 390-004200-139 1 390-004200-139 1 390-004200-139 1 390-004200-139 1 390-004200-139 1
COIL, SOLENOID VALVE (USED IN
390-004260-139 4 390-004260-B13 4 390-004260-139 4 390-004260-139 4 390-004260-139 4 390-004260-139 4
LOAD/UNLOAD)
SCREEN, SUCTION STRAINER:
R-717 HIGH STAGE 031-01094B-004 1 031-01094B-004 1 031-01094B-004 1 031-01094B-005 1 031-01094B-005 1 031-01094B-005 1
SCREEN, MAIN OIL
TSOC H.S. 370-007595-110 1 370-007595-110 1 370-007595-110 1 370-007595-110 1 370-007595-110 1 370-007595-110 1
INJECTION STRAINER
VALVE, COMBO 370-015090-000 1 370-015090-000 1 370-015090-000 1 370-015090-000 1 370-015090-000 1 370-015090-000 1
VALVE, DRAIN 370-015130-000 1 370-015130-000 1 370-015130-000 1 370-015130-000 1 370-015130-000 1 370-015130-000 1
THERMOSIPHON OIL COOLING
ELEMENT, THERMOSTATIC 120°F 370-003240-120 1 370-003240-120 1 370-003240-120 1 370-003240-120 1 370-003240-120 1 370-003240-120 1
O-RING, SLEEVE (TYPE RF)* 370-003290-000 1 370-003290-000 1 370-003290-000 1 370-003290-000 1 370-003290-000 1 370-003290-000 1
O-RING, THERMAL ELEMENT 370-003230-001 1 370-003230-001 1 370-003230-001 1 370-003230-001 1 370-003230-001 1 370-003230-001 1
* Type RF is a new "face seal" design and is identified by a "-F" after the FES P/N on the nameplate. The RF design replaces the RT design.
Page 1 of 2 Document: GL-9

Revision: 1D
Effective: 01-12
GForce™ CONTROL PANEL
DESCRIPTION FES PART NO. QTY

PROCESSOR ASSEMBLY 726-06002M-001 1
PROGRAM NOTE 1 726-06051M-001* 1
BOARD, GPIO NOTE 4 725-06319C-001 1
BOARD, I/O RACK 725-06002B-002 1
BOARD, ANALOG OUTPUT NOTE 3 725-06320C-001 1
MODULE, AC INPUT, FOR GFORCE 120VAC NOTE 2 725-060220-002 2
MODULE, AC INPUT, FOR GFORCE 240VAC NOTE 2 725-060220-003 2
MODULE, AC OUTPUT, FOR GFORCE 24-240VAC 725-060210-004 2
RELAY, 2 POLE, 8 AMP - 120V NOTE 2 715-002940-000 1
RELAY WITH BASE, 2 POLE, 8 AMP - 120V NOTE 2 715-002930-000 1
RELAY, 2 POLE, 8 AMP - 240V NOTE 2 715-002940-002 1
RELAY WITH BASE, 2 POLE, 8 AMP - 240V NOTE 2 715-002930-003 1
BREAKER, CIRCUIT 5 AMP NOTE 3 715-003231-005 1
BREAKER, CIRCUIT 10 AMP 715-003231-010 1
BREAKER, CIRCUIT 15 AMP 715-003231-015 1
TRANSDUCER, PRESSURE, 4-20mA, 0-100 PSIA 745-007000-100 1
TRANSDUCER, PRESSURE, 4-20mA, 0-500 PSIG 745-007000-500 1
TRANSDUCER, PRESSURE, 4-20mA, 0-200 PSIA 745-007030-200 1
CABLE, TRANSDUCER 010-02214A-000 1
PROBE, TEMPERATURE, 4" LENGTH 715-00006A-000 1
PROBE, TEMPERATURE, 5.375" LENGTH 715-00006A-001 1
PROBE, TEMPERATURE, 8.375" LENGTH 715-00006A-002 1
OIL SEPARATOR TEMP PROBE REPLACEMENT 715-005100-101 1
INLET OIL TEMP PROBE REPLACEMENT 715-005100-100 1
DISCHARGE TEMP PROBE REPLACEMENT 715-005100-103 1
SUCTION TEMP PROBE REPLACEMENT 715-005100-102 1
FUSE, LOW LINE VOLTAGE TRANSFORMER 0.25A 715-060150-P25 1
FUSE, I/O RACK, 1A 715-060040-001 1
FUSE, OUTPUT MODULE, 4A 715-060030-004 1
POWER SUPPLY 24V, 3A, UL/NEC CLASS 2 715-004060-003 1
BOARD, SLIDE VALVE DIN RAIL MOUNT NOTE 3 726-00701B-001 1
CT/4-20MA CONVERTER NOTE 3 725-060230-000 1
Notes:
1. MUST INCLUDE FES JOB NUMBER, THIS PART IS AN ELECTRONIC FILE
2. SELECT PART BASED ON PANEL POWER SUPPLY
3. OPTION, MAY NOT BE USED IN ALL PANELS
4. 725-06319C-001 REPLACES 725-06200C-001 AND 725-05045C-001
The recommended spare parts listing represents those items FES believes to be prudent customer selections for continued operation with minimum downtime during routine or
emergency maintenance.
Page 2 of 2 Document: GL-9

Revision: 1D
Effective: 01-12

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INSTRUCTION MANUAL

GEA FES CUSTOMER:

P.O. NO. 001-0020416

GEA FES PROJECT NO. 03991-001

-02 COMPRESSOR MODEL 290GLE

Texas Regional Branch Office

California Regional Branch Office

Arkansas Regional Branch Office

Coupling “C” “A” “B” “D” “E”

Figure/Table 1-2: Coupling Dimensions

Figure 1-3: B-LOC Assembly

375 110 M8 X 60 28 (21)

Table 1-4: Torque Specifications for Tensioning Screws

52-350 130 (95)

52-375 176 (130)

Table 1-5: Torque Specifications for Coupling Bolts

Motor Mounting and Preliminary Alignment Procedure

Compressor Min. Shaft Gap

Table 1-7: Required Motor to Compressor Shaft Gap

Figure 1-8: Shimless Motor Mounting (SMM)

Coupling Final Alignment Procedure

Figure 1-10: Types of Coupling Misalignment

Table 1-11: Approximate Oil Charge

Figure 1-12: Liquid Injection Feed Arrangement Number 1

Figure 1-14: Liquid Injection Feed Arrangement Number 3

HIGH STAGE BOOSTER

Table 1-15: Liquid Injection Feed Requirements

TX Valve Liquid Injection Cooling

Table 1-18: Minimum Liquid Supply Volume

R-717 OCHR R-22 OCHR

Table 1-19:Maximum Capacities for Liquid Line from Condenser to Receiver

OCHR LIQ. LIQ/VAP

Table 1-21: Thermosiphon Line Size Requirements To/From Oil Cooler

Figure 1-22: Two Common Economizer Systems

GFORCE CONTROL PANEL INSTALLATION GUIDE

Figure 1-24: Improper Grounding – “Daisy Chaining”

Figure 1-25: Improper Grounding – Grounding Interconnections prior to Starter Panel

Figure 1-26: MOV Installation

General Design Limits

General Operating Parameters

Table 2-1: Operating Limitations

Figure 2-1: Typical Horizontal FES Oil Separator Schematic

Compressor Oil Cooling Systems

Figure 2-3: Single Port Liquid Injection Oil Cooling

IntelliSOCTM Liquid Injection Cooling

Figure 2-5: IntelliSOC™ Liquid Injection Oil Cooling

01 = ICM20 with ICAD 600 Actuator

Figure 2-6: ICAD Actuator

Table 2-7: ICM Valve Calibration

Figure 2-8: Jordan Valve Liquid Injection Oil Cooling

Outlet Pressure Regulating Valve Adjustment

Figure 2-9: Compressor Hydraulic System (Fixed VI)

Figure 2-10: Capacity Control Solenoid Block

Figure 2-11: Compressor Hydraulic System

Figure 2-12: VI Control Solenoid Block

Network Setup, MCP-170 GForce™ Network Installation & User's Guide.

Register Map, MCP-171 GForce™ Communications Protocol.