Form 070.

250-IOM1 (NOV 2013)

Installation – Operation – Maintenance
File: Service Manual – Section 070
Replaces: Nothing
Distribution: 3, 3a, 3b, 3c
Revised: April 2016, p. 2, 8, 16
October 31, 2022

TDS_
Rotary Screw Compressor
Models TDS_163 - TDS_355

This manual contains installation, operation, and maintenance

instructions. Read thoroughly before beginning installation. Failure
to follow these instructions may result in personal injury or death,
damage to the unit, or incorrect operation.

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

070.250-IOM1 (NOV 2013) TDS_ Rotary Screw Compressor
Page 2 Installation - Operation - Maintenance

Table of Contents
General information Operation
Preface .............................................................................. 3 Operation and start-up instructions ................................ 18
Design limitations .............................................................. 3 Initial start-up ............................................................ 18
Job inspection ................................................................... 3 Initial start-up procedure ........................................... 18
Standard bare compressor ................................................ 3 Normal start-up procedure ......................................... 18
Transit damage claims ....................................................... 3
Compressor identification ................................................. 3 Maintenance
Long-term storage............................................................. 4 General information ........................................................ 19
Preparing compressor for storage................................. 5 Normal maintenance operations ..................................... 19
Maintaining compressor................................................ 5 General maintenance................................................... 19
Description......................................................................... 5 Changing oil................................................................ 19
TDS_ compressor ......................................................... 5 Recommended maintenance program ........................ 20
Compressor lubrication system .................................... 5 Vibration analysis ............................................................ 20
Oil pump........................................................................ 6 Oil quality and analysis .................................................... 20
Construction details........................................................... 6 Maintenance schedule...................................................... 20
Operating log ............................................................. 21
Installation Troubleshooting guide ..................................................... 21
Design limits...................................................................... 7 Abnormal operation analysis and correction .............. 21
Outline dimensions............................................................ 7 Bare compressor replacement ........................................ 21
Holding charge and storage............................................. 12 Shutdown due to improper oil pressure (high-stage and
Rigging and handling........................................................ 12 booster) ................................................................... 22
Lifting instructions....................................................... 12 Troubleshooting the TDS_ compressor (Frick RWB II
Foundation ...................................................................... 12 package)................................................................... 22
Customer connections..................................................... 13 Troubleshooting the hydraulic system.............................. 22
Oil system requirements.................................................. 13 Troubleshooting the oil pump and system ....................... 23
Oil selection................................................................ 13 Read this first: compressor prestart checklist.................. 24
Oil pressure................................................................. 13 Vibration data sheet......................................................... 26
Oil cooling requirements............................................. 13
Oil filters .................................................................... 14
Oil pump.......................................................................... 14
Oil heaters ...................................................................... 14
Compressor oil................................................................. 14
Compressor...................................................................... 14
Motor mounting (foot mounted only).......................... 14
Compressor/motor coupling requirements.................. 14
Coupling alignment requirements................................ 14
Coupling alignment procedure......................................... 15
Hot alignment of compressor/motor................................ 15
SV position potentiometer
replacement and adjust­ment..................................... 15
Volumizer potentiometer
replacement and adjustment..................................... 16
Compressor hydraulic system.......................................... 16
Volumizer volume ratio control ....................................... 17
Vi increase.................................................................. 17
Vi decrease ................................................................ 17 Referenced manuals:
Low ambient operation ................................................... 17 090.020-M: Quantum LX Maintenance
Balance piston pressure regulator 160.802-SPC: Compressor Oil Specifications
for TDSH 355 compressors....................................... 17 090.022-O: Quantum HD Operation

Safety precaution definitions

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious
DANGER injury.
Indicates a potentially hazardous situation or practice which, if not avoided, will result in death or
WARNING serious injury.
Indicates a potentially hazardous situation or practice which, if not avoided, will result in damage
CAUTION to equipment and/or minor injury.

NOTICE Indicates an operating procedure, practice, etc., or portion thereof which is essential to highlight.
 TDS_ Rotary Screw Compressor 070.250-IOM1 (NOV 2013)
Installation - Operation - Maintenance Page 3

Note: T
 he information contained in this document is Standard bare compressor
subject to change without notice
Items not included with the bare compressor that are
General information available as sales order options: Solenoid Valves, Tank
Drain Tubing (T connection), Oil Feed Line (P connection),
Connection Fittings, Coupling.
Preface
This manual has been prepared to acquaint the owner and Transit damage claims
serviceman with the installation, operation, and mainte- All claims must be made by the consignee. This is an ICC
nance procedures as recommended by Johnson Controls- requirement. Request immediate inspection by the agent
Frick® for TDS_ Rotary Screw Compressors. of the carrier and be sure the proper claim forms are ex-
It is most important that these compressors be properly ecuted. Report damage or shortage claims immediately to
applied to an adequately controlled refrigerant or gas Johnson Controls-Frick Sales Administration Department,
system. Your authorized Johnson Controls-Frick represen- in Waynesboro, PA.
tative should be consulted for his expert guidance in this
determination. Compressor identification
Proper performance and continued satisfaction with these Each compressor has an identification data plate, contain-
units is dependent upon: ing compressor model and serial number mounted on the
compressor body.
• Correct installation
• Proper operation
• Regular, systematic maintenance NOTICE
To ensure correct installation and application, the equip- When inquiring about the compressor or unit, or order-
ment must be properly selected and connected to a prop- ing repair parts, provide the model, serial, and Johnson
erly designed and installed system. The Engineering plans, Controls - Frick sales order numbers from the data plate.
piping layouts, etc. must be detailed in accordance with See Figure 1.
the best practices and local codes, such as those outlined
in ASHRAE literature. Figure 1: Compressor identification data plate

A screw compressor is a vapor pump. To be certain that

it is not being subjected to pumping liquid, it is necessary
that controls are carefully selected and in good operat-
ing condition; the piping is properly sized and traps, if
necessary, are correctly arranged; the suction line has an
accumulator or slugging protection; that load surges are
known and provisions are made for control; operating
cycles and stand still periods are reasonable; and that high
side components are sized within system and compressor
design limits.
It is required that the discharge temperature be kept high
enough to prevent condensation of any moisture in the
compressor and oil separator.

Design limitations
TDS_ compressors are designed for operation within the
pressure and temperature limits which are specified by
Johnson Controls-Frick and the Johnson Controls-Frick
selection software COOLWARE™. They are primarily used
for compressing refrigerant gas and most hydrocarbon
gasses. Rotary screw compressor serial numbers are defined by the
following information:
If your application is for sour gas, there are special re-
quirements to protect the compressor. Contact Johnson Example: 10240A90000015Z
Controls - Frick Compressor Engineering for application Plant Decade Month Year Global Additional
details. seq. no. remarks
1024 0 A 9 0000015 Z

Job inspection Plant: 1024 = Waynesboro, 1153 = Monterrey

Immediately upon delivery examine all crates, boxes and Month:
exposed compressor and component surfaces for damage. A = JAN, B = FEB, C = MAR, D = APR, E = MAY, F = JUN,
Unpack all items and check against shipping lists for any G = JUL, H = AUG, K = SEP, L = OCT, M = NOV, N = DEC.
discrepancy. Examine all items for damage in transit.
070.250-IOM1 (NOV 2013) TDS_ Rotary Screw Compressor
Page 4 Installation - Operation - Maintenance

Table 1: Geometrical swept volume

Compressor model Rotor Rotor Max speed Geometrical swept volume, Displacement
diameter drive shaft end 3550 rpm 2950 rpm
mm L/D rpm  ft³/rev m³/rev cfm m³/h
TDSH 163S 163 1.35 4,500 0.10069 0.002849 357 504
TDSH 163L 163 1.7 4,500 0.12679 0.003588 450 635
TDSH/TDSL 193S 193 1.35 4,500 0.16653 0.004713 591 834
TDSH/TDSL 193L 193 1.8 4,500 0.22204 0.006284 788 1,112
TDSH/TDSL 233S 233 1.35 4,500 0.29301 0.008292 1,040 1,468
TDSH/TDSL 233L 233 1.7 4,500 0.36897 0.010442 1,310 1,848
TDSH 233XL 233 2.1 4,500 0.45580 0.012899 1,618 2,283
TDSH/TDSL 283S 283 1.35 4,200 0.52501 0.014858 1,864 2,630
TDSH/TDSL 283L 283 1.7 4,200 0.66115 0.018711 2,347 3,312
TDSH 283SX 283 2.1 4,200 0.79546 0.022512 2,824 3,985
TDSH/B 355S 355 1.1 4,200 0.89858 0.025430 3,190 4,501
TDSH/B 355L 355 1.5 4,200 1.12154 0.031739 3,981 5,618
TDSH/B 355XL 355 1.9 4,200 1.42748 0.040398 5,068 7,150
TDSB 355U 355 2.4 4,200 1.80328 0.051033 6,402 9,033

Additional Remarks: Long-term storage

R = Remanufactured;
Long term storage (6 months to 5 years) provisions are re-
R1 = Rebuild;
quired, regardless of storage environment, if start-up and/
R2 = Rebuild Plus;
or useful operation does not occur within six (6) months of
Z = Deviation from Standard Configuration.
equipment shipment. Special provisions may be required
The name plates in Figure 2 show which refrigerants are for storage of less than six (6) months if the storage area
compatible with the compressor as manufactured. is subject to unusual environment such as high humidity,
large changes in temperature, dusty atmosphere, etc.
Figure 2: Refrigerant name plates The standard Johnson Controls-Frick Warranty for an
TDS_ screw compressor covers twelve (12) months from
start-up or 18 months from shipment, whichever comes
first. It is recommended that arrangements be made with
the local Johnson Controls-Frick service organization
(arranged through factory service) regarding surveillance
and maintenance during the storage period. It will be
the customer’s responsibility to submit a monthly report
showing the condition of the unit and noting any discrep-
ancies to the guidelines listed herein. Failure to comply
with this Long Term Storage Recommendation may void
the warranty.

Table 2: Compressor and packaged equipment storage log

Model Serial no. Compressor* shaft Rotor Charge Visual Charge Checked by Date
rotation 1½ turn housing added inspection
charge per QAI-3

*Compressor, Motor, Oil Pump and Refrigerant Pump

 TDS_ Rotary Screw Compressor 070.250-IOM1 (NOV 2013)
Installation - Operation - Maintenance Page 5

Long term storage of equipment may lead to the deterio- Description

ration of components over the period of time. Synthetic
components in the compressor may deteriorate over time TDS_ compressor
even if they are kept flooded with oil. A warm and dry The Frick TDS_ rotary screw compressor utilizes mating
environment is essential to minimize environmental and asymmetrical profile helical rotors to provide a continu-
corrosion damage. Long-term storage of the affected ous flow of refriger­ant vapor and is designed for both high
equipment at a customer’s site may involve additional pressure and low pressure applica­tions. The compressor
requirements and interested parties should refer to the incorpor­ates the following features:
Johnson Controls web site,
www.johnsoncontrols.com/frick, for specific instructions. 1. High capacity roller bearings to carry radial loads at
both the inlet and outlet ends of the compres­sor.
The following guidelines must be followed to maintain the
screw compressor warranty. 2. Heavy‑duty, two-point or four-point angular contact
ball bearings to carry axial loads are mounted at the dis-
Preparing the compressor for storage charge end of compressor.
1. Evacuate the compressor to remove moisture. 3. Balance piston located in the inlet end of the compres­
sor to reduce axial loads on the axial load bearings and
2. Connect the evacuation lines to the three Schrader ac-
increase bearing life.
cess valves provided with the compressor. One valve is
connected to the compressor suction and the other two 4. Moveable slide valve to provide infinite step capacity
valves are located at the block on the cylinder. control from 100 to 10%.
3. Break the vacuum with dry nitrogen and bring pressure 5. Volumizer volume ratio control to allow infinite­ly variable
to 0 psig volume ratio from 2.2 to 5.0 during compres­sor operation
for all models except TDSH 283SX which is 2.2 to 4.2.
4. Pump oil into the SM1. Use break-in oil P/N
111Q0831809 for storage purposes. The amounts of oil 6. A hydraulic unloader cylinder to operate the slide stop
needed per compressor are: and slide valve.
• 163 mm - 8 gal 7. Bearing and casing design for 400 PSI discharge pres-
• 193 mm - 12 gal sure. This PSI rating applies only to the compressor and
• 233 mm - 15 gal does not reflect the design pressure of the various system
• 283 mm - 25 gal components.
• 355 mm - 35 gal 8. All bearing and control oil vented to closed thread in the
5. After the compressor is oil charged, pressurize the com- compressor instead of suction port to avoid performance
pressor to 15 psig with nitrogen. penalties from superheating suction gas.
9. Shaft seal design to maintain operating pressure on seal
Maintaining the compressor well below discharge pressure, for increased seal life.
1. Maintain the 5 psig to 15 psig nitrogen charge, but ide-
10. Oil injected into the rotors to maintain good volumet-
ally at 15 psig.
ric and adiabatic efficiency even at very high compression
2. Rotate the male rotor shaft every two weeks. Mark the ratios.
shaft to ensure the rotor does not return to the original
position.. 11. Shaft rotation clockwise facing compressor shaft, suit-
able for all types of drives.
3. Store the compressor inside a dry building environment.
4. Grease the male rotor shaft to prevent rust. WARNING
5. Record all information in a compressor long-term Compressor rotation is clockwise when facing the
storage log. See Table 2. compressor drive shaft. The compressor should never
be operated in reverse rotation, as bearing damage
Contact Johnson Controls-Frick Service with any ques- will result.
tions regarding long term storage.
12. Dual compressor casing design for very low airborne
noise transmission.

Compressor lubrication system

The lubrication system on a TDS_ screw compressor
performs several functions:
1. Provides lubrication to bearings and seal.
2. Provides a cushion between the rotors to minimize noise
and vibrations.
3. Helps keep the compressor cool and prevents overheating.
070.250-IOM1 (NOV 2013) TDS_ Rotary Screw Compressor
Page 6 Installation - Operation - Maintenance

4. Provides an oil supply to hydraulically actuate the slide Volumizer variable volume ratio control: The Frick com-
valve and slide stop. pressor includes a method of varying the internal volume
5. Provides oil pressure to the balance piston to help increase ratio to match the system pressure ratio. Control of the
bearing life. internal volume ratio eliminates the power penalty associ-
ated with over- or under-compression. Volume ratio control
6. Provides an oil seal between the rotors to prevent rotor is achieved by the use of a slide stop which is a movable
contact or gas bypassing. portion of the rotor housing that moves axially with the
rotors to control discharge port location. The slide stop is
Oil pump moved by hydraulic actuation of a control piston. The range
A demand oil pump is required for low differential pres- of adjustment is listed in Table 3.
sure applications (CoolWare™ will provide a warning when Stepless capacity control: Capacity control is achieved by
the oil differential pressure is too low). Oil being supplied use of a movable slide valve. The slide valve moves axially
to the compressor from the oil separator is at system dis- under the rotors to provide fully modulated capacity con-
charge pressure. Within the compressor, oil porting to all trol from 100% to minimum load capacity. Minimum load
parts of the compressor is vented back to a location in the capacity varies slightly with compressor model, pressure
compressor’s body that is at a pressure lower than com- ratio, discharge pressure level, and rotor speed. See the
pressor discharge pressure. All oil entering the compressor Table 1 for minimum capacity for all TDS_ models.
is moved by the compressor rotors out the compressor
outlet and back to the system oil separator. The slide valve is positioned by hydraulic movement of its
control piston. When in the unloaded position, gas is by-
Construction details passed back to suction through a recirculation slot before
compression begins and any work is expended, providing
Housing: All TDS_ screw compressor castings are close the most efficient unloading method available for part-
grain, pressure tight, grey cast iron to ensure structural load operation of a screw compressor.
integrity and mechanical and thermal stability under all
operating conditions. Ductile iron and steel housings are Table 3: Compressor volume and capacity ratio
also available for special applications. Contact Johnson
Model Min Max Min. Slide Slide
Controls – Frick Sales for additional information. Vi* vi* Capa- valve stop
Rotors: The rotors are made from the highest quality city travel travel
rolled steel to exacting tolerances of the latest industry % (in.) (in.)
standard asymmetric profile. The four-lobed male rotor
is directly connected to the driver. The six-lobed female
rotor is driven by the male on a thin oil film.
Bearings: Antifriction bearings with L10 rated life in TDSH 163S 2.2 5.0 5.494 2.140
excess of 50,000 hours (using the Frick Superfilter™) at TDSH 163L 2.2 5.0 6.918 2.694
design conditions are used for reduced frictional horse- TDSH 193S 2.2 5.0 6.497 2.530
power and superior rotor positioning, resulting in reduced TDSL 193L 2.2 5.0 8.662 3.374
Refer to Coolware™

power consumption, particularly at higher pressure ratios. TDSH 233S 2.2 5.0 7.843 3.055
Cylindrical roller bearings are provided to handle the TDSH 233L 2.2 5.0 9.877 3.847
radial loads and the thrust loads are absorbed by two-
TDSH 233XL 2.2 5.0 9.889 4.752
point or four-point angular contact bearings. In addition,
TDSH 283S 2.2 5.0 9.526 3.710
a thrust balance piston is provided to reduce the thrust
load and improve bearing life. TDSH 283L 2.2 5.0 11.996 4.672
TDSH 283SX 2.2 4.2 11.951 4.680
Shaft seal: The compressor shaft seal is a single-face TDSH/B 355S 2.2 5.0 10.360 5.690
type with a spring-loaded carbon stationary surface riding TDSH/B 355L 2.2 5.0 14.127 5.031
against a cast iron rotating seat. The seal is capable of TDSH/B 355XL 2.2 5.0 15.443 6.373
withstanding static pressure up to 400 psig. During opera-
TDSB 355U 2.4 4.5 15.482 6.399
tion it is vented to low pressure to provide extended life.
* Optional 1.7 min. to 3.0 max.
 TDS_ Rotary Screw Compressor 070.250-IOM1 (NOV 2013)
Installation Page 7

Installation
Design limits
General information for all of the models is provided be-
low. Please see CoolWare to determine the limits for a
specific application.
TDS_ units are arranged for direct motor drive and require
a flexible drive coupling to connect the compressor to
the motor. The rotor and bearing design set limitations
must not be exceeded (See CoolWare). Refer to Johnson
Controls - Frick Compressor Control Panel instruction
090.022-O for additional information on setpoint limits.

Outline dimensions
Drawings for reference only can be found on the following
pages. Complete dimensions and access connections can
be found on the outline drawings.
TDSH 163 DWG# 534E0424
TDSH 193 DWG# 534E0425
TDSL 193 DWG# 534E0591
TDSH 233 1.35 & 1.7 DWG# 534D0224
TDSH 233 2.1 DWG# 534E0499
TDSL 233 DWG# 534D1025
TDSH 283 1.35 & 1.7 DWG# 534E0054
TDSH 283 2.1 DWG# 534E0605
TDSL 283 1.35 & 1.7 DWG# 534E0582
TDSL 283 2.4 DWG# 534E0583
TDXB 355 S, L, XL, U DWG# 534E1406
TDXH 355 S, L, XL, U DWG# 534E1406

If you do not have these drawings, please request any you
require by contacting Johnson Controls - Frick sales.
070.250-IOM1 (NOV 2013) TDS_ Rotary Screw Compressor
Page 8 Installation

Figure 3: Compressor port locations, 163/193

Symbol Size
SC-1 3/8-18 NPTF
SC-2 3/8-18 NPTF
SC-3 3/8-18 NPTF
SC-4 3/8-18 NPTF
SC-5 3/8-18 NPTF
SC-6 3/8-18 NPTF
SC-7 1/8-27 NPTF
SC-8 1-11½ NPTF
SC-9 3/8-18 NPTF
SC-10 3/4-14 NPTF
SC-11 3/4-14 NPTF
SC-13 3/8-18 NPTF
SB-2 3/8-18 NPTF
SB-3 3/4-14 NPTF
SM-1 3/8-18 NPTF
SV-1 1¼ SQ flange
SL-1 3/4-14 NPTF
SL-2 3/4-14 NPTF
SE-1 1/2-14 NPTF
SE-2 1/2-14 NPTF
SD-1 3/4-16 UNF-2B
 TDS_ Rotary Screw Compressor 070.250-IOM1 (NOV 2013)
Installation Page 9

Figure 4: Compressor port locations, 233

Symbol Size
SB-2 3/8-18 NPTF
SB-3 3/4-14 NPTF
SC-1 3/8-18 NPTF
SC-2 3/8-18 NPTF
SC-3 3/8-18 NPTF
SC-4 3/8-18 NPTF
SC-5 3/8-18 NPTF
SC-6 3/8-18 NPTF
SC-7 1/8-27 NPTF
SC-8 1-11½ NPTF
SC-9 3/8-18 NPTF
SC-10 3/4-14 NPTF
SC-11 3/4-14 NPTF
SC-12 3/8-18 NPTF
SD-1 1 1/16-12 UN-2B
SL-1 3/4-14 NPTF
SL-2 3/4-14 NPTF
SM-1 3/4-14 NPTF
SV-1M 1½ SQ flange
070.250-IOM1 (NOV 2013) TDS_ Rotary Screw Compressor
Page 10 Installation

Figure 5: Compressor port locations, TDS_ 283

Symbol Size
SB-2 3/4-14 NPTF
SB-3 1-11½ NPTF
SC-1 3/8-18 NPTF
SC-2 3/8-18 NPTF
SC-3 3/8-18 NPTF
SC-4 1/2-14 NPTF
SC-5 3/8-18 NPTF
SC-6 3/8-18 NPTF
SC-7 1/8-27 NPTF
SC-8 1-11½ NPTF
SC-9 1¼-11½ NPTF
SD-1 1 1/16-12 UN-2B
SL-1 1-11½ NPTF
SL-2 1-11½ NPTF
SM-1 1-11½ NPTF
ST-1 2 SQ flange
 TDS_ Rotary Screw Compressor 070.250-IOM1 (NOV 2013)
Installation Page 11

Figure 6: Compressor port locations, TDS_ 355

Symbol Size
SB-2 3/4-14 NPTF
SB-3 1½-11½ NPTF
SC-1 1/2-14 NPTF
SC-2 1/2-14 NPTF
SC-3 1/2-14 NPTF
SC-4 1/2-14 NPTF
SC-5 3/8-18 NPTF
SC-6 3/4-14 NPTF
SC-7 1/8-27 NPTF
SC-8 1¼-11½ NPTF
SC-9 1½-11½ NPTF
SD-1 1 1/16-12 UN-2B
SL-1 2½-12 NPTF
SL-2 2½-12 NPTF
SM-1 2" FLANGE
ST-1 3¼-14 NPTF
SV-1 3 in. FLANGE
TW-1 3/4-14 NPTF
070.250-IOM1 (NOV 2013) TDS_ Rotary Screw Compressor
Page 12 Installation

Holding charge and storage Lifting instructions

Every TDS_ compressor is pressure and leak tested at the Lifting rings are located to facilitate the rigging and lifting
Johnson Controls–Frick factory and then thoroughly evacu- of the bare compressor. See Figure 8. Ensure only a quali-
ated and charged with dry nitrogen to ensure its integrity fied operator performs the lifting and that they follow the
during shipping and short term storage prior to installation. necessary precautions.

All compressors must be kept in a clean, dry location • L ift rings are intended for lifting the bare compressor
to prevent corrosion damage. Compressors that will be only.
stored for more than two months must have their nitro- • E
 xamine the lift rings for damage before lifting the
gen charge checked periodically (see pages in GENERAL compressor. Replace any damaged rings
INFORMATION for complete instructions).
• F
 ully screw in the lift rings and seat them firmly against
WARNING the contact surface before lifting.
• L oad the lift rings in the vertical direction only; that
Holding-charge shipping gauges (if mounted) are rated is, ensure the load is parallel to the threaded portion
for 30 psig and are for checking the shipping charge
of the lift ring. See Figure 8. This may require the use
only. They must be removed before pressure testing
of a spreader beam. Loading the lift rings at an angle
and operating the system. Failure to remove these
gauges may result in catastrophic failure of the gauge reduces their load capacity.
resulting in serious injury or death. • E
 nsure that the load is level and stable before lifting
more than a few inches.
Access valves are bronze and they must be replaced
with steel plugs when package is assembled. • Lift the compressor slowly.
• R
 emove the lift rings from the compressor before
CAUTION operation. The vibration of a running compressor can
cause the lift rings to loosen and become damaged.
This equipment has been pressurized with nitrogen
gas. Temporary valves and gauges have been Figure 8: Lifting rings orientation
installed.
1. Relieve pressure before opening lines or making
field connections.
2. Remove charging valves or gauges before pressur-
izing system.
3. Refer to installation operation and maintenance
manual for additional information.

Escaping gas may cause injury.

Foundation
Each TDS_ Rotary Screw Compressor is shipped mounted
Rigging and handling on a wooden skid, which must be removed prior to unit
The compressor can be moved with rigging, using a crane installation.
or forklift, by hooking into the two lifting rings on the main
housing (some models only have one ring). The compres-
sor lifting rings shall only be used to lift the compressor CAUTION
itself. See the following figure. Allow proper spacing for servicing (see Dimensional
Outline Drawing).
Figure 7: Lifting rings, model 355
The first requirement of the compressor foundation is that
it must be able to support the weight.
163S 1,220 lb 233S 2,670 lb
163L 1,280 lb 233L 2,950 lb
193S 1,720 lb 233XL 3,300 lb
193L 1,895 lb 283S 4,100 lb
355S 7,200 lb 355XL 9,200 lb
355L 8,240 lb 355U 10,200 lb
Screw compressors are capable of converting large quan-
tities of shaft power into gas compression in a relatively
small space. The compression process creates relatively
high frequency vibrations that require sufficient mass in
the base to effectively dampen them.
 TDS_ Rotary Screw Compressor 070.250-IOM1 (NOV 2013)
Installation Page 13

The best insurance for a trouble-free installation is to Oil system requirements

firmly anchor the compressor to a suitable foundation
using proper bolting and by preventing piping stress from
being imposed on the compressor. Once the compressor
WARNING
is rigged into place, its feet must be shimmed to level it. Access valves in brass material must be removed and
There must be absolutely no stresses introduced into the the holes filled with steel plugs when package is as-
compressor body due to bolting of the feet and flanges. sembled.

In any screw compressor installation, suction and dis- Figure 9: Caution/identification tag on access valve
charge lines should be supported in pipe hangers (pref-
erably within 2 ft of vertical pipe run) so that the lines
won’t move if disconnected from the compressor. See the
following table for allowable flange loads.

Table 4: Allowable flange loads

Noz. Moments (ft-lbf) Load (lbf)
size Axial Vert. Lat. Axial Vert. Lat.
NPS MR MC ML P VC VL
1 25 25 25 50 50 50
1.25 25 25 25 50 50 50 The oil system must provide oil to the compressor within
1.5 50 40 40 100 75 75 limitation on:
2 100 70 70 150 125 125 • Oil selection
3 250 175 175 225 250 250 • Oil pressure
4 400 200 200 300 400 400 • Oil temperature
5 425 400 400 400 450 450
• Oil cleanliness
6 1,000 750 750 650 650 650
8 1,500 1,000 1,000 1,500 900 900
10 1,500 1,200 1,200 1,500 1,200 1,200 Oil selection
14 2,000 1,800 1,800 1,700 2,000 2,000 The selected oil most be suitable for the application,
refrigerant and operation condition. The compressor
bearing require a minimum viscosity based on size and
Customer connections speed, rpm. A maximum viscosity of 100 cSt should not be
As a minimum you must connect to the following locations exited. Frick compressor oils per 160.802-SPC are recom-
in addition to suction and discharge. mended. Frick Coolware compressor selection program in-
SB-2 Inlet Bearings and Balance Piston clude properties for the Frick oils and provide information
SB-3 Compressor oil supply on viscosity requirement for a given compressor selection.
SM-1 Main oil injection
SC-1 Slide Valve Unload Port Oil pressure
SC-2 Slide Valve Load Port The complete oil system shall be designed for a pressure
SC-3 Volume Ratio Increase Port drop no higher than 15 psi with a clean oil filter element.
SC-4 Volume Ratio Decrease Port These is critical for the proper function of the balance
SD-1 Coalescer Bleed piston and ensure the life of the axial bearings. At booster,
low pressure and low pressure ratio operation an oil pump
Other connections are available for instrumentation and
must be build in to provide sufficient oil pressure.
service as noted on the Dimensional Outline drawing. The
electrical connections for the slide stop and the slide valve The control system should have means to check the oil
transmitters and the solenoid valve coils must be connected pressure and compare to both suction and discharge pres-
to your control system. sure. In general oil pressure shall be minimum (1.5 times
the suction pressure +15 psi) and higher than (discharge
The oil supply system for the compressor must be de- pressure – 25 psi). For application with economizer and/or
signed for a total pressure drop of no more than 15 psi sideload the oil pressure shall additional be more than 15
with a new oil filter element. This is critical for the proper psi above the pressure at the side port when in operation.
operation of the balance piston which is used to ensure
the life of the male axial bearing. Excessive pressure drop Advanced control systems like the Frick Quantum will
in the oil circuit can also prevent proper operation of the check on the oil pressure in many more ways in order to
slide valve and slide stop pistons. keep the compressor running beyond these basic lim-
its e.g. keep compressor running safely in partial loaded
condition.

Oil cooling requirements

Compressor oil needs to be cooled to control the discharge
temperature, maintain proper oil viscosity and to preserve
the life of the oil. Normally the discharge temperature will
be in the 170° to 180°F range (see CoolWare™).
070.250-IOM1 (NOV 2013) TDS_ Rotary Screw Compressor
Page 14 Installation

One application that typically requires higher discharge Compressor oil

temperatures (as high as 250°F) is natural gas gathering at
the wellhead. Moisture is normally present in the gas and
it is imperative that the discharge temperature be at least WARNING
40°F higher than the discharge dew point temperature for DO NOT MIX OILS of different brands, manufacturers,
the gas. Run Coolware with the “Water Saturated” block or types. Mixing of oils can cause excessive oil foam-
checked to get the discharge dew point temperature for ing, nuisance oil level cutouts, oil pressure loss, gas or
your application. Oil temperatures as high as 170°F can oil leakage and catastrophic compressor failure. For
be used to achieve the necessary discharge temperature most applications, CoolWare will select a specific Frick
to prevent moisture from condensing in the oil separator. oil for the gas/refrigerant being used. Depending on
Contact Johnson Controls–Frick for additional information the application, a different oil can be selected provided
it is of the proper viscosity and is compatible with the
for natural gas compression.
gas/refrigerant and compressor elastomers.
The main oil injection line that is connected to port SM1
must have a regulating valve to permit adjustment of the Compressor
oil flow to maintain the desired discharge temperature at Compressor rotation is clockwise when facing the end of
all times. the compressor shaft
The use of a three-way mixing valve is recommended Confirm motor will rotate the compressor clockwise be-
to keep the oil temperature in the normal range of 120° fore installing the coupling.
- 140°F. The valve will provide warm oil to the compres-
sor quickly, reducing the pressure drop caused by cold, Motor mounting (foot mounted only)
viscous oil. This ensures proper oil flow and temperature 1. Thoroughly clean the motor feet and mounting pads of
over the full range of operating conditions. grease, burrs, and other foreign matter to ensure firm
seating of the motor.
Oil filters 2. Attach the motor to the base using bolts and motor rais-
ing blocks, if required.
Use of filter elements other than Johnson Controls-Frick 3. Weld the four kick bolts (not included with compressor)
must be approved in writing by Johnson Controls-Frick into place so that they are positioned to allow movement
engineering or a warranty claim may be denied. Typical oil of the motor feet.
filter specification is 5 micron absolute (98.6% effecient)
4. After the motor has been set, check to see that the
per ISO 4572 to obtain the recommended oil cleanliness.
shafts are properly spaced for the coupling being used.
Check the appropriate Dimensional Outline drawing for
Oil pump the minimum clearance required between the shaft ends
If your TDS_ compressor application requires an oil pump, to change the shaft seal.
it is recommended that a strainer be mounted upstream
to protect it. Frick supplied pumps are a positive displace- Compressor/motor coupling requirements.
ment gear type that must have a safety relief valve to Frick TDS_ compressors are arranged for direct motor
ensure the oil pressure will not be more than 50 psi above drive and require a flexible drive coupling to connect the
compressor discharge pressure for all models. compressor to the motor.
With a foot-mounted motor, it is essential that the
CAUTION coupling be properly aligned to ensure proper bearing and
seal performance.
If oil pressure exceeds 55 PSI above compressor dis-
charge it could cause catastrophic compressor failure 1. Coupling must be selected and installed so that it doesn’t
due to male axial bearing failure. See CoolWare™ for transmit any axial load to the compressor shaft.
your application’s requirements. 2. Set up the minimum distance between compressor shaft
and motor shaft to allow for seal removal (see Outline
Oil heaters drawings).
3. Coupling must be able to take up any misalignment
Your package must be equipped with oil heaters that
between motor and compressor. It is critical to the life of
provide sufficient heat to prevent condensation from
the shaft seal that misalignment is kept to the minimum
occurring during shutdown cycles.
possible value. Be sure to follow the coupling manu-
facturer’s guidelines for checking and correcting any
misalignment. See the next section for Johnson Con-
trols–Frick requirements.
Coupling alignment requirements
Coupling alignment must be performed prior to start-up.
After the compressor has been installed on the job site,
alignment must be checked again and if necessary cor-
rected prior to start-up. After a few hours operation, the
alignment must be checked while the package is still hot.
Correct hot alignment is critical to ensure the life of the
shaft seal and compressor bearings.
 TDS_ Rotary Screw Compressor 070.250-IOM1 (NOV 2013)
Installation Page 15

Maximum radial runout is .004 in. total indicator reading. SV position potentiometer
Maximum axial runout is .004 in. total indicator reading.
replacement and adjust­ment
A dial indicator or another appropriate measuring device is The Slide Valve Position potentiometer is located on the
to be used to determine the Total Indicator Runout. end of the compressor unloader cylinder. See Figure 10.

Indicator bracket sag must be checked as all brackets have Figure 10: Potentiometer
some flexibility. The best way to measure this is to attach
the dial indicator and bracket on a pipe at the coupling span
distance. Zero the indicator in the 12:00 position, and rotate FLEXIBLE
the pipe so the indicator is in the 6:00 position. The reading CO UPLING
on the indicator in the 6:00 position is the bracket sag. This
PO TENTIO M ETER
value must be included in the dial indicator readings when
affixed to the coupling for an accurate alignment.

Coupling alignment procedure

The life of the compressor shaft seal and bearings, as
well as the life of the motor bearings, is dependent upon
proper coupling alignment. Couplings may be aligned at
the factory but realignment must always be done on the
job site after the unit is securely mounted on its founda­ LO CKNUT
tion. Initial alignment must be made prior to start-up and
rechecked after a few hours of operation. Final (HOT) field
alignment can only be made when the unit is at operating
CO VER
tempera­ture. After final (HOT) alignment has been made
and found to be satisfac­tory for approximately one week,
the motor may be dowelled to maintain align­ment.
1. Shut off control power.
NOTICE 2. Remove the four socket head cap screws securing the
Frick recommends cold aligning the motor .005” high. potentiometer cover to the unloader cylinder.
This cold misalignment compensates for thermal growth
when the unit is at operating temperature. 3. Unsolder leads to the potentiometer and remove.
4. Loosen the setscrew on the potentiometer side of the
Hot alignment of compressor/motor flexible coupling.
Hot alignments can only be made after the unit has oper- 5. Remove the locknut to remove the potentiometer
ated for several hours and all components are at operating from the base plate. The potentiometer should slip out
temperatures. of the coupling. For early versions, three retainer clips
Shut down the unit and quickly affix dial indicator to cou- that secure the poten­tiometer to the base plate will need
pling motor hub, then take readings of both the face and removed.
rim of the compressor hub. If these readings are within 6. Install the new potentiometer and reassemble.
tolerance, record reading, attach coupling guard and
restart unit. However, if the reading is not within limits, 7. Adjustment:
compare the hot reading with the cold alignment and ad- Rough adjustment is made with the slide valve fully un-
just for this difference; i.e. if the rim at 0° and 180° read- loaded and the control power off. Remove connector P5.
ings indicates that the motor rises 0.005 in. between its With a digital voltmeter, measure the resistance across the
hot and cold state, 0.005 in. of shims should be removed red and white wires, having removed them from the SBC.
from under the motor. The resistance should be 1000 +/‑ 50 ohms. If adjustment
After the initial hot alignment adjustment is made, restart is necessary, loosen the locknut and rotate the potenti-
ometer clockwise or counterclock­wise until the resistance
unit and bring to operating temperature. Shut down and
reading is a close to a 1000 ohms as possible. Retighten
recheck hot alignment. Repeat procedure unit hot align-
the locknut and replace wires.
ment is within specified tolerance.
NOTICE
CAUTION Mechanical travel of the slide valve potentio­meter is 300
Install coupling guard before operating compressor. degrees rotation when the slide stop is confirmed to be
in the 2.2 Vi position. The travel will be less than 300
degrees if the slide stop is in any position above 2.2 Vi.

Fine adjustment must be made with the slide valve fully

unloaded and the compressor running. The Operating
display at this time should indicate a slide valve position of
0%. If the display is greater than 0%, adjust potentio­meter
070.250-IOM1 (NOV 2013) TDS_ Rotary Screw Compressor
Page 16 Installation

POT #4 on the SBC until 0% is indicated. If 0% is not at- POT #1 on the SBC until 5.0 (4.2 for TDSH 283SX, 4.5
tainable, get as close as possible and then proceed to the for TDSB 355U) is indicated. Repeat this sequence until
next step. The adjust­ments of POT #4 and POT #3 are the slide stop indicates 2.2 when fully decreased and
interactive and POT #3 may require adjustment to allow 5.0 (4.2 for TDSH 283SX, 4.5 for TDSB 355U) when fully
POT #4 to come into range. increased.
Completely load the slide valve. The display at this time
should indicate 100%. If the display is less than 100%, NOTICE
adjust potentiometer POT #3 on the SBC until 100% is
The total travel on the volumizer® potentiometer is
indicated. .394 in.
Repeat this sequence until the slide valve indicates 0%
fully unloaded and 100% fully loaded. Compressor hydraulic system
(The solenoid valves and manifold block are available as a
Volumizer potentiometer sales order option)
replacement and adjustment The compressor hydraulic system moves the movable
The volumizer potentiometer is located under a cover on
the right side of the compressor (facing shaft) at the inlet slide valve (MSV) to load and unload the compressor. It
end. See Figure 11. also moves the movable slide stop (MSS) to increase or
decrease the compressor’s volume ratio (Vi).
1. Shut off control power.
The hydraulic cylinder located at the inlet end of the TDS
2. Remove the potentiometer cover and gasket.
compressor serves a dual purpose. It is separated by a
3. Remove the potentiometer and mounting bracket. fixed bulkhead into two sections. The movable slide valve
4. Install new potentiometer and bracket. (MSV) sec­tion is to the left of the bulkhead and the mov-
able slide stop (MSS) to the right. Both sections are con-
Figure 11: Potentiometer sidered double acting hydraulic cylinders as oil pressure
moves the pistons in either direction.
Both sections are controlled by double‑acting, four‑way
solenoid valves which are actuated when a signal from the
appropriate micropro­cessor output energizes the solenoid
valve.
Compressor Loading: The compressor loads when MSV
solenoid YY2 is energized and oil flows from the oil
manifold through valve ports P and B to cylinder port SC‑2
and enters the load side of the cylinder. Simultaneously,
oil con­tained in the unload side of the cylinder flows out
cylinder port SC‑1 through valve ports A and T to com­
pressor closed thread port.
Compressor Unloading: The compressor un­loads when
MSV solenoid YY1 is energized and oil flows from the oil
manifold through valve ports P and A to cylinder port SC‑1
and enters the unload side of the cylinder. Simultaneous­
ly, oil contained in the load side of the cylinder flows out
compressor port SC‑2 through valve ports B and T to
com­pressor closed thread port.

 djustment must be made with the compressor running

5. A
and the slide valve fully unloaded. With the slide stop NOTICE
at maximum (Vi) position, check that the potentiometer High Stage Operation: An alternative piping arrange-
pushrod is in contact with the slide stop pushrod. If not, ment has been provided to increase slide valve response
the bracket must be ground or trimmed until contact is time during high stage operation.
made. Complete­ly decrease the slide stop. The Operat-
ing display at this time should indicate a (Vi) of 2.2. If
greater than 2.2, adjust potentio­meter POT #2 on the CAUTION
SBC until 2.2 is indicated. If 2.2 is not ob­tainable, get as Never open valve 1 and valve 2 at the same time during
close as possible and proceed to the next step. Adjust- compressor operation.
ment of POT #2 and POT #1 are interac­tive and POT #1
may require adjustment to allow POT #2 to come into Higher operating pressures will slow the com­pressor
range. Now, completely increase the slide stop. The unloading response time. Unloading response time can be
display at this time should indicate a (Vi) of 5.0 (4.2 for increased by closing valve 1 (oil manifold pressure) and
TDSH 283SX, 4.5 for TDSB 355U). If less than 5.0 (4.2 for opening valve 2 to compressor suction pressure. See Figure
TDSH 283SX, 4.5 for TDSB 355U), adjust poten­tiometer 13.
 TDS_ Rotary Screw Compressor 070.250-IOM1 (NOV 2013)
Installation Page 17

Figure 12: MSV and MSS hydraulic cylinder and solenoid valves

Volumizer volume ratio control Figure 13: Pressure regulating valve

Vi increase 954A0014H01 PRESSURE-REG ULATING VALVE (A4ALE)

FRO M
The volume ratio Vi is increased when MSS solenoid YY3 is TO SB-2 CO M PRESSO R
CO M PRESSO R DISCHARG E O R
energized and oil flows from the oil manifold through valve PO RT O IL M ANIFO LD
ports P and A to cylinder port SC‑3 and enters the increase
side of the cylinder. Simul­taneous­ly, oil contained in the 951A0007H01 (O R H03)
decrease side of the cylinder flows out cylinder port SC‑4 SO LENO ID VALVE
through valve ports B and T to compressor closed thread
port. 534B0325H01 1/8"RESTRICTIO N O RIFICE FRO M O IL
M ANIFO LD
BLPSPREG
Vi decrease
The volume ratio Vi is decreased when MSS solenoid YY4 High-stage SB-2 oil supply line diagram: Shows the three
is ener­gized and oil flows from the oil manifold through additions described below arranged in parallel.
valve ports P and B to cylinder port SC‑4 and enters the
decrease side of the cylinder. Simul­taneous­ly, oil contained Pressure-regulating valve: Discharge pressure determines
in the increase side of the cylinder flows out cylinder port compressor thrust balance. The proper setting for the
SC‑3 through valve ports A and T to compressor closed pressure-regulating valve is 50 psi below DISCHARGE pres-
thread port. sure. This pressure may vary based on operating conditions.

Solenoid valve: Energizing, or opening, the solenoid valve

Low ambient operation pressurizes the balance piston with full oil pressure from the
It is recommended that package oil separators be insu- oil manifold, bypassing the A4ALE Pressure Regulating Valve.
lated as a minimum requirement to preserve the heat De-energizing, or closing, the solenoid valve pressurizes
generated by the oil heaters, to prevent condensation and the balance piston with oil pressure regulated by the A4ALE
secure lubrication at start-up. Pressure Regulating Valve.

Signals from the control panel operate the solenoid valve

Balance piston pressure regulator (output module 12 on Frick micro panel). The solenoid valve
for TDSH 355 compressors should open when the slide valve position is 70% or greater,
A Balance Piston Pressure Regulator is required to reduce and close when the slide valve position is 65% or less. These
the extended overbalance from the thrust balance piston may vary based on operating conditions.
at part load.
Orifice: The orifice ensures oil supply to the inlet end bear-
ings during upset conditions such as start-up.
070.250-IOM1 (NOV 2013) TDS_ Rotary Screw Compressor
Page 18 Operation

Operation Initial start-up

Prior to the start-up, the prestart check must be
accomplished. See Forms section for Checklist.
Operation and start-up instructions
The Frick TDS_ Rotary Screw Compressor will be a com-
ponent in an integrated system. As such the compressor
Initial start-up procedure
requires some specific operation and conditions to ensure Having performed the prestart check, the compressor unit
trouble-free running. is ready for start-up. It is important that an adequate gas
load be available to load test the unit at normal operating
The information in this section of the manual provides the conditions. The following points should be kept in mind
logical step-by-step instructions to properly start up and during initial start-up.
operate the TDS_ Rotary Screw Compressor in your Unit.
Only matters which may influence the proper operation of 1. For proper and safe operation, the compressor must be
the TDS_ compressor are included. run at the proper speed and discharge pressure. Exceeding
design conditions creates a potential hazard.

NOTICE 2. After 1 to 3 hours of operation adjust oil cooling system.

3. Pull and clean suction strainer after 24 hours of opera-
The following subsections must be read and understood tion. If it is excessively dirty, repeat every 24 hours until
before attempting to start or operate the unit. system is clean. Otherwise, follow the normal mainte-
nance schedule.
WARNING 4. Perform baseline vibration analysis if equipment is
available.
The compression process creates noise and operating
screw compressors are loud. Wear the correct hearing
protection when near the compressor during operation. Normal start-up procedure
If people are expected to be in the vicinity of the run- 1. Confirm system conditions permit starting the compres-
ning compressor for extended time periods, provide sor.
warnings. 2. Start.
3. Observe the compressor unit for mechanical tightness
of the external piping, bolts and valves. Ensure that the
machine has no oil and vapor leaks. If any of these occur,
shut down the compressor and correct the problem as
necessary using good safety precautions.
 TDS_ Rotary Screw Compressor 070.250-IOM1 (NOV 2013)
Maintenance Page 19

Maintenance service. Water vapor condensing in the compressor while

running or more likely while shut down, can cause rusting
of critical components and reduce life.
General information
This section provides instructions for normal maintenance, 2. Keep suction strainer clean. Check periodically,
a recommended maintenance program, and troubleshoot- particularly on new systems where welding slag or pipe
ing and correction guides. scale could find its way to the compressor suction. Exces-
sive dirt in the suction strainer could cause it to collapse,
WARNING dumping particles into the compressor.
3. Keep oil filters clean. If filters show increasing pressure
This section must be read and understood before at- drop, indicating dirt or water, stop the compressor and
tempting to perform any maintenance or service to change filters. Running a compressor for long periods with
the unit. high filter pressure drop can starve the compressor of oil
and lead to premature bearing failure. Dual oil filters are
CAUTION recommended so that the filters can be changed without
shutting down the package.
Cylinder assembly under high spring load. Consult
manual before disassembly. Improper disassembly may 4. Avoid slugging the compressor with liquids (oil).
cause injury due to spring tension release. While screw compressors are probably the most tolerant
of any compressor type available today about ingestion
WARNING of some liquid, they are not liquid pumps. Make certain a
properly sized suction accumulator is used to avoid dump-
Compressor surfaces, especially those on the discharge ing liquid into compressor suction.
housing, may become hot during operation. Addition- 5. Protect the compressor during long periods of shut-
ally, surfaces near the suction flange may be cold. down. If the compressor will be sitting for long periods
Contact with compressor surfaces during or soon after without running, it is advisable to evacuate to low pres-
operation may cause burns. If it is likely that anyone sure and charge with oil (or dry nitrogen for packages).
may touch the compressor during operation and the This is particularly true on systems known to contain
conditions are such that burns may occur, the pack- water vapor.
ager must implement protection measures. For com-
6. Preventive maintenance inspection is recommended
pressors that must comply with the Machinery Directive,
any time a compressor exhibits a noticeable change in
refer to the requirements of EN ISO 13732-1.
vibration level, noise, or performance.

WARNING Changing oil

Opening any part of the compressor unit to atmosphere
while under pressure may cause injury. Ensure that the
WARNING
compressor pressure is at 0 psig before removing any DO NOT MIX OILS of different brands, manufacturers,
pressure containing part. or types. Mixing of oils may cause excessive oil foam-
ing, nuisance oil level cutouts, oil pressure loss, gas or
oil leakage and catastrophic compressor failure.
Normal maintenance operations
When performing maintenance you must take several Shut down the unit when changing oil. At the same time,
precautions to ensure your safety: you must change all oil filter cartridges and remove and
clean all oil strainer elements. The procedure is as follows:
WARNING 1. Stop the compressor unit.
1. If unit is running, press [stop] key. 2. Lock out the motor starter.
3. Close the suction and discharge service valves
2. Disconnect power from unit before performing any 4. Using appropriate equipment, lower the compressor
maintenance. pressure to 0 psig.
3. Wear proper safety equipment when compressor unit 5. Open the drain valves and drain oil into a suitable
is opened to atmosphere. container.
4. Ensure adequate ventilation. 6. Drain the oil filters and the oil coolers.
7. Remove the old filter cartridges, and install new ones.
5. Take necessary safety precautions required for the 8. Remove, clean, and reinstall elements in the strainers.
refrigerant being used. 9. Evacuate the unit.
10. Open the suction service valve and pressurize the unit
General maintenance to system suction pressure. Close the suction valve
Proper maintenance is important in order to ensure long and leak test.
and trouble-free service from your screw compressor. Some 11. Add oil.
areas critical to good compressor operation are: 12. Open the suction and discharge service valves
1. Keep oil clean and dry, avoid moisture contamina- 13. Remove the lockout from the motor starter.
tion. After servicing any portion of the refrigeration 14. Start the unit
system, evacuate to remove moisture before returning to Note: Allow time for oil to cool before opening the drain
plugs.
070.250-IOM1 (NOV 2013) TDS_ Rotary Screw Compressor
Page 20 Maintenance

Recommended maintenance program 1. Always take vibration readings from exactly the same
In order to obtain maximum compressor performance places and at exactly the same percentage of load.
and ensure reliable operation, a regular maintenance 2. Use vibration readings taken from the new unit at
program should be followed. The compressor unit should start-up as the baseline reference.
be checked regularly for leaks, abnormal vibration, noise, 3. Evaluate vibration readings carefully as the instrument
and proper operation. A log should also be maintained. range and function used can vary. Findings can be easily
Oil analysis should be performed on a regular basis. It is a misinterpreted.
valuable tool that can identify the presence of moisture,
acid, metallics and other contaminants that will shorten 4. Vibration readings can be influenced by other equip-
compressor life if not corrected. In addition, an analysis of ment operating in the vicinity or connected to the same
the compressor vibration should be made periodically. piping as the unit.

Vibration analysis Oil quality and analysis

Periodic vibration analysis can be useful in detecting High quality and suitable oil is necessary to ensure com-
bearing wear and other mechanical failures. If vibration pressor longevity and reliability. Oil quality will rapidly de-
analysis is used as a part of your preventive maintenance teriorate in systems containing moisture and air or other
program, take the following guidelines into consideration. contaminants. In order to ensure the quality of the oil in
the compressor unit:

Maintenance schedule
This schedule should be followed to ensure trouble-free operation of the compressor unit.
Frequency or hours of operation (maximum)
10,000
15,000
20,000
25,000
30,000
35,000
40,000
45,000
50,000

55,000

60,000
65,000
70,000
75,000
80,000
85,000
90,000
95,000
1000
5000
8000

Maintenance
200

Change oil As directed by oil analysis

Oil analysis n Every 6 months
Replace filters n n n n n n n n n n n
Clean oil strainers n n n n n n n n n n n
Clean liquid strainers n n n n n n n n n n n
Replace coalescers n n n
Check and clean suction strainer n n n n n n n n n n n n
Check alignment n n n n n n n n n n n
Check coupling (b) n n n n n n n n n n n
Suction and disch. flange bolts (c) n n n n n n n n n n n n n n n n n n n n n n
Vibration analysis (c) n Every 6 months, more frequently if levels increase
Replace shaft seal When Leak rate exceeds 7 to 8 drops per minute
a. Check bolts, shim packs, center inserts, keys, and all bolt torques.
b. Verify tightness of bolts on suction and discharge flanges. See Table 5 below for torque requirements.
c. Vibration measurement must be carried out continuously to obtain optimum preventative control on bearings. If not continuously
controlled, then every 6 months, more frequently if levels increase.
Note: The bolt torque requirements for the compressor flange to separator flange are based on:
•  Gaskets: Garlock® Blue-Gard® 3300
•  Bolts: class 8.8 or stronger hex head bolts, lightly oiled and clean
Table 5: TDSH flange bolt torque
Discharge flange to separator flange Suction flange
TDS_ compressor model
Bolt size (in.) Torque (ft-lb) Bolt size (in.) Torque (ft-lb)
163S M20 X 2.5 100 M16 X 2.0 120
163L M20 X 2.5 100 M16 X 2.0 120
193S M20 X 2.5 140 M20 X 2.5 180
193L M20 X 2.5 140 M20 X 2.5 160
233S M20 X 2.5 160 M20 X 2.5 160
233L M20 X 2.5 160 M20 X 2.5 200
233XL M20 X 2.5 160 M22 X 2.5 220
283S M22 X 2.5 230 M22 X 2.5 220
283L M22 X 2.5 230 M22 X 2.5 220
283SX M22 X 2.5 230 M24 X 3.0 220
355_ M24 X 3.0 240 M30 X 3.5 350
 TDS_ Rotary Screw Compressor 070.250-IOM1 (NOV 2013)
Maintenance Page 21

1. Only use Frick oil or high quality oils approved by The following list of abnormal system conditions can cause
Johnson Controls-Frick for your application. abnormal operation of the TDS_ compressor:
2. Only use Frick filter elements. Substitutions must be 1. Insufficient or excessive gas load.
approved in writing by Johnson Controls-Frick engineering 2. Excessively high suction pressure.
or warranty claim may be denied. 3. Excessively high suction superheat.
3. Participate in a regular, periodic oil analysis program to 4. Excessively high discharge pressure.
maintain oil and system integrity. 5. Inadequate refrigerant charge or low receiver oil level.
6. Excessively high or low temperature coolant to the oil
Operating log cooler.
The use of an operating log as included in this manual 7. Liquid return from system (slugging).
permits thorough analysis of the operation of a system 8. Refrigerant underfeed or overfeed to evaporators.
by those responsible for its maintenance and servicing. 9. Blocked tubes in water cooled oil cooler from high min-
Continual recording of gauge pressures, temperatures, eral content of water.
and other pertinent information, enables the observer and 10. Insufficient evaporator or condenser sizing.
serviceman to be constantly familiar with the operation of 11. Incorrect gas/refrigerant line sizing.
the system and to recognize immediately any deviations 12. Improper system piping.
from normal operating conditions. It is recommended that 13. Problems in electrical service to compressor unit.
readings be taken at least daily. 14. Air and moisture present in the system.
Make a list of all deviations from normal plant operation
Troubleshooting guide and normal compressor unit operation. Delete any items
Successful problem solving requires an organized approach which do not relate to the symptom and separately list
to define the problem, identify the cause, and make the those items that might relate to the symptom. Use the list
proper correction. Sometimes it is possible that two as a guide to further investi­gate the problem.
relatively obvious problems combine to provide a set of
symptoms that can mislead the troubleshooter. Be aware The second step in problem solving is to decide which
of this possibility and avoid solving the “wrong problem”. items on the list are possible causes and which items are
additional symptoms. High discharge temperature and
Abnormal operation analysis and correction high oil temperature readings on a display may both be
Four logical steps are required to analyze an opera­tional symptoms of a problem and not casually relat­ed. High
problem effectively and make the necessary correc­tions: suction superheat or a low receiver level, however, could
cause both symptoms.
1. Define the problem and its limits.
2. Identify all possible causes. The third step is to identify the most likely cause and
3. Test each cause until the source of the problem is take action to correct the problem. If the symptoms are
found. not relieved move to the next item on the list and repeat
4. Make the necessary corrections. the procedure until you have identified the cause of the
problem. Once the cause has been identi­fied and con­
The first step in effective problem solving is to define the firmed make the necessary correc­tions.
limits of the problem. If, for example, the compressor
periodically experiences high oil tempera­tures, do not rely
on this observation alone to help identify the problem.
Bare compressor replacement
On the basis of this information the apparent corrective The following procedure is required only when a bare
measure would appear to be a readjustment of the liquid compressor is replaced in the field.
injection system. Lowering the equalizing pres­sure on the 1. Verify that the starter is locked out.
thermal expansion valve would increase the refriger­ant 2. Remove gas/refrigerant
feed and the oil temperature should drop. 3. Remove all tubing, piping, and wiring that is connected
to the compressor.
If the high oil temperature was the result of high suction
4. Disconnect the coupling from the driver shaft.
superheat, however, and not just a matter of improper
5. While supporting the compressor assembly with a
liquid injection adjustment, increasing the liquid feed could
crane, remove the bolts at the compressor feet.
lead to other problems. Under low load conditions the
6. Thoroughly clean the compressor feet and mounting
liquid injection system may have a tendency to overfeed.
pads of burrs and other foreign matter to ensure firm
The high suction superheat condition, moreover, may only
seating of the compressor.
be temporary. When system conditions return to normal
7. Thoroughly clean the new compressor and remove all
the units’ liquid injection will overfeed and oil temperature
cover plates and protection etc.
will drop. In solving the wrong problem a new problem
8. Install new gaskets and sealing in all connections.
was created.
9. Set the new compressor in place and shim feet where
When an operating problem develops compare all operat­ required.
ing information on the MAIN OPERATING SCREEN with 10. Reattach the drive coupling.
normal operating conditions. If an Operating Log has been 11. Check the shaft alignment.
maintained the log can help determine what constitutes 12. Complete tubing, piping, and wiring.
normal operation for the compressor unit in that particular
system.
070.250-IOM1 (NOV 2013) TDS_ Rotary Screw Compressor
Page 22 Maintenance

Shutdown due to improper oil pressure (high-stage and booster)

The compressor must not operate with incorrect oil pressure.

1. Refer to CONTROL SETUP

Troubleshooting the TDS_ compressor (Frick RWB II package)

Symptom Probable causes and corrections
Excessive noise and vibration Main oil injection valve may be closed. Open valve.
Bearing damage or excessive wear. CONTACT Frick Factor or Frick.
Coupling loose on shaft. Tighten coupling. Replace if damaged.
Misalignment between driver and compressor. Realign driver and compressor.
Refrigerant flood back. Correct system problem.
Slide valve and/or slide stop 4-way hydraulic control valve failed - repair or replace.
Will not move
Slide stop indicator rod stuck. Contact Frick Factor or Frick for assistance.
Check both S.V. and S.S. potentiometer for wiring and resistance.
Compressor must be running with sufficient oil pressure.
Unloader piston stuck. Contact Frick Factor or Frick for assistance.
Slipper seals worn out or damaged. Contact Frick Factor or Frick for assistance.

NOTICE
Troubleshooting the compressor is limited to identifying the probable cause. If a mechanical problem is suspected
contact the Service Department, Frick. DO NOT ATTEMPT TO DISASSEMBLE THE COMPRESSOR.

Troubleshooting the hydraulic system

Symptom Probable causes and corrections
Slide valve will not load or Solenoid coils may be burned out, replace.
Unload
Valve may be closed. Open hydraulic service valves.
Solenoid spool may be stuck or centering spring broken, replace.
Check outputs 2 and 3 and fuses.
Solenoid may be mechanically actuated by inserting a piece of 3/16” rod
against armature pin and pushing spool to opposite end. Push A side to
confirm unload capability. If valve works, problem is electrical.
Slide valve will load but A side solenoid coil may be burned out, replace.
Will not unload
Dirt inside solenoid valve preventing valve from operating both ways, clean.
Solenoid may be mechanically actuated by inserting a piece of 3/16” rod
against armature pin and pushing spool to opposite end. Push A side to
confirm unload capability. If valve works, problem is electrical.
Slide valve will unload but A side solenoid coil may be burned out, replace.
Will not load
Dirt inside solenoid valve preventing valve from operating both ways, clean.
Solenoid may be mechanically actuated by inserting a piece of 3/16” rod against
armature pin and pushing spool to opposite end. If valve works, problem is electrical.
Slide stop will not function Solenoid coils may be burned out, replace.
Either direction
Solenoid service valves may be closed, open.
Manually actuate solenoid. If slide stop will not move mechanical problems
are indicated. Consult Frick factor or Frick.
 TDS_ Rotary Screw Compressor 070.250-IOM1 (NOV 2013)
Maintenance Page 23

Troubleshooting the oil pump and system

Symptom Probable causes and corrections
Pump will not produce enough oil Check that service valves are open.
pressure at start-up Filter cartridges may be blocked. Check PSID across filters.
Strainer may be blocked. Clean.
Oil pressure regulator set too low or stuck open. Readjust or repair.
Pump worn out. Repair or replace.
Oil pressure rapidly drops off Main oil injection throttling valve too wide open or oil pressure regulating valve
when compressor starts improperly adjusted. Readjust both valves.

Noise and vibration Pump strainer blocked. Clean.

Pump worn out. Repair or replace.
Oil pressure drops as head Normal behavior. Set main oil injection and oil pressure for maximum head pressure
pressure increases condition.
Main unit filter psid is too high Filters clogged with dirt. Replace.
Oil is too cold. Allow oil to warm up and check again.
Service valve on filter outlet is partially closed. Open valves fully.
070.250-IOM1 (NOV 2013) TDS_ Rotary Screw Compressor
Page 24 Maintenance

Read this first: compressor prestart checklist

The following items must be checked and completed by the installer prior to the arrival of the Frick Field Service
Supervisor. Details on the checklist can be found in this manual. Certain items on this checklist will be reverified by
the Frick Field Service Supervisor prior to the actual start-up.

Mechanical Checks Electrical Checks

__ Package installed according to Frick publication __ Package installed according to Frick publication
070.210-IB, Screw Compressor Foundations. 090.400-SB, Proper Installation of Electrical
__ Confirm that motor disconnect is open Equipment In An Industrial Environment.
__ Isolate suction pressure transducer __ Confirm that main disconnect to motor starter and micro
__ Pressure test and leak check unit is open
__ Evacuate unit __ Confirm that electrical contractor has seen this sheet,
__ Check alignment all pertinent wiring information, and drawings
__ Remove compressor drive coupling guard __ Confirm proper power supply to the starter package
__ Remove coupling center and do not reinstall __ Confirm proper motor protection (breaker sizing)
(motor rotation must be checked without center) __ Confirm that all wiring used is stranded copper and is
__ Check for correct position of all hand, stop, and check 14 AWG or larger (sized properly)
valves before charging unit with oil or refrigerant __ Confirm all 120 volt control wiring is run in a separate
__ Charge unit with correct type and quantity of oil conduit from all high voltage wiring
__ Lubricate electric drive motor bearings before __ Confirm all 120 volt control wiring is run in a separate
checking motor rotation conduit from oil pump and compressor motor wiring
__ Check oil pump alignment (if applicable) __ Confirm no high voltage wiring enters the micro panel
__ Check for correct economizer piping (if applicable) at any point
__ Check separate source of liquid refrigerant supply (if __ Check current transformer for correct sizing and instal-
applicable, liquid injection oil cooling) lation
__ Check water supply for water-cooled oil cooler (if ap- __ Check all point-to-point wiring between the micro and
plicable, water cooled oil cooling) motor starter
__ Check thermosyphon receiver refrigerant level (if ap- __ Confirm all interconnections between micro, motor
plicable, thermosyphon oil cooling) starter, and the system are made and are correct
__ Check for proper pipe supports and correct foundation __ Ensure all electrical panels are free from installation
__ Check to ensure all piping including relief valves is debris, metal particles, and moisture
completed
After the above items have been checked and verified:
__ Close the main disconnect from the main power supply to the motor starter
__ Close the motor starter disconnect to energize the micro
__ Manually energize oil pump and check oil pump motor rotation
­­­­__ Leave micro energized to ensure oil heaters are on and oil temperature is correct for start-up
__ Do not energize compressor drive motor ! This should only be done by authorized Factory Field Service Technicians.
Summary: The Frick field service supervisor should arrive to find the above items completed. He should find an uncoupled
compressor drive unit (to verify motor rotation and alignment) and energized oil heaters with the oil at the proper standby
temperatures. Full compliance with the above items will contribute to a quick, efficient and smooth start-up.

The Start-up supervisor will:

1. Verify position of all valves 6. Verify and finalize alignment (if applicable)
2. Verify all wiring connections 7. Calibrate slide valve and slide stop
3. Verify compressor motor rotation 8. Calibrate temperature and pressure readings
4. Verify oil pump motor rotation 9. Correct any problem in the package
5. Verify the % of FLA on the micro display 10. Instruct operation personnel

Note: C
 ustomer connections are to be made per the electrical diagram for the motor starter listed under the
installation section and per the wiring diagram listed under the maintenance section of the IOM.
Complete and sign this form & fax to 717-762-8624 as confirmation of completion.
Frick Sales Order Number:_______________________ Print Name:____________________________________
Compressor Model Number:______________________ Company:______________________________________
Unit Serial Number:_____________________________ Job Site Contact:________________________________
End User Name:________________________________ Contact Phone Number:_________________________
Address of Facility:______________________________
City, State, Zip: _________________________________ Signed: _______________________________________
 TDS_ Rotary Screw Compressor 070.250-IOM1 (NOV 2013)
Maintenance Page 25

Drive train alignment

Ambient Temperature at Time of Alignment___________ Oil Separator Temperature at Time of Alignment______________
Motor Coupling Type_______________Size_______________Distance Between Coupling Hub Faces________________
Soft Foot Check OK as Found Shimming Required Amount of Shims used to Correct_______________
Indicator Readings in in./1000 mm Indicator Clamped to Motor Compressor
Indicator Readings Facing Compressor Motor Magnetic Center Checked Marked N/A
Compressor Coupling Hub Runout________________ Motor Coupling Hub Runout_________________

Initial cold alignment Initial hot alignment Final hot alignment

Face Rim Face Rim Face Rim

Thickness of shims added Thickness of shims added Thickness of shims added

Compressor operating log sheet Starter operating log sheet

Date                   Average current                  
Time                   Current phase A                  
Hour meter reading                   Current phase B                  
Equip. room temp.                   Current phase C                  
Suction pressure                   Full load amps                  
Suction temperature                   Output frequency                  
Suction superheat                   Output voltage                  
Discharge pressure                   DC bus voltage                  
Discharge temperature                   Input power kW                  
Corresponding temperature                   Actual speed                  
Oil pressure                   Speed command                  
Oil temperature                   Ambient temp °F                  
Oil filter pressure drop                   Convert heatsink temp. °F                  
Separator temperature                   Baseplate temp. °F                  
Slide valve position                   VSD operating mode                  
Volume ratio (VI)                   Harmonic filter present                  
Motor amps / FLA %                   Harmonic filter mode                  
Capacity control setpoint                   Water pump energized                  
Oil level                   Precharge relay energized                  
Oil added                   Trigger SCR’s energized                  
Seal leakage (drops/min.)                   DC inverter link current                  
Evaporator. EWT F.                   Motor winding temp. °F                  
Evaporator LWT F.                   Humidistat % RH                  
Condenser EWT F.                   Vyper coolant temp. °F                  
Condenser LWT F.                   Total kWh                  
070.250-IOM1 (NOV 2013) TDS_ Rotary Screw Compressor
Page 26 Maintenance

Vibration data sheet

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

Equipment ID (As in Microlog): _____________________ Final Hot Alignment

Compressor Model Number:___________________________
Compressor Serial Number:___________________________
Unit Serial Number:__________________________________ Face Rim
National Board Number:______________________________
Running Hours:______________________________________
Manufacturer and Size of Coupling:_____________________
Motor Manufacturer: RAM_____________________________ Total Thickness of Shims Added
Motor Serial Number:_________________________________
RPM:_________ Frame Size:____________ H.P.___________ Soft Foot Soft Foot
Refrigerant:
Ambient Room Temperature: _____________°F
Operating Conditions:
Soft Foot Soft Foot

Suction Discharge Oil Separator Slide valve position %

Press # Press # Press # Temp °F Vi Ratio
Temp °F Temp °F Temp °F F.L.A. %

Compressor Inboard
Compressor Inboard Motor Inboard (Coupled End)
(Coupling End Male)
(Coupling End) Horizontal _______ . ______ IPS Overall
Axial Direction
Vertical Direction Vertical _______ . ______ IPS Overall
____.____ IPS Overall
____.____ IPS Overall Axial _______ . ______ IPS Overall

Compressor Outboard Compressor Inboard

(Coupling End Female) Motor Outboard (Noncoupled End)
(Nondrive End) Horizontal _______ . ______ IPS Overall
Vertical Direction Axial Direction
____.____ IPS Overall Vertical _______ . ______ IPS Overall
____.____ IPS Overall Axial _______ . ______ IPS Overall
 TDS_ Rotary Screw Compressor 070.250-IOM1 (NOV 2013)
Installation - Operation - Maintenance Page 27

Index
A L T
accumulator, 3 lifting rings, 12 thermal stability, 6
allowable flange loads, 13 load surges, 3 traps, 3
antifriction bearings, 6 long term storage, 4 troubleshooting, 19
ASHRAE, 3 lubrication system, 5 troubleshooting
filter cartridges, 23
B M oil pressure, 23
oil pressure regulator, 23
balance piston, 6 maintenance, 19
pressure regulating valve, 23
balance piston pressure regulator, 17 male rotor, 6
pump, 23
bare compressor, 21 male rotor shaft, 5
pump strainer, 23
motor, 21, 25
service valves, 23
C
strainer, 23
O
capacity control, 6
compressor operating log sheet, 25 oil analysis, 20 U
compressor port locations, 8 oil cooling system, 18
under-compression, 6
compressor prestart checklist, 24 oil filter cartridges, 19
unloading, 6
compressor shaft seal, 6 oil filters, 14, 19
condensation, 3, 14 oil heater(s), 15 V
coolware™, 3 oil pressure, 6, 14
corrosion, 5, 12 oil quality, 20 vacuum, 5
coupling, 21 oil seal, 6 vapor pump, 3
customer connections, 13 oil strainer elements, 19 vibration analysis, 18, 20
oil supply, 6 vibration level, 19
D operating log, 21 volume ratio, 17
orifice, 17
dimensions, 7 W
over-compression, 6
discharge pressure, 6
discharge temperature, 3 P warranty, 4
drive coupling, 21 water vapor, 19
drive train alignment, 25 pipe hangers, 13
dry nitrogen, 12 piping layouts, 3
piping stress, 13
E potentiometer, 16
pressure ratio, 6
evacuation lines, 5
prestart checklist, 24
F R
female rotor, 6
rigging and handling, 12
foundation, 12
rotor housing, 6
G S
gaskets, 21
serial number, 3
shaft alignment, 21
H
shipping gauges, 12
holding charge, 12 shutdown, 19
hydrocarbon gasses, 3 slide stop, 6
slide valve, 6
I starter operating log sheet, 25
start-up, 17, 24
identification data plate, 3 storage, 12
installation, 7 suction accumulator, 19
insulated, 17 suction line, 3
suction strainer, 18, 19
October 2022 revisions
Throughout – Updated Frick and Johnson Controls logos
Cover – Updated web address
– Updated cover statement
Page 12 – Added Lifting instructions section
Page 18 – Add warning statement
Page 19 – Add 2nd and 3rd warning statement in General information
– Added note in Changing oil section

April 2016 Form Revisions

p.2 – Added bookmark Table of Contents PDF functionality
p.8 – Noted drawings reference 163 and 193
p.16 – Removed typical package reference information
– Update Vi adjustment by compressor model

– New Frick logo added throughout

Form 070.250-IOM1 (2013-11) rev (2022-10) Johnson Controls

Supersedes: 070.250-IOM1 (2013-11) rev (2016-04) 100 Cumberland Valley Avenue
Subject to change without notice Waynesboro, PA 17268-1206 USA
Published in USA • 10/22 • PDF Phone: 717-762-2121 • FAX: 717-762-8624
© 2022 Johnson Controls - All Rights Reserved www.johnsoncontrols.com/frick