Form 070.

650-IOM (NOV 2013)

INSTALLATION - OPERATION - MAINTENANCE
File: EQUIPMENT MANUAL - Section 070
Replaces: 070.650-IOM (OCT 2009)
Dist: 3, 3a, 3b, 3c

SGC
ROTARY SCREW COMPRESSOR
MODELS SGC1913 - SGC3524

THIS MANUAL CONTAINS RIGGING, ASSEMBLY, START-UP,

AND MAINTENANCE INSTRUCTIONS. READ THOROUGHLY
BEFORE BEGINNING INSTALLATION. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR DEATH,
DAMAGE TO THE UNIT, OR IMPROPER OPERATION.

Please check www.jci.com/frick for the latest version of this publication.

070.650-IOM (NOV 13) SGC ROTARY SCREW COMPRESSOR
Page 2 INSTALLATION - OPERATION - MAINTENANCE

Contents
GENERAL Information OPERATION
PREFACE ........................................................................... 3 OPERATION and START-UP INSTRUCTIONS . ..................19
DESIGN LIMITATIONS ........................................................ 3 INITIAL START-UP ............................................................19
JOB INSPECTION ............................................................... 3 INITIAL START-UP PROCEDURE ...................................19
STANDARD BARE COMPRESSOR ...................................... 3 NORMAL START-UP PROCEDURE ................................19
TRANSIT DAMAGE CLAIMS ............................................... 3
COMPRESSOR IDENTIFICATION . ....................................... 3 MAINTENANCE
LONG TERM STORAGE....................................................... 4 GENERAL INFORMATION ................................................. 20
PREPARING COMPRESSOR FOR STORAGE......................... 5 NORMAL MAINTENANCE OPERATIONS ......................... 20
MAINTAINING COMPRESSOR.............................................. 5 GENERAL MAINTENANCE ............................................ 20
DESCRIPTION..................................................................... 5 CHANGING OIL............................................................. 20
SGC COMPRESSOR ....................................................... 5 RECOMMENDED MAINTENANCE PROGRAM ............... 20
COMPRESSOR LUBRICATION SYSTEM .......................... 5 VIBRATION ANALYSIS ..................................................... 20
OIL PUMP....................................................................... 6 OIL QUALITY and ANALYSIS ...........................................21
Construction details................................................... 6 OPERATING LOG ..........................................................21
MAINTENANCE SCHEDULE................................................21
INSTALLATION TROUBLESHOOTING GUIDE . ............................................22
DESIGN LIMITS................................................................... 7 ABNORMAL OPERATION
OUTLINE DIMENSIONS....................................................... 7 ANALYSIS and CORRECTION ...................................22
HOLDING CHARGE AND STORAGE................................... 14 CAPACITY LINEAR TRANSMITTER REPLACEMENT -
RIGGING AND HANDLING.................................................. 14 SLIDE VALVE .............................................................22
FOUNDATION .................................................................. 14 VOLUMIZER® TRANSMITTER REPLACEMENT -
CUSTOMER CONNECTIONS...............................................15 SLIDE STOP................................................................22
COMPRESSOR OIL.............................................................15 BARE COMPRESSOR REPLACEMENT ................................23
OIL PUMP..........................................................................15 SHUTDOWN DUE TO IMPROPER OIL PRESSURE.................23
COMPRESSOR...................................................................15 TROUBLESHOOTING THE SGC COMPRESSOR ..................23
COMPRESSOR ROTATION IS CLOCKWISE WHEN FACING TROUBLESHOOTING THE HYDRAULIC SYSTEM.................23
THE END OF THE COMPRESSOR SHAFT.......................15 TROUBLESHOOTING THE OIL PUMP AND SYSTEM ......... 24
MOUNTING (USE OF MOTOR TUNNEL) - PROPOSAL....15 FORMS..............................................................................25
COMPRESSOR/MOTOR COUPLING REQUIREMENTS......16 VIBRATION DATA SHEET................................................... 28
COUPLING ALIGNMENT REQUIREMENTS
(FOOT MOUNTED ONLY)............................................16 Referenced manuals:
OIL HEATER(S) .................................................................16
070.610-IOM RWF II Rotary Screw Compressor Units
OIL FILTER(S) . ..................................................................16
090.020-M Quantum LX Maintenance
OIL COOLING requIrementS..........................................16
160.802-SPC Compressor Oil Specifications
DEHYDRATION / EVACUATION TEST..................................17
090.040-O Quantum HD Operation
ELECTRICAL INSTALLATION...............................................17
SLIDE STOP TRANSMITTER...........................................17
CAPACITY SLIDE VALVE TRANSMITTER........................17
Directional control valves .................................18
COMPRESSOR HYDRAULIC SYSTEM ................................18
VOLUMIZER VOLUME RATIO CONTROL ..........................18
LOW AMBIENT OPERATION . ............................................19

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.
 SGC ROTARY SCREW COMPRESSOR 070.650-IOM (NOV 13)
INSTALLATION - OPERATION - MAINTENANCE Page 3

STANDARD BARE COMPRESSOR

NOTICE Items not included with bare compressor that are available
THE INFORMATION CONTAINED IN THIS as sales order options: Motor Mount, Solenoid Valve Block,
DOCUMENT IS SUBJECT TO CHANGE Solenoid Valves, Tank Drain Tubing (T connection), Oil Feed
WITHOUT NOTICE Line (P connection), Connection Fittings, Coupling.
TRANSIT DAMAGE CLAIMS
GENERAL Information
All claims must be made by consignee. This is an ICC re-
PREFACE quirement. Request immediate inspection by the agent of
the carrier and be sure the proper claim forms are execut-
This manual has been prepared to acquaint the owner and
ed. Report damage or shortage claims immediately to
serviceman with the INSTALLATION, OPERATION, and
Johnson Controls-Frick Sales Administration Department,
MAINTENANCE procedures as recommended by Johnson
in Waynesboro, PA.
Controls-Frick for SGC Rotary Screw Compressors.

It is most important that these compressors be properly COMPRESSOR IDENTIFICATION

applied to an adequately controlled refrigerant or gas sys-
Each compressor has an identification data plate, containing
tem. Your authorized Johnson Controls-Frick representa-
compressor model and serial number mounted on the
tive should be consulted for his expert guidance in this de-
compressor body.
termination.

Proper performance and continued satisfaction with these

units is dependent upon:
NOTICE
When inquiring about the compressor or unit, or
CORRECT INSTALLATION
ordering repair parts, provide the MODEL, SERIAL, and
PROPER OPERATION
JOHNSON CONTROLS - FRICK SALES ORDER NUMBERS
REGULAR, SYSTEMATIC MAINTENANCE
from the data plate. See Figure 1.
To ensure correct installation and application, the equipment
must be properly selected and connected to a properly
designed and installed system. The Engineering plans,
piping layouts, etc. must be detailed in accordance with the
best practices and local codes, such as those outlined in
ASHRAE literature.

A screw compressor is a VAPOR PUMP. To be certain that it

is not being subjected to pumping liquid, it is necessary that
controls are carefully selected and in good operating
condition; the piping is properly sized and traps, if necessary,
are correctly arranged; the suction line has an accumulator
or slugging protection; that load surges are known and
provisions are made for control; operating cycles and stand
still periods are reasonable; and that high side components
are sized within system and compressor design limits.

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
Figure 1 - Identification Data Plate
SGC compressors are designed for operation within the
pressure and temperature limits which are specified by Rotary screw compressor serial numbers are defined by the
Johnson Controls-Frick and the Johnson Controls-Frick following information:
selection software COOLWARE™. They are primarily used for
compressing refrigerant gas and most hydrocarbon gasses. EXAMPLE: 10240A90000015Z
GLOBAL ADDITIONAL
If your application is for sour gas, there are special require- PLANT DECADE MONTH YEAR SEQ NO. REMARKS
ments to protect the compressor. Contact Johnson Con- 1024 0 A 9 0000015 Z
trols-Frick Compressor Engineering for application details.
Month: A = JAN, B = FEB, C = MAR, D = APR, E = MAY, F =
JOB INSPECTION JUN, G = JUL, H = AUG, K = SEP, L = OCT, M = NOV, N = DEC.
Additional Remarks: R = Remanufactured; Z = Deviation
Immediately upon delivery examine all crates, boxes and
from Standard Configuration.
exposed compressor and component surfaces for damage.
Unpack all items and check against shipping lists for any Geometrical swept volume table ...
discrepancy. Examine all items for damage in transit.
070.650-IOM (NOV 13) SGC ROTARY SCREW COMPRESSOR
Page 4 INSTALLATION - OPERATION - MAINTENANCE

Geometrical
Rotor Max Swept Volume
Compressor diameter Rotor speed Drive shaft end CFM m³/h
Model mm L/D rpm ft³/ rev m³/rev 3550 rpm 2950 rpm
SGC1913 193 1.35 4,500 0.16653 0.004713 591 834
SGC 1918 193 1.8 4,500 0.22204 0.006284 788 1,112
SGC 2313 233 1.35 4,500 0.29301 0.008292 1,040 1,468
SGC 2317 233 1.7 4,500 0.36897 0.010442 1,310 1,848
SGC 2321 233 2.1 4,500 0.45580 0.012899 1,618 2,283
SGC 2813 283 1.35 4,200 0.52501 0.014858 1,864 2,630
SGC 2817 283 1.7 4,200 0.66115 0.018711 2,347 3,312
SGC 2821 283 2.1 4,200 0.79546 0.022512 2,824 3,985
SGC 2824 283 2.4 4,200 0.89858 0.025430 3,190 4,501
SGCH/B 3511 355 1.1 4,200 0.82248 0.023276 2,920 4,120
SGCH/B 3515 355 1.5 4,200 1.12154 0.031739 3,981 5,618
SGCH/B 3519 355 1.9 4,200 1.42748 0.040398 5,068 7,150
SGCB 3524 355 2.4 4,200 1.80328 0.051033 6,402 9,033

The name plates in Figure 2 show which refrigerants are of equipment shipment. Special provisions may be required
compatible with the compressor as manufactured. for storage of less than six (6) months if the storage area is
subject to unusual environment such as high humidity, large
changes in temperature, dusty atmosphere, etc.

The standard Johnson Controls-Frick Warranty for an SGC

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
discrepancies to the guidelines listed herein. Failure to
comply with this Long Term Storage Recommendation may
void the warranty.

Figure 2 - Refrigerant Name Plates Long term storage of equipment may lead to the deterioration
of components over the period of time. Synthetic
LONG TERM STORAGE components in the compressor may deteriorate over time
even if they are kept flooded with oil. A warm and dry
Long term storage (6 months to 5 years) provisions are environment is essential to minimize environmental and
required, regardless of storage environment, if start-up corrosion damage. Long term storage of the affected
and/or useful operation does not occur within six (6) months equipment at a customer’s site may involve additional

Compressor And Packaged Equipment Storage Log

Compressor, Motor
Oil Pump and
Refrigerant Pump Rotor Visual
Shaft Rotation Housing Charge Inspection
Model Serial No. 1½ Turn Charge Added Per Qai-3 Charge Checked By Date
 SGC ROTARY SCREW COMPRESSOR 070.650-IOM (NOV 13)
INSTALLATION - OPERATION - MAINTENANCE Page 5

requirements and interested parties should refer to the 2. Heavy-duty, four-point contact ball or angular-contact
Johnson Controls web site, www.johnsoncontrols.com/ bearings are mounted at the discharge end of the
frick, for specific instructions (Location: Bare Compressors\ compressor to carry axial loads.
General\Warranties\Screw Compressor Purchased for Long
3. Balance pistons, located in the inlet end of the compressor,
Term Storage).
reduce axial loads on the male axial bearings to increase
The following guidelines must be followed to maintain the bearing life.
SCREW COMPRESSOR WARRANTY. 4. Moveable slide valve to provide fully modulating capacity
control from 100% to approximately 15% (except SGC3524
PREPARING COMPRESSOR FOR STORAGE
at 26%) of full load capacity.
Evacuate compressor to remove moisture. Evacuation lines 5. VOLUMIZER volume ratio control to allow infinitely
are to be connected to port SM1. Evacuation lines are to be variable volume ratio from 2.2 to 5.0 for all SGC models
connected to the three Schrader access valves provided (except the SGC 3524: Vi = 2.4 – 4.5) during compressor
with the compressor. One valve is connected to compressor operation.
suction. The other two valves are located at the block on
the cylinder. 6. A hydraulic cylinder to operate the slide stop and slide
valve.
Break vacuum with dry nitrogen and bring pressure to zero
psig. 7. Housings are designed for 400 psig pressure.

Pump oil into the same ports mentioned in step 1. Johnson 8. All bearing and control oil vented to closed thread in the
Controls-Frick recommends break-in oil P/N 111Q0831809 compressor instead of suction pressure to avoid
for storage purposes. The amounts of oil needed per performance penalties from superheating and displacing
compressor are: suction gas.

95mm - 2Gal 9. Shaft seal housing is designed to maintain operating

120mm - 3Gal pressure on seal well below discharge pressure for increased
seal life.
163mm - 8Gal
193mm - 12Gal 10. Oil injected into the rotors to maintain good volumetric
233mm - 15Gal and adiabatic efficiency even at very high compression
283mm - 25Gal ratios.
355mm - 35Gal 11. Shaft rotation clockwise facing compressor, suitable for
After compressor is oil charged, pressurize compressor to all types of drives. SEE FOLLOWING WARNING.
15 psig with nitrogen.

MAINTAINING COMPRESSOR IN STORAGE WARNING

Compressor rotation is clockwise when facing the
Ensure that the 5-15 psig nitrogen charge is maintained compressor drive shaft. The compressor should never
with 15 psig preferred. be operated in reverse rotation, as bearing damage
Rotate the male rotor shaft every two weeks. Mark the will result.
shaft to ensure the rotor does not return to the original 12. Suction and discharge flanges are ANSI B16.1 Class 300
position. for all models.
The compressor must be stored inside a dry building 13. Integral suction strainers are provided for all models
environment. except the SGC 35XX series. The SGC 35XX models must be
Grease the male rotor shaft to prevent rust. fitted with a suitable strainer, #60 mesh X .0065” diameter
stainless steel wire or better, to prevent damage to the
Record all information in a “Compressor Long Term Storage compressor from particles entering the suction area.
Log.” See bottom of page 4.
COMPRESSOR LUBRICATION SYSTEM
Contact Johnson Controls-Frick Service with any
The lubrication system on an SGC screw compressor unit
questions regarding long term storage.
performs several functions:
DESCRIPTION 1. Provides lubrication to bearings and seal.

SGC COMPRESSOR 2. Provides a cushion between the rotors to minimize noise

and vibrations.
The Frick SGC rotary screw compressor utilizes mating
asymmetrical profile helical rotors to provide a continuous 3. Helps keep the compressor cool and prevents overheating.
flow of vapor and is designed for both high-pressure and 4. Provides an oil supply to hydraulically actuate the slide
low-pressure applications. The compressor incorporates valve and slide stop.
the following features: 5. Provides oil pressure to the balance piston to help
1. High-capacity roller bearings to carry radial loads at both increase bearing life.
the inlet and outlet ends of the compressor. 6. Provides an oil seal between the rotors to prevent rotor
contact or gas bypassing.
070.650-IOM (NOV 13) SGC ROTARY SCREW COMPRESSOR
Page 6 INSTALLATION - OPERATION - MAINTENANCE

OIL PUMP The slide valve is positioned by hydraulic movement of its

A demand oil pump is required for low differential pressure control piston. When in the unloaded position, gas is
applications (CoolWare™ will provide a warning when the oil bypassed back to suction through a recirculation slot before
differential pressure is too low). Oil being supplied to the compression begins and any work is expended, providing
compressor from the oil separator is at system discharge the most efficient unloading method available for part-load
pressure. Within the compressor, oil porting to all parts of operation of a screw compressor.
the compressor is vented back to a location in the com- MOTOR MOUNT: The SGC series is designed with a drive
pressor’s body that is at a pressure lower than compressor end flange that mates with a cast iron motor mount
discharge pressure. All oil entering the compressor is (available as a sales order option). The motor mount is
moved by the compressor rotors out the compressor outlet precision machined so that it ensures proper alignment of
and back to the system oil separator. the compressor and motor coupling.
Construction details TABLE 1
Housing: All SGC screw compressor castings are close COMPRESSOR VOLUME and CAPACITY RATIO
grain, ASTM-A-48 Class 40 cast iron to ensure structural SLIDE SLIDE
MIN.
integrity and mechanical and thermal stability under all M. MAX. VALVE STOP
MODEL CAPA-
operating conditions. Ductile iron and steel housings are VI* VI TRAVEL TRAVEL
CITY %
also available for special applications. Contact Johnson (IN.) (IN.)
Controls – Frick Sales for additional information. SGC 1913 2.2 5.0 6.497 2.530
SGC 1918 2.2 5.0 8.662 3.374
Rotors: The rotors are machined from AISI-1141 steel to SGC 2313 2.2 5.0 7.843 3.055

REFER TO COOLWARE™
the exacting tolerances of the latest industry standard SGC 2317 2.2 5.0 9.877 3.847
asymmetric profile. The four-lobed male rotor is directly SGC 2321 2.2 5.0 12.200 4.752
connected to the driver. The six-lobed female rotor is SGC 2813 2.2 5.0 9.526 3.710
driven by the male on a thin oil film. SGC 2817 2.2 5.0 11.996 4.672
SGC 2821 2.2 5.0 13.679 5.615
Bearings: Antifriction bearings with L10 rated life in SGC 2824 2.0 4.1 15.633 6.418
excess of 50,000 hours (using the Frick Superfilter™) at SGC 3511 2.2 5.0 10.360 3.690
design conditions are used for reduced frictional SGC 3515 2.2 5.0 14.127 5.031
horsepower and superior rotor positioning, resulting in SGC 3519 2.2 5.0 15.443 6.373
reduced power consumption, particularly at higher SGC 3524 2.4 4.5 15.482 6.399
pressure ratios. Cylindrical roller bearings are provided to * Optional 1.7 - 3.0 Vi
handle the radial loads and the thrust loads are absorbed
by four point contact or angular contact bearings. In
addition, thrust balance pistons are provided to reduce the
thrust load and improve bearing life.
Shaft Seal: The compressor shaft seal is a single-face
type with a spring-loaded carbon stationary surface riding
against a cast iron rotating seat. The seal is capable of
withstanding static pressure up to 400 psig. During
operation it is vented to low pressure to provide extended
life.

Volumizer VARIABLE VOLUME RATIO CONTROL: The

Frick compressor includes a method of varying the internal
volume ratio to match the system pressure ratio. Control of
the internal volume ratio eliminates the power penalty
associated with over- or under-compression. Volume ratio
control is achieved by the use of a slide stop which is a
movable portion of the rotor housing that moves axially with
the rotors to control discharge port location. The slide stop
is moved by hydraulic actuation of a control piston. The
range of adjustment is listed in the COMPRESSOR VOLUME
and CAPACITY RATIO table.

STEPLESS CAPACITY CONTROL: Capacity control is

achieved by use of a movable slide valve. The slide valve
moves axially under the rotors to provide fully modulated
capacity control from 100% to minimum load capacity.
Minimum load capacity varies slightly with compressor
model, pressure ratio, discharge pressure level, and rotor
speed. See the table 1 for minimum capacity for all SGC
models.
 SGC ROTARY SCREW COMPRESSOR 070.650-IOM (NOV 13)
INSTALLATION Page 7

INSTALLATION
DESIGN LIMITS
General information for all of the models is provided below.
Please see CoolWare to determine the limits for a specific
application.

SGC compressors are primarily designed for connecting to

an electric drive motor using a tunnel mount. If the applica-
tion requires it, the compressor can also be driven with a
foot-mounted motor. The tunnel mount ensures proper
alignment of the compressor and motor so that the shaft
seal and coupling will operate properly. The rotor and bear-
ing design set limitations must not be exceeded (See Cool-
Ware). Refer to Johnson Controls - Frick Compressor Con-
trol Panel instruction 090.020-M for additional information
on setpoint limits.

For proper piping, also see the Frick package manual,

070.610-IOM for RWF II rotary screw compressor units,
Models 100 through 1080.

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.
SGC 1913 & 1918 DWG# 534E0677
SGC 2313 & 2317 DWG# 534E0700
SGC 2321 DWG# 534E0714
SGC 2813 & 2817 DWG# 534E0749
SGC 2821 DWG# 534E0768
SGC 2824 DWG# 534E0973
SGCH 3511 & SGCB 3511 DWG# 534E0966
SGCH 3515 & SGCB 3515 DWG# 534E0971
SGCH 3519 & SGCB 3519 DWG# 534E0972
SGCB 3524 DWG# 534E0974

If you do not have these drawings, please request any you

require by contacting Johnson Controls - Frick sales.
070.650-IOM (NOV 13) SGC ROTARY SCREW COMPRESSOR
Page 8 INSTALLATION

COMPRESSOR PORT LOCATIONS - SGC 1913 & 1918

Port THREAD SIZE O-ring NOTE

SB-3 1Z\zn-12 UN-2B 980A0012K66 X
SC-5 9/16-18 UNF-2B 980A0012K60 O
SC-6 9/16-18 UNF-2B 980A0012K60 O
SC-8 1Z\zn-12 UN-2B 980A0012K66 S
SC-9 9/16-18 UNF-2B 980A0012K60 S
SC-13 9/16-18 UNF-2B 980A0012K60 S
SC-14 9/16-18 UNF-2B 980A0012K60 O
SD-1 1Z\zn-12 UN-2B 980A0012K66 O
SL-1 1Z\zn-12 UN-2B 980A0012K66 O
SL-2 1Z\zn-12 UN-2B 980A0012K66 O
SM-1 1Z\zn-12 UN-2B 980A0012K66 X
SV-1 1½ Square Flange N/A N/A

X - Must connect to
O - Optional connect to
S - Service connection
 SGC ROTARY SCREW COMPRESSOR 070.650-IOM (NOV 13)
INSTALLATION Page 9

COMPRESSOR PORT LOCATIONS - SGC 2113, 2317, & 2321

Port THREAD SIZE O-ring NOTE
SB-3 1Z\zn-12 UN-2B 980A0012K66 X
SC-5 9/16-18 UNF-2B 980A0012K60 O
SC-6 9/16-18 UNF-2B 980A0012K60 O
SC-8 1Z\zn-12 UN-2B 980A0012K66 S
SC-9 9/16-18 UNF-2B 980A0012K60 S
SC-11 1B\zn-12 UN-2B 980A0012K69 S
SC-13 9/16-18 UNF-2B 980A0012K60 S
SC-14 9/16-18 UNF-2B 980A0012K60 O
SD-1 1Z\zn-12 UN-2B 980A0012K66 O
SL-1 1Z\zn-12 UN-2B 980A0012K66 O
SL-2 1Z\zn-12 UN-2B 980A0012K66 O
SM-1 1B\zn-12 UN-2B 980A0012K69 X
SV-1 1½ Square Flange N/A N/A
X - Must connect to
O - Optional connect to
S - Service connection
070.650-IOM (NOV 13) SGC ROTARY SCREW COMPRESSOR
Page 10 INSTALLATION

COMPRESSOR PORT LOCATIONS - SGC 2813 & 2817

Port THREAD SIZE O-ring NOTE

SB-3 1Z\zn-12 UN-2B 980A0012K66 X
SC-5 9/16-18 UNF-2B 980A0012K60 O
SC-6 9/16-18 UNF-2B 980A0012K60 O
SC-8 1Z\zn-12 UN-2B 980A0012K66 S
SC-9 9/16-18 UNF-2B 980A0012K60 S
SC-13 9/16-18 UNF-2B 980A0012K60 S
SC-14 9/16-18 UNF-2B 980A0012K60 O
SD-1 1Z\zn-12 UN-2B 980A0012K66 O
SL-1 1Z\zn-12 UN-2B 980A0012K66 O
SL-2 1Z\zn-12 UN-2B 980A0012K66 O
SM-1 1Z\zn-12 UN-2B 980A0012K66 X
SV-1 1½ Square Flange N/A N/A
X - Must connect to
O - Optional connect to
S - Service connection
 SGC ROTARY SCREW COMPRESSOR 070.650-IOM (NOV 13)
INSTALLATION Page 11

COMPRESSOR PORT LOCATIONS - SGC 2821 & 2824

Port O-ring
SC-5 980A0012K62
SC-6 980A0012K60
SC-8 980A0012K69
SC-9 980A0012K60
SC-13 980A0012K60
SC-14 980A0012K60
SD-1 980A0012K66
SL-1 980A0012K69
SL-2 980A0012K69
SM-1 980A0012K71

Port THREAD SIZE NOTE

SC-5 3/4-16 UNF-2B O
SC-6 9/16-18 UNF-2B O
SC-8 1B\zn-12 UN-2B S
SC-9 9/16-18 UNF-2B S
SC-13 9/16-18 UNF-2B S
SC-14 9/16-18 UNF-2B O
SD-1 1Z\zn-12 UN-2B O
SL-1 1B\zn-12 UN-2B O
SL-2 1B\zn-12 UN-2B O
SM-1 1B\,-12 UN-2B X
SV-1 1½ Square Flange N/A
X - Must connect to
O - Optional connect to
S - Service connection
070.650-IOM (NOV 13) SGC ROTARY SCREW COMPRESSOR
Page 12 INSTALLATION

COMPRESSOR PORT LOCATIONS - SGC 3511 & 3515

PORT NPTF SIZE NOTE

SB-2 3/4-14 X
SB-3 1½-11½ X
SC-3 1/2-14 X
SC-4 1/2-14 S
SC-5 3/8-18 O
SC-6 3/8-18 O
SC-7 1/8-27 X
SC-8 1¼-11½ S
SC-9 1½-11½ S
SC-10 1½-11½ S
SD-1 1/2-14 O
SL-1 1¼-11½ O
SL-2 1¼-11½ O
SM-1 2 Sq Flg X
SP-1 3/4-14 X
ST-1 3/4-14 O
SV-1 3 Sq Flg O
TW-1 3/4-14 O
X - Must connect to
O - Optional connect to
S - Service connection
 SGC ROTARY SCREW COMPRESSOR 070.650-IOM (NOV 13)
INSTALLATION Page 13

COMPRESSOR PORT LOCATIONS - SGC 3519 & 3524

PORT NPTF SIZE NOTE

SB-2 3/4-14 X
SB-3 1½-11½ X
SC-3 1/2-14 X
SC-4 1/2-14 S
SC-5 3/8-18 O
SC-6 3/8-18 O
SC-7 1/8-27 X
SC-8 1¼-11½ S
SC-9 1½-11½ S
SC-10 1½-11½ S
SD-1 1/2-14 O
SL-1 1¼-11½ O
SL-2 1¼-11½ O
SM-1 2 Sq Flg X
SP-1 3/4-14 X
ST-1 3/4-14 O
SV-1 3 Sq Flg O
TW-1 3/4-14 O
X - Must connect to
O - Optional connect to
S - Service connection
070.650-IOM (NOV 13) SGC ROTARY SCREW COMPRESSOR
Page 14 INSTALLATION

HOLDING CHARGE AND STORAGE

Every SGC compressor is pressure and leak tested at the
Johnson Controls–Frick factory and then thoroughly evacu-
ated and charged with dry nitrogen to ensure its integrity
during shipping and short term storage prior to installation.

All compressors must be kept in a clean, dry location to

prevent corrosion damage. Compressors that will be stored
for more than two months must have their nitrogen charge
checked periodically (see pages in GENERAL INFORMATION
for complete instructions).

WARNING
Holding-charge shipping gauges (if mounted) are rated
for 30 psig and are for checking the shipping charge
only. They must be removed before pressure testing
Figure 4 - Lifting Rings, Model 355
and operating the system. Failure to remove these
gauges may result in catastrophic failure of the gauge
resulting in serious injury or death.
FOUNDATION
Each SGC Rotary Screw Compressor is shipped mounted on
a wooden skid, which must be removed prior to unit
CAUTION installation.
THIS EQUIPMENT HAS BEEN PRESSURIZED WITH
NITROGEN GAS. TEMPORARY VALVES & GAUGES
HAVE BEEN INSTALLED.
CAUTION
Allow proper spacing for servicing (see Dimensional
1. RELIEVE PRESSURE PRIOR TO OPENING LINES OR Outline Drawing).
MAKING FIELD CONNECTIONS.
2. REMOVE CHARGING VALVES OR GAUGES PRIOR The first requirement of the compressor foundation is that
TO PRESSURIZING SYSTEM. it must be able to support the weight.
3. REFER TO INSTALLATION OPERATION AND MAIN- SGC 1913 1,830 lb SGC 2321 3,115 lb
TENANCE MANUAL FOR ADDITIONAL INFORMA-
SGC 1918 2,050 lb SGC 2813 4,505 lb
TION.
SGC 2313 2,690 lb SGC 2817 4,585 lb
ESCAPING GAS MAY CAUSE INJURY SGC 2317 2,990 lb SGC 2824 6,440 lb
SGC 3511 8,525 lb
RIGGING AND HANDLING
SGC 3515 9,000 lb
The compressor can be moved with rigging, using a crane SGC 3519 9,500 lb
or forklift, by hooking into the two lifting rings at each end SGC 3524 10,000 lb
of the main housings. The compressor lifting rings shall only
be used to lift the compressor itself. See Figures 3 and 4. Screw compressors are capable of converting large
quantities of shaft power into gas compression in a relatively
small space. The compression process creates relatively
high frequency vibrations that require sufficient mass in the
base to effectively dampen them.

The best insurance for a trouble-free installation is to 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 is rigged into
place, its feet must be shimmed to level it. There must be
absolutely no stresses introduced into the compressor body
due to bolting of the feet and flanges.

The compressor motor mount is not designed to carry the

unsupported weight of the motor. The full motor weight
Figure 3 - Lifting Rings must be supported using the motor lifting point during the
motor installation process. After the necessary bracket to
support the motor have been welded into place on the
package and the rear motor feet and the motor mount have
been bolted into place, the weight of the motor can rest on
the support bracket and the motor mount.
 SGC ROTARY SCREW COMPRESSOR 070.650-IOM (NOV 13)
INSTALLATION Page 15

In any screw compressor installation, suction and discharge compressor oils per SPC 160.802 are recommended. Frick
lines should be supported in pipe hangers (preferably within Coolware compressor selection program include properties
2 feet of vertical pipe run) so that the lines won’t move if for the Frick oils and provide information on viscosity re-
disconnected from the compressor. See table for Allowable quirement for a given compressor selection.
Flange Loads.
Oil pressure
ALLOWABLE FLANGE LOADS The complete oil system shall be designed for a pressure
NOZ. MOMENTS (ft-lbf) LOAD (lbf) drop no higher than 15 psi with a clean oil filter element.
SIZE AXIAL VERT. LAT. AXIAL VERT. LAT. These is critical for the proper function of the balance pis-
NPS MR MC ML P VC VL ton and ensure the life of the axial bearings. At booster-,
1 25 25 25 50 50 50 low pressure and low pressure ratio operation an oil pump
1.25 25 25 25 50 50 50 must be build in to provide sufficient oil pressure.
1.5 50 40 40 100 75 75
2 100 70 70 150 125 125 The control system should have means to check the oil
3 250 175 175 225 250 250 pressure and compare to both suction and discharge pres-
4 400 200 200 300 400 400 sure. In general oil pressure shall be minimum (1.5 times the
5 425 400 400 400 450 450 suction pressure +15 psi) and higher than (discharge pres-
6 1,000 750 750 650 650 650 sure – 25 psi). For application with economizer and/or side-
8 1,500 1,000 1,000 1,500 900 900 load the oil pressure shall additional be more than 15 psi
10 1,500 1,200 1,200 1,500 1,200 1,200 above the pressure at the side port when in operation.
14 2,000 1,800 1,800 1,700 2,000 2,000
Advanced control systems like the Frick Quantum will check
CUSTOMER CONNECTIONS on the oil pressure in many more ways in order to keep the
compressor running beyond these basic limits e.g. keep
As a minimum you must connect to the locations specified compressor running safely in partial loaded condition.
on the port location and oil hydraulic schematic, in addition
to suction and discharge. OIL COOLING requIrementS
Compressor oil needs to be cooled to control the discharge
Other connections are available for instrumentation, oil
temperature, maintain proper oil viscosity and to preserve
return, and service as noted on the Dimensional Outline
the life of the oil. Normally the discharge temperature will
drawing. The electrical connections for the slide stop and
be in the 170° - 180°F range (see CoolWare™).
the slide valve transmitters and the solenoid valve coils
must be connected to your control system. One application that typically requires higher discharge
temperatures (as high as 250°F) is natural gas gathering
OIL SYSTEM REQUIREMENTS at the wellhead. Moisture is normally present in the gas
and it is imperative that the discharge temperature be at
WARNING least 30°F higher than the discharge dew point tempera-
ture for the gas. Run Coolware with the “Water Saturated”
Access valves in brass material must be removed and block checked to get the discharge dew point temperature
the holes filled with steel plugs when package is as- for your application. Oil temperatures as high as 170°F can
sembled. be used to achieve the necessary discharge temperature
to prevent moisture from condensing in the oil separator.
Contact Johnson Controls–Frick for additional information
for natural gas compression.

The main oil injection line that is connected to port SM1

must have a regulating valve to permit adjustment of the
oil flow to maintain the desired discharge temperature at
all times.

The use of a three-way mixing valve is recommended to

Figure 5 - Caution/Identification Tag on Access Valve keep the oil temperature in the normal range of 120° -
140°F. The valve will provide warm oil to the compressor
The oil system must provide oil to the compressor within quickly, reducing the pressure drop caused by cold, viscous
limitation on: oil. This ensures proper oil flow and temperature over the
• Oil selection full range of operating conditions.
• Oil pressure
• Oil temperature OIL FILTER(S)
• Oil cleanliness Use of filter elements other than Johnson Controls-Frick
must be approved in writing by Johnson Controls-Frick en-
Oil selection gineering or a warranty claim may be denied. Typical oil
The selected oil most be suitable for the application, refrig- filter specification β5 = 75 according to ISO 4572 is required
erant and operation condition. The compressor bearing re- to obtain the recommended oil cleanliness class 16/14/11
quire a minimum viscosity based on size and speed, rpm. A according to ISO 4406.
maximum viscosity of 100 cSt should not be exited. Frick
070.650-IOM (NOV 13) SGC ROTARY SCREW COMPRESSOR
Page 16 INSTALLATION

OIL HEATER(S)
Your package must be equipped with oil heaters that provide
sufficient heat to prevent condensation from occurring
during shutdown cycles.

COMPRESSOR OIL

WARNING
DO NOT MIX OILS of different brands, manufacturers,
or types. Mixing of oils can cause excessive oil foam-
ing, nuisance oil level cutouts, oil pressure loss, gas or
oil leakage and catastrophic compressor failure. Cool-
Ware will select a specific Frick oil for the refrigerant
being used. Depending on the application, a different
oil can be selected provided it is of the proper viscos-
ity and is compatible with the refrigerant and com-
pressor elastomers. Figure 6 - SGC Compressor with Tunnel Mount

OIL PUMP
CAUTION
If your SGC compressor application requires an oil pump, it
The compressor-tunnel-motor assembly must be free
is recommended that a strainer be mounted upstream to of internal stress which can misalign the coupling!
protect it. Frick supplied pumps are a positive displacement
gear type that must have a safety relief valve to ensure the 1. Place a new gasket on the oil separator flange. Assemble
oil pressure will not be more than 50 psi above compressor the new compressor to the tunnel and hand tighten the bolts
discharge pressure for all models. in a star pattern. Then torque to 1/3 of table value in star
pattern increasing by 1/3’s to full torque. Refer to Table 2 for
CAUTION torque specifications.

If oil pressure exceeds 55 PSI above compressor dis- 2. Set the compressor and motor assembly on the separator
charge it could cause catastrophic compressor failure flange and align the oil separator flange bolt holes to the
due to male axial bearing failure. See CoolWare™ for compressor discharge flange bolt holes while supporting
your application’s requirements. the assembly with a hydraulic piston underneath the motor.
The hydraulic piston must support the motor weight, motor
COMPRESSOR support / tunnel weight. Alternately... lift with a crane in the
motor lifting ring.
COMPRESSOR ROTATION IS CLOCKWISE WHEN FACING
THE END OF THE COMPRESSOR SHAFT 3. Insert the bolts through the oil separator flange and into
Confirm motor will rotate the compressor clockwise before the compressor discharge flange. Tighten bolts using a star
installing the coupling. pattern. Lube bolts then finger tight on all bolts, then torque
to 1/3 of table value in star pattern increasing by 1/3’s to
full torque. Reference Table that is with the Maintenance
CAUTION Schedule.
To prevent injury or damage to components, and for 4. The compressor and motor feet should rise above their
complete details regarding pressurized refrigerant vapor respective support bases. If not, remove the compressor, add
transfer and recovery, see the current Installation- another gasket on top of the oil separator flange and repeat
Operation-Maintenance Manual for your unit.
steps 2 and 3.
MOUNTING (USE OF MOTOR TUNNEL) - PROPOSAL 5. While the assembly is still supported, measure the
This is a proposal for mounting on a horizontal oil separator clearance between the compressor feet and base plate with
like the Frick RWF II. a feeler gage. Shim the compressor feet to gage reading plus
.002” gap between each compressor foot and the support
base. Then, bolt the compressor to the support base and
torque the bolts. Reference Table 2.

6. While the assembly is still supported, measure the

clearance between the motor feet and base plate with a
feeler gage. Shim the motor feet to gage reading plus .002”
gap between each motor foot and the support base. Then,
bolt the motor to the mounting base and torque the motor
mounting bolts.

7. Connect all tubing and pipe connections to the compressor

and all wiring to the motor.
 SGC ROTARY SCREW COMPRESSOR 070.650-IOM (NOV 13)
INSTALLATION Page 17

TABLE 2 - BOLT TORQUE VALUE Maximum radial runout is .004” total indicator reading.
Torque Maximum axial runout is .004” total indicator reading.
Compressor
Screw Size
Model ft-lb NM A dial indicator or another appropriate measuring device is
SGC 19XX M12 X 1.75 58 79 to be used to determine the Total Indicator Runout.
SGC 23XX M12 X 1.75 58 79
SGC 28XX M16 X 2.0 144 195 Indicator bracket sag must be checked as all brackets have
SGC 35XX M20 X 2.5 260 353 some flexibility. The best way to measure this is to attach
the dial indicator and bracket on a pipe at the coupling span
MOTOR MOUNTING (FOOT MOUNTED ONLY)
distance. Zero the indicator in the 12:00 position, and rotate
1. Thoroughly clean the motor feet and mounting pads of the pipe so the indicator is in the 6:00 position. The reading
grease, burrs, and other foreign matter to ensure firm on the indicator in the 6:00 position is the bracket sag. This
seating of the motor. value must be included in the dial indicator readings when
affixed to the coupling for an accurate alignment.
2. Attach the motor to the base using bolts and motor
raising blocks, if required. DEHYDRATION / EVACUATION TEST
3. Weld the four kick bolts (not included with compressor) Evacuate the system to 1000 microns. Valve off the vacuum
into place so that they are positioned to allow movement pump and hold vacuum for one hour.
of the motor feet.
Pass – Vacuum cannot rise more than 500 microns during
4. After the motor has been set, check to see that the one hour hold period.
shafts are properly spaced for the coupling being used. Fail – Vacuum rise is more than 500 microns during one
Check the appropriate Dimensional Outline drawing hour hold period. Identify and repair any system leaks.
for the minimum clearance required between the shaft Repeat vacuum test until requirements are met.
ends to change the shaft seal.

COMPRESSOR/MOTOR COUPLING REQUIREMENTS.

ELECTRICAL INSTALLATION
SGC compressors are arranged for direct motor drive and SLIDE STOP TRANSMITTER
require a flexible drive coupling to connect the compressor The slide stop transmitter (Figure 7) measures the position
to the motor. of the slide stop (SS) using a 20 to 4 mA signal to cover
the range of minimum to maximum VI. The signal is sent
If you are using the Johnson Controls – Frick motor mount,
to your control system so that it can adjust the position of
the mount is machined to ensure that motor to compressor
SS according to system pressures. The correct SS position
alignment is in specification (see the above “MOTOR
is important to achieve the most efficient compressor
MOUNTING” section for mounting details).
operation. Connect to +/- and signal as show in the wiring
If you are using a foot mounted motor, it is essential that diagram in Figure 6. Refer to Frick compressor panel
the coupling be properly aligned to ensure proper bearing instructions 090.040-O for calibration procedure.
and seal performance.

1. Coupling must be selected and installed so that it

doesn’t transmit any axial load to the compressor
shaft.

2. Set up the minimum distance between compressor

shaft and motor shaft to allow for seal removal (see
Outline drawings).

3. Coupling must be able to take up any misalignment

between motor and compressor. It is critical to the
life of the shaft seal that misalignment is kept to the
minimum possible value. Be sure to follow the coupling Figure 7 - Slide Stop Transmitter
manufacturer’s guidelines for checking and correcting
any misalignment. See the next section for Johnson
Controls–Frick requirements.

COUPLING ALIGNMENT REQUIREMENTS

(FOOT MOUNTED ONLY)
Coupling alignment must be performed prior to start-
up. After the compressor has been installed on the job
site, alignment must be checked again and if necessary
corrected prior to start-up. After a few hours operation,
the alignment must be checked while the package is still
hot. Correct hot alignment is critical to ensure the life of the
shaft seal and compressor bearings.
070.650-IOM (NOV 13) SGC ROTARY SCREW COMPRESSOR
Page 18 INSTALLATION

Directional control valves

Solenoids YY1, YY2, YY3 and YY4 must be wired to give
the correct function. A description of their function is given
in the OPERATION chapter. For control system information
refer to Frick Compressor Control Panel 090.040-O. See
wiring diagram in Figure 11.

Figure 8 - Wiring Diagram for Slide Stop Transmitter

CAPACITY SLIDE VALVE TRANSMITTER

The slide valve transmitter (Figure 9) measures the position Figure 11 - Directional Control Valve Wiring Diagram
of the slide valve (SV) and sends a 4 to 20mA signal to
your control system. See Figure 8. The controller will adjust
COMPRESSOR HYDRAULIC SYSTEM
(The solenoid valves and manifold block are available as
the position of the SV according to the motor load set
a sales order option - See Figures 12 and 13)
point. The correct position is important to properly load the
compressor and motor. It is important not to overload the The compressor hydraulic system actuates the movable slide
compressor and motor. Observe the maximum power input valve (SV) to load and unload the compressor. It also actuates
and ensure design limitations are not exceeded. Connect to the movable slide stop (SS) to increase or decrease the
+/- and signal as shown in the wiring diagram, Figure 10. compressor’s volume ratio (Vi). The hydraulic cylinder located
Refer to Frick compressor panel instructions for calibration at the inlet end of the SGC compressor serves a dual purpose.
procedure 090.040-O. It is separated by a fixed bulkhead into two sections. The SV
section is to the left of the bulkhead and the SS is to the right
SHADED AREA SHOWS if you are facing the right side of the compressor. Both
END VIEW CAPACITY LINEAR TRANSMITTER operations are controlled by double-acting, four-way solenoid
STAINLESS STEEL WELL valves, which are actuated when a signal from the appropriate
DIN CONNECTOR microprocessor output energizes the solenoid valve.
SINGLE-ACTING MODE - High Stage
Open valve at SC1
Close valve at SC2
HEAT ISOLATOR Open valve at BP (bypass)

High stage compressor loading: The compressor loads

when SV solenoid YY2 is energized and oil flows from the
COMPRESSOR UNLOAD CYLINDER
unload side of the cylinder out port SC1, through valve ports
CAST ALUMINUM HOUSING A and T to compressor suction. Simultaneously, discharge
pressure loads the slide valve.
Figure 9 - Capacity Slide Valve Transmitter
High stage compressor unloading: The compressor
unloads when SV solenoid YY1 is energized and oil flows
from the oil manifold through valve ports P and A to cylinder
port SC1 and enters the unload side of the cylinder.
Simultaneously, gas on the load side of the cylinder is
vented through port SC2 and valve BP to compressor
suction.

NOTICE
To control the rate of loading and unloading, throttle
the needle valve at SC1 port.

DOUBLE-ACTING MODE - Booster (low differential)

Open valve at SC1
Open valve at SC2
Figure 10 - Wiring Diagram for Slide Valve Transmitter Close valve at BP (bypass)
 SGC ROTARY SCREW COMPRESSOR 070.650-IOM (NOV 13)
OPERATION Page 19

SC1 SC2 SC3 SC4 SC1 SC2 SC3

SC 4 NOT USED
2 2 2 2 2 2 2
DIRECTION
SC1 SC2 SC3 SC4 CONTROL SC1 SC2 SC3 SC4 DIRECTION
2 VALVE 2 CONTROL VALVE
1 1 1 1 1 1 1
BP BP
A B A B A B A B
YY1 YY2 1
YY3 YY4 YY1 YY2 1
YY3 YY4
P T P T P T P T

SV-2 SV-3 SV-2 SV-3

P T P T
SCREW IN FLOW SCREW IN FLOW
DIRECTION REGULATING REGULATING
CONTROL VALVE NEEDLE VALVE NEEDLE VALVE

HYDRAULIC SCHEMATIC HYDRAULIC SCHEMATIC

SGC 1913 – 2824 SP-1 SGC 3511 – 3524
Valve 1

SC4 SC3
Valve 1 P
T
Valve 2 BP COMPRESSOR TOP VIEW
(INCREASE VI) YY3 YY4 (DECREASE VI) SC2 SC1
(UNLOAD) YY1 YY2 (LOAD)

COMPRESSOR TOP VIEW

SC-5 Valve 2

(INCREASE VI) YY3 YY4 (DECREASE VI)

(UNLOAD) YY1 YY2 (LOAD)

Figure 12 - Hydraulic Schematic

Booster Compressor Loading: The compressor loads when

SV solenoid YY2 is energized and oil flows from the oil
manifold through valve ports P and B to cylinder port SC2
and enters the load side of the cylinder. Simultaneously, oil
contained in the unload side of the cylinder flows out
cylinder port SC1 through valve ports A and T to compressor
suction.

Booster Compressor Unloading: The compressor unloads

when SV solenoid YY1 is energized and oil flows from the
oil manifold through valve ports P and A to cylinder port
SC1 and enters the unload side of the cylinder. Simultaneously, Figure 13 - Solenoid Valve Block
oil contained in the load side of the cylinder flows out of
compressor port SC2 through valve ports B and T to
compressor suction. CAUTION
NEVER open valve BP and valve SC2 at the same time
NOTICE during compressor operation.

To control the rate of loading and unloading, throttle

valves SC1 and SC2.
VOLUMIZER VOLUME RATIO CONTROL
Open valve at SC3
NOTICE Open valve at SC4
To slow all valve movements - loading, unloading, and Compressor Vi increase: The volume ratio Vi is increased
Vi change - throttle valve 2. when MSS solenoid valve YY3 is energized and oil flows
from the oil manifold through valve ports P and A to
compressor port SC3, enters the increase side of the
cylinder and overcomes the decreased spring tension.
Simultaneously, oil flows from SC4 port through valve ports
B and T to compressor suction.
070.650-IOM (NOV 13) SGC ROTARY SCREW COMPRESSOR
Page 20 OPERATION

Compressor Vi decrease: The volume ratio Vi is decreased OPERATION

when MSS solenoid valve YY4 is energized and oil flows
from the oil manifold through valve ports P and B to OPERATION and START-UP INSTRUCTIONS
compressor port SC4, enters the decrease side of the
cylinder. Simultaneously, oil flows form SC3 port through The Frick SGC Rotary Screw Compressor will be a component
valve ports A and T to compressor suction. in an integrated system. As such the compressor requires
some specific operation and conditions to ensure trouble-
TO CONTROL THE RATE OF Vi CHANGE, THROTTLE THE free running.
NEEDLE VALVE AT SC3 PORT.
The information in this section of the manual provides the
LOW AMBIENT OPERATION logical step-by-step instructions to properly start up and
operate the SGC Rotary Screw Compressor in your Unit.
It is recommended that package oil separators be insulated Only matters which may influence the proper operation of
as a minimum requirement to preserve the heat generated the SGC compressor are included.
by the oil heaters, to prevent condensation and secure
lubrication at start-up.
NOTICE
THE FOLLOWING SUBSECTIONS MUST BE READ AND
UNDERSTOOD BEFORE ATTEMPTING TO START OR
OPERATE THE UNIT.

INITIAL START-UP
Prior to the start-up, the prestart check must be
accomplished. See Forms section for Checklist.

INITIAL START-UP PROCEDURE

Having performed the prestart check, the compressor unit
is ready for start-up. It is important that an adequate gas
load be available to load test the unit at normal operating
conditions. The following points should be kept in mind
during initial start-up.

1. For proper and safe operation, the compressor must be

run at the proper speed and discharge pressure. Exceeding
design conditions creates a potential hazard.
2. After 1 to 3 hours of operation adjust oil cooling system.
3. Pull and clean suction strainer after 24 hours of operation.
If it is excessively dirty, repeat every 24 hours until system
is clean. Otherwise, follow the normal maintenance
schedule.
4. Perform vibration analysis if equipment is available.

NORMAL START-UP PROCEDURE

1. Confirm system conditions permit starting the
compressor.
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.
 SGC ROTARY SCREW COMPRESSOR 070.650-IOM (NOV 13)
MAINTENANCE Page 21

5. Protect the compressor during long periods of

MAINTENANCE shutdown. If the compressor will be sitting for long periods
without running, it is advisable to evacuate to low pressure
GENERAL INFORMATION and charge with dry nitrogen or oil. This is particularly true
This section provides instructions for normal maintenance, on systems known to contain water vapor.
a recommended maintenance program, and troubleshooting 6. Preventive maintenance inspection is recommended
and correction guides. any time a compressor exhibits a noticeable change in
vibration level, noise, or performance.

WARNING CHANGING OIL

THIS SECTION MUST BE READ AND UNDERSTOOD BE-
FORE ATTEMPTING TO PERFORM ANY MAINTENANCE
OR SERVICE TO THE UNIT.
WARNING
DO NOT MIX OILS of different brands, manufacturers,
or types. Mixing of oils may cause excessive oil foam-
ing, nuisance oil level cutouts, oil pressure loss, gas or
CAUTION oil leakage and catastrophic compressor failure.
Cylinder assembly under high spring load. Consult
manual before disassembly. Improper disassembly may Shut down the unit when changing oil. At the same time all
cause injury due to spring tension release. oil filter cartridges must be changed and all oil strainer ele-
ments removed and cleaned. The procedure is as follows:
NORMAL MAINTENANCE OPERATIONS 1. Stop the compressor unit.
2. Lock out the motor starter.
When performing maintenance you must take several
precautions to ensure your safety: 3. Close the suction and discharge service valves
4. Using appropriate equipment, lower the compressor
1. IF UNIT IS RUNNING, PRESS [STOP] KEY.
pressure to 0 psig.
2. STOP MOTOR AND LOCK OUT STARTER BEFORE
PERFORMING ANY MAINTENANCE. 5. Open the drain valve(s) and drain oil into a suitable
3. WEAR PROPER SAFETY EQUIPMENT WHEN container.
COMPRESSOR UNIT IS OPENED TO ATMOSPHERE. 6. Drain the oil filter(s) and the oil coolers.
4. ENSURE ADEQUATE VENTILATION. 7. Remove the old filter cartridges, and install new ones.
5. TAKE NECESSARY SAFETY PRECAUTIONS REQUIRED 8. Remove, clean, and reinstall elements in the strainers.
FOR THE GAS BEING USED. 9. Evacuate the unit.
GENERAL MAINTENANCE 10. Open the suction service valve and pressurize the unit
to system suction pressure. Close the suction valve and
Proper maintenance is important in order to assure long and leak test.
trouble-free service from your screw compressor. Some areas 11. Add oil.
critical to good compressor operation are:
12. Open the suction and discharge service valves
1. Keep oil clean and dry, avoid moisture contamination. 13. Remove the lockout from the motor starter.
After servicing any portion of the refrigeration system, 14. Start the unit
evacuate to remove moisture before returning to service.
Water vapor condensing in the compressor while running RECOMMENDED MAINTENANCE PROGRAM
or more likely while shut down, can cause rusting of critical In order to obtain maximum compressor performance and
components and reduce life. ensure reliable operation, a regular maintenance program
2. Keep suction strainer clean. Check periodically, should be followed. The compressor unit should be checked
particularly on new systems where welding slag or pipe regularly for leaks, abnormal vibration, noise, and proper
scale could find its way to the compressor suction. Excessive operation. A log should also be maintained. Oil analysis
dirt in the suction strainer could cause it to collapse, should be performed on a regular basis. It is a valuable tool
dumping particles into the compressor. that can identify the presence of moisture, acid, metallics
and other contaminants that will shorten compressor life if
3. Keep oil filters clean. If filters show increasing pressure
not corrected. In addition, an analysis of the compressor
drop, indicating dirt or water, stop the compressor and
vibration should be made periodically.
change filters. Running a compressor for long periods with
high filter pressure drop can starve the compressor of oil VIBRATION ANALYSIS
and lead to premature bearing failure. Dual oil filters are
recommended so that the filters can be changed without Periodic vibration analysis can be useful in detecting bearing
shutting down the package. wear and other mechanical failures. If vibration analysis is
4. Avoid slugging the compressor with liquids (oil). While used as a part of your preventive maintenance program,
screw compressors are probably the most tolerant of any take the following guidelines into consideration.
compressor type available today about ingestion of some 1. Always take vibration readings from exactly the same
liquid, they are not liquid pumps. Make certain a properly places and at exactly the same percentage of load.
sized suction accumulator is used to avoid dumping liquid 2. Use vibration readings taken from the new unit at start-
into compressor suction. up as the baseline reference.
070.650-IOM (NOV 13) SGC ROTARY SCREW COMPRESSOR
Page 22 MAINTENANCE

3. Evaluate vibration readings carefully as the instrument 2. Only use Frick filter elements. Substitutions must be
range and function used can vary. Findings can be easily approved in writing by Johnson Controls - Frick engineering
misinterpreted. or warranty claim may be denied.
4. Vibration readings can be influenced by other equipment 3. Participate in a regular, periodic oil analysis program to
operating in the vicinity or connected to the same piping as maintain oil and system integrity.
the unit.
OPERATING LOG
OIL QUALITY and ANALYSIS The use of an operating log as included in this manual
permits thorough analysis of the operation of a system by
High quality and suitable oil is necessary to ensure
those responsible for its maintenance and servicing.
compressor longevity and reliability. Oil quality will rapidly
Continual recording of gauge pressures, temperatures, and
deteriorate in systems containing moisture and air or other
other pertinent information, enables the observer and
contaminants. In order to ensure the quality of the oil in the
serviceman to be constantly familiar with the operation of
compressor unit:
the system and to recognize immediately any deviations
1. Only use Frick oil or high quality oils approved by Johnson from normal operating conditions. It is recommended that
Controls - Frick for your application. readings be taken at least daily.

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
200

Maintenance

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
Check Coupling (a) n Annually Regardless of Operating Hours
Suction & Disch Flange Bolts (d) n n n n n n n n n n n n n n n n n n n n n n
VFD Units Check Skip Freq. (f) n n n n n n n n n n n n n n n n n n n n n n
Check Electrical Connections (b) n n n n n n n n n n n n n n n n n n n n
Check Sensor Calibration (c) n n n n n n n n n n n n n n n n n n n n n
Vibration Analysis (e) n Every 6 Months, More Frequently If Levels Increase
Replace Shaft Seal When Leak Rate Exceeds 7 - 8 Drops Per Minute
a. Check bolts, shim packs, center inserts, keys, and all bolt torques.
b. Check and torque all terminals in the processor and starter panel per the specification posted in the enclosure.
c. Check calibration of Slide Valve, Slide Stop, pressures and temperatures. Calibration should be conducted with NIST certified devices.
d. Verify tightness of bolts on suction and discharge flanges. See table below for torque requirements.
e. Vibration measurement must be carried out continuously to obtain optimum preventative control on bearings. If not continuously
controlled, then every 6 months, more frequently if levels increase.
f. Units with varible speed drives - check for excess vibration and skip frequencies anytime unit operating conditions change.

Compressor Discharge Flange to Separator Flange Suction Flange

Model Bolt Size Torque* (ft-lb) Bolt Size (in.) Torque* (ft-lb)
SGC 1913 M20 X 2.5 140 M20 X 2.5 180
SGC 1918 M20 X 2.5 140 M20 X 2.5 160
SGC 2313 M20 X 2.5 160 M20 X 2.5 160
SGC 2317 M20 X 2.5 160 M20 X 2.5 200
SGC 2321 M20 X 2.5 160 M22 X 2.5 220
SGC 2813, 2817 M22 X 2.5 230 M22 X 2.5 220
SGC 2821 M22 X 2.5 230 M24 X 3.0 220
SGC 3511 M24 X 3.0 240 M30 X 3.5 350
SGC 2824 M22 X 2.5 240 M24 X 3.0 220
SGC 3515, 3519, 3524 M24 X 3.0 240 M30 X 3.5 350
* Based on: Gaskets-Garlock® Blue-Gard® 3300; Bolts-class 8.8 or stronger hex head bolts, lightly oiled and clean
 SGC ROTARY SCREW COMPRESSOR 070.650-IOM (NOV 13)
MAINTENANCE Page 23

TROUBLESHOOTING GUIDE 2. Remove DIN connector plug from transmitter.

3. Loosen cap screws.
Successful problem solving requires an organized approach 4. Remove transmitter unit.
to define the problem, identify the cause, and make the 5. Install new transmitter unit.
proper correction. Sometimes it is possible that two 6. Tighten cap screws.
relatively obvious problems combine to provide a set of 7. Apply DIN connector plug to transmitter.
symptoms that can mislead the troubleshooter. Be aware of 8. Turn on control power.
this possibility and avoid solving the “wrong problem”.
SHADED AREA SHOWS
ABNORMAL OPERATION ANALYSIS and CORRECTION END VIEW CAPACITY LINEAR TRANSMITTER
Four logical steps are required to analyze an operational
STAINLESS STEEL WELL
problem effectively and make the necessary corrections:
DIN CONNECTOR
1. Define the problem and its limits.
2. Identify all possible causes.
3. Test each cause until the source of the problem is found.
4. Make the necessary corrections.

The first step in effective problem solving is to define the HEAT ISOLATOR
limits of the problem. The following list of abnormal system
conditions can cause abnormal operation of the SGC
compressor:
COMPRESSOR UNLOAD CYLINDER
1. Insufficient or excessive refrigerant or gas load.
2. Excessively high suction pressure. CAST ALUMINUM HOUSING
3. Excessively high discharge pressure.
4. Excessively high or low temperature coolant to the oil Figure 14 - Capacity Linear Transmitter
cooler.
VOLUMIZER® TRANSMITTER REPLACEMENT - SLIDE STOP
5. Excessive liquid entering the compressor (slugging).
6. Insufficient oil cooling. The VOLUMIZER® Transmitter is located on the right side
7. Excessive oil cooling of the compressor (facing shaft) at the inlet end (see
8. Incorrect gas line sizing. Figure 15).
9. Improper system piping.
10. Wrong operation of hydraulic operated slide valve.
11. Problems in electrical service to compressor.
12. Moisture present in the system.

Make a list of all deviations from normal compressor

operation. Delete any items, which do not relate to the
symptom and separately list those items that might relate
to the symptom. Use the list as a guide to further investigate
the problem.
The second step in problem solving is to decide which
items on the list are possible causes and which items are
Figure 15 - Volumizer® Transmitter
additional symptoms. High discharge temperature and high
oil temperature readings on a display may both be symptoms The linear transmitter, with hermetic, enclosure is based on
of a problem and not causally related. the inductive measuring principle. It features removable
electronics (from the sensor well) eliminating the need to
The third step is to identify the most likely cause and take
evacuate the compressor for replacement. This type of
action to correct the problem. If the symptoms are not
transmitter is dedicated to volume ratio control and has no
relieved, move on to the next item on the list and repeat the
user adjustments.
procedure until you have identified the cause of the
problem. Once the cause has been identified and confirmed 1. Shut off control power.
make the necessary corrections. 2. Remove DIN connector plug from transmitter.
3. Loosen setscrews.
CAPACITY LINEAR TRANSMITTER REPLACEMENT - 4. Remove transmitter unit.
SLIDE VALVE 5. Install new transmitter unit.
The Capacity Linear Transmitter is located on the end of the 6. Tighten setscrews.
compressor cylinder (see Figure 14). The linear transmitter 7. Apply DIN connector plug to transmitter.
with hermetic enclosure is based on the inductive measuring 8. Turn on control power.
principle. It features removable electronics (from the sensor
well) eliminating the need to evacuate the compressor for
replacement. This type of transmitter is dedicated to
capacity control and is not adjustable.
1. Shut off control power.
070.650-IOM (NOV 13) SGC ROTARY SCREW COMPRESSOR
Page 24 MAINTENANCE

6. Thoroughly clean the new compressor and remove all

NOTICE cover plates and protection etc.
For calibration of the Volumizer® unit, refer to the 7. Install new gaskets and sealing in all connections.
Analog Calibration instructions in publication 090.040-O. 8. Set the new compressor in place and shim feet where
required.
BARE COMPRESSOR REPLACEMENT 9. Reattach the drive coupling.
10. Check the shaft alignment.
The following procedure is required only when a bare 11. Complete tubing, piping, and wiring.
compressor is replaced in the field.
1. Verify that the starter is locked out. SHUTDOWN DUE TO IMPROPER OIL PRESSURE
2. Remove all tubing, piping, and wiring that is connected (High Stage and Booster)
to the compressor.
The compressor must not operate with incorrect oil pressure.
3. Disconnect the coupling from the motor shaft.
4. While supporting the motor and compressor assembly 1. Refer to CONTROL SETUP
with a crane, remove the bolts at the compressor feet.
5. Thoroughly clean the compressor feet and mounting
pads of burrs and other foreign matter to ensure firm
seating of the compressor.

TROUBLESHOOTING THE SGC COMPRESSOR

SYMPTOM PROBABLE CAUSES and CORRECTIONS
SLIDE VALVE and/or SLIDE STOP 4-way hydraulic control valve failed. Repair or replace.
WILL NOT MOVE Slide stop indicator rod stuck. Contact Johnson Controls–Frick Service for assistance.
Check both S.V. and S.S. feedback devices for wiring and resistance.
Compressor must be running with sufficient oil pressure.
Unloader piston stuck. Contact Johnson Controls–Frick service for assistance.
Piston Seals worn out or damaged. Contact Johnson Controls-Frick Service.

NOTICE
Unless the Service Technician has been certified by Johnson Controls – Frick to rebuild our compressors,
troubleshooting the compressor is limited to identifying the probable cause. If a mechanical problem is suspected
contact Johnson Controls – Frick Service. DO NOT ATTEMPT TO DISASSEMBLE COMPRESSOR.
 SGC ROTARY SCREW COMPRESSOR 070.650-IOM (NOV 13)
MAINTENANCE Page 25

TROUBLESHOOTING THE HYDRAULIC SYSTEM

SYMPTOM PROBABLE CAUSES and CORRECTIONS
SLIDE VALVE WILL NOT LOAD OR Solenoid coils burned out. Replace.
UNLOAD Valve closed. Open hydraulic service valves.
Solenoid spool stuck or centering spring broken. Replace.
Check LED on coil. If lit, there is power to the coil. Check coil.
Solenoid may be actuated mechanically by inserting a piece of 3/16” rod against
armature pin and pushing spool to opposite end. Push A side to confirm unload
capability. If valve works, problem is electrical.
SLIDE VALVE WILL LOAD BUT A side solenoid coil may be burned out. Replace.
WILL NOT UNLOAD Dirt inside solenoid valve preventing valve from operating both ways. Clean.
Check LED on coil. If lit, valve is functioning mechanically. Problem is electrical.
Solenoid may be actuated mechanically by inserting a piece of 3/16” rod against
armature pin and pushing spool to opposite end. Push A side to confirm unload
capability. If valve works, problem is electrical.
SLIDE VALVE WILL 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.
Check LED on coil. If lit, valve is functioning mechanically. Problem is electrical.
Solenoid may be actuated mechanically by inserting a piece of 3/16” rod against
armature pin and pushing spool to opposite end. Push A side to confirm unload
capability. If valve works, problem is electrical.
SLIDE 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 Johnson Controls - Frick Service.

TROUBLESHOOTING THE OIL PUMP AND SYSTEM

SYMPTOM PROBABLE CAUSES and CORRECTIONS

PUMP WILL NOT PRODUCE Check that service valves are open.
ENOUGH OIL PRESSURE AT Filter cartridges may be blocked. Check PSID across filters.
START-UP
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 Main oil injection throttling valve too wide open or oil pressure regulating valve
OFF WHEN COMPRESSOR improperly adjusted. Readjust both valves.
STARTS
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 Filters clogged with dirt. Replace.
HIGH Oil is too cold. Allow oil to warm up and check again.
Service valve on filter outlet is partially closed. Open valves fully.
070.650-IOM (NOV 13) SGC ROTARY SCREW COMPRESSOR
Page 26 MAINTENANCE

FORMS ROTARY SCREW COMPRESSOR OPERATING LOG SHEET

 SGC ROTARY SCREW COMPRESSOR 070.650-IOM (NOV 13)
MAINTENANCE Page 27

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,
__ Remove compressor drive coupling guard all pertinent wiring information, and drawings
__ Remove coupling center and do not reinstall __ Confirm proper power supply to the starter package
(motor rotation must be checked without center) __ Confirm proper motor protection (breaker sizing)
__ Check for correct position of all hand, stop, and check __ Confirm that all wiring used is stranded copper and is
valves prior to charging unit with oil or refrigerant 14 AWG or larger (sized properly)
__ Charge unit with correct type and quantity of oil __ Confirm all 120 volt control wiring is run in a separate
__ Lubricate electric drive motor bearings PRIOR to conduit from all high voltage wiring
checking motor rotation __ Confirm all 120 volt control wiring is run in a separate
__ Check oil pump alignment (if applicable) conduit from oil pump and compressor motor wiring
__ Check for correct economizer piping (if applicable) __ Confirm no high voltage wiring enters the micro panel
__ Check separate source of liquid refrigerant supply (if at any point
applicable, liquid injection oil cooling) __ Check current transformer for correct sizing and instal-
__ Check water supply for water-cooled oil cooler (if ap- lation
plicable, water cooled oil cooling) __ Check all point-to-point wiring between the micro and
__ Check thermosyphon receiver refrigerant level (if ap- motor starter
plicable, thermosyphon oil cooling) __ Confirm all interconnections between micro, motor
__ Check for proper pipe supports and correct foundation starter, and the system are made and are correct
__ Check to ensure ALL piping INCLUDING RELIEF VALVES __ Ensure all electrical panels are free from installation
is completed debris, METAL PARTICLES, and moisture

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: Customer connections are to be made per the electrical diagram for the motor starter listed under
the installation section and per the wiring diagram listed under the maintenance section of the IOM.
Please complete and sign this form & fax to 717-762-8624 as confirmation of completion.

Frick Sales Order Number:_______________________ 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: _ ______________________________________
070.650-IOM (NOV 13) SGC ROTARY SCREW COMPRESSOR
Page 28 MAINTENANCE

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

Operating Log Sheet

Date
Time
Hour Meter Reading
Equip. Room Temp.
Suction Pressure
Suction Temperature
Suction Superheat
Discharge Pressure
Discharge Temperature
Corresponding Temperature
Oil Pressure
Oil Temperature
Oil Filter Pressure Drop
Separator Temperature
Slide Valve Position
Volume Ratio (VI)
Motor Amps / FLA %
Capacity Control Setpoint
Oil Level
Oil Added
Seal Leakage (Drops/Min.)
 SGC ROTARY SCREW COMPRESSOR 070.650-IOM (NOV 13)
MAINTENANCE Page 29

VIBRATION DATA SHEET

Date: ___________________________________________ Sales Order Number:_________________________________

End User: ________________________________________ Installing Contractor:_________________________________
Address: ___________________________________________ Service Technician:___________________________________

Equipment ID (As in Microlog): _____________________

Compressor Serial Number:_ __________________________
Unit Serial Number:_ _________________________________
National Board Number:_ _____________________________
Running Hours:______________________________________
Manufacturer and Size of Coupling:_____________________
Motor Manufacturer: _________________________________
Motor Serial Number:_________________________________
RPM:_________ Frame Size:____________ H.P.___________
Refrigerant:
Ambient Room Temperature: _____________°F
Operating Conditions:

SUCTION DISCHARGE OIL SEPARATOR Slide Valve Position %

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

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

Compressor Inboard
Compressor Outboard Motor Outboard (Noncoupled End)
(Coupling End Female)
(Nondrive End) Horizontal _______ . ______ IPS Overall
Axial Direction
Vertical Direction Vertical _______ . ______ IPS Overall
____.____ IPS Overall
____.____ IPS Overall Axial _______ . ______ IPS Overall
070.650-IOM (NOV 13) SGC ROTARY SCREW COMPRESSOR
Page 30 INSTALLATION - OPERATION - MAINTENANCE

Index
A hydrocarbon gasses, 3

accumulator, 3 I
Allowable Flange Loads, 15
angular-contact bearings, 5 identification data plate, 3
Antifriction bearings, 6 INSTALLATION, 7
ASHRAE, 3 insulated, 19

B L
balance piston, 5 lifting rings, 14
Balance pistons, 5 linear transmitter, 22
bare compressor, 23 load surges, 3
Booster, 18 Long term storage, 4
bulkhead, 18 lubrication system, 5

C M
Capacity control, 6 maintenance, 20
Capacity Linear Transmitter, 22 Maintenance
Compressor Oil, 15 Maintenance Schedule, 21
Compressor Port Locations, 8 MAINTENANCE
Compressor Prestart Checklist, 26 Operating Log Sheet, 25
Compressor rotation, 5 male rotor, 6
compressor shaft seal, 6 male rotor shaft, 5
compressor suction, 18 motor, 23
condensation, 3, 16 Motor, 27
Coolware™, 3 motor mount, 6
corrosion, 4, 14 MSV solenoid, 18
coupling, 23
Customer Connections, 15 N
needle valve, 18
D
dimensions, 7 O
DIN connector plug, 22 Oil analysis, 20
discharge pressure, 6, 18, 22 oil cooler, 22
discharge temperature, 3 oil cooling system, 19
drive coupling, 23 oil filter cartridges, 20
Drive Train Alignment, 27 oil filters, 20
dry nitrogen, 14 Oil Filter(S), 16
Oil Heater(S), 16
E oil manifold, 18
Evacuation lines, 5 oil pressure, 5, 15
Oil Pump, 15
F Oil quality, 21
oil seal, 5
female rotor, 6 oil strainer elements, 20
FOUNDATION, 14 oil supply, 5
operating log, 21
G Operating Log Sheet, 27
gaskets, 23 Operating Log Sheet, 25
gas load, 22 over-compression, 6

H P
hermetic enclosur, 22 pipe hangers, 15
hermetic enclosure, 22 piping layouts, 3
High capacity roller bearings, 5 piping stress, 14
Holding Charge, 14 pressure ratio, 6
hydraulic cylinder, 5, 18 Prestart Checklist, 26
 SGC ROTARY SCREW COMPRESSOR 070.650-IOM (NOV 13)
INSTALLATION - OPERATION - MAINTENANCE Page 31

R Pump strainer, 24
service valves, 24
Rigging And Handling, 14 Slide Stop, 23
rotor housing, 6 Slide stop indicator rod, 23
RXF/XJF Slide Valve, 23
Compressor Replacement Solenoid coils, 23
Discharge flange, 15 Solenoid spool, 23
Separator flange, 15 Strainer, 24
Shim motor feet, 16 Unloader piston, 23
Tunnel Mount, 15
S
seal life, 5
U
seal well, 5 under-compression, 6
serial number, 3 unloading, 6
shaft alignment, 23
Shaft rotation, 5 V
Shaft seal housing, 5
shipping gauges, 14 vacuum, 5
shutdown, 20 Vacuum, 17
slide stop, 6 vacuum pump, 17
slide valve, 5, 6, 17, 22 valve ports, 18
slide valve transmitter, 17 Vapor Pump, 3
Solenoids, 18 Vi, 18
solenoid valves, 18 vibration analysis, 19, 20
start-up, 19 vibration level, 20
Start-up, 26 Volume Ratio, 18
storage, 14 Volumizer volume ratio control, 5
suction accumulator, 20
suction gas, 5 W
suction line, 3 Warranty, 4
suction pressure, 22 water vapor, 20
suction strainer, 19, 20 Water vapor, 20
suction strainers, 5
superheating, 5
system piping, 22

T
thermal stability, 6
transmitter unit, 22
traps, 3
troubleshooting, 20
Troubleshooting, 23
Filter cartridges, 24
hydraulic control valve, 23
Oil Pressure, 24
Oil pressure regulator, 24
Piston Seals, 23
pressure regulating valve, 24
Pump, 24
070.650-IOM (NOV 13) SGC ROTARY SCREW COMPRESSOR
Page 32 INSTALLATION - OPERATION - MAINTENANCE

Form 070.650-IOM (2013-11) Johnson Controls

Supersedes: 070.650-IOM (2009-10) 100 CV Avenue
Subject to change without notice Waynesboro, PA 17268-1206 USA
Published in USA • GUI • 12/13 PDF Phone: 717-762-2121 • FAX: 717-762-8624
© 2013 Johnson Controls Inc. - ALL RIGHTS RESERVED www.jci.com/frick