Frick RTF Roof-Top Freezer Systems Installation Operation and Maintenance Guide

Brand: Frick

Model: RTF Roof-Top Freezer Systems

Type: Installation Operation and Maintenance Guide

This manual contains installation, operation, and maintenance

instructions. Read thoroughly before you begin installing. Failure

to follow these instructions may result in personal injury or death,

damage to the unit, or incorrect operation.

RTF

Rooftop Freezer Systems

Form 200.108-IOM (OCT 2022)

Installation – Operation – Maintenance

File: Service Manual – Section 200

Replaces: 200.108-IOM (FEB 2018)

Distribution: 3, 3a, 3b, 3c

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

200.108-IOM (OCT 2022)

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RTF Rooftop Freezer Systems

Installation - Operation - Maintenance

Indicates an imminently hazardous situation that, if not avoided, results in death or serious in-

jury.

Indicates a potentially hazardous situation or practice that, if not avoided, results in death or

serious injury.

Safety precaution denitions

Indicates a potentially hazardous situation or practice that, if not avoided, results in damage to

equipment and/or minor injury.

Indicates an operating procedure, practice, or portion thereof that is essential to highlight.

DANGER

WARNING

CAUTION

NOTICE

Contents

Read before proceeding .................................................... 3

Changeability of this document ........................................ 3

General information

Receiving the shipment .....................................................4

Inspecting the shipment ............................................... 4

Checking for a leak .......................................................4

Transit damage and shortage claim .............................. 4

Safety ................................................................................4

Warranty ........................................................................... 5

Pre-installation requirements ............................................5

Training and safety considerations .............................. 5

Preliminary site layout considerations .......................... 5

Preliminary eld piping design considerations ............. 5

Electrical power ............................................................6

Refrigeration ................................................................ 6

Condensate drain .........................................................6

Installation

Installation safety guidelines .............................................8

Electric ......................................................................... 8

Fans ..............................................................................8

Vibration and noise ......................................................8

Support structure information .......................................... 8

RTF supported by roof curb ..............................................9

Suggested roof to curb nish ............................................ 9

Roof curb ........................................................................10

Preparing the roof curb .............................................. 10

Rigging the roof curb..................................................10

Setting the roof curb ..................................................10

RTF unit .......................................................................... 11

Preparing the RTF unit ................................................ 11

Rigging and lifting the RTF unit .................................. 11

Setting the RTF unit ................................................... 12

Setting the RTF unit without a roof curb .................... 12

Installing the roof membrane ..................................... 13

Sealing the RTF enclosure .......................................... 15

Discharge air plenum ...................................................... 16

Preparation the discharge plenum ..............................16

Installing the discharge plenum .................................. 16

Electrical ......................................................................... 17

120 V service power ..................................................17

Refrigeration ................................................................... 19

Refrigerant piping .................................................. 19

Flooded surge vessels support ................................... 19

Evaporator condensate drain piping ........................... 19

Operation

Start-up ..........................................................................20

Before start-up ........................................................... 20

Maintenance

Unit exterior ...................................................................21

Coil maintenance ............................................................ 21

200.108-IOM (OCT 2022)

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RTF Rooftop Freezer Systems

Installation - Operation - Maintenance

Read before proceeding

Use the information in this manual to safely and correctly

install, operate, and maintain the Roof Top Freezer (RTF)

Systems Units.

Frick® strongly suggests that personnel become fully

familiar with this manual before operating or working on a

RTF unit.

After installing the unit, the relevant personnel must

correctly connect it to an appropriately designed and

installed refrigeration system. The engineering plans, pip-

ing layouts, and any other relevant design and installation

material must be detailed in accordance with local codes

and applicable industry standards and practices.

Rig and install units as outlined in this manual. Review

these procedures in detail before the actual rigging

operation to acquaint all personnel with the procedures.

If you have any questions or comments about this manual,

call your sales representative.

NOTICE

This manual, in combination with the applicable

cooling coil data, unit G&A drawing, unit electrical

drawing, roof curb drawing, and, discharge plenum

drawing, provides the information necessary to

safely install and start up a Frick RTF unit. Due to the

possibility of customization associated with the RTF

product line, there may be areas beyond the scope

of this manual. If there are any questions about a

special application lacking the required information,

contact the installing contractor or your local Frick

sales ofce.

Changeability of this document

In complying with Johnson Controls® policy for continu-

ous product improvement, the information contained in

this document is subject to change without notice. While

Frick makes no commitment to update or provide current

information automatically to the manual owner, that in-

formation, if applicable, can be obtained by contacting the

nearest Frick Factor or the nearest Frick Sales ofce.

It is the responsibility of operating or service personnel to

verify the applicability of these documents to the equip-

ment in question. If there is any question in the mind of

operating or service personnel as to the applicability of

these documents, then before working on the equipment,

they need to verify with the owner whether the equipment

has been modied and if current literature is available.

WARNING

External wiring is not to be connected inside an

RTF factory mounted electrical panel unless spe-

cically indicated as required eld wiring on the

Frick electrical drawings provided. Devices such as

relays, switches, transducers and controls may not

be installed inside the Frick RTF electrical panel.

No external wiring is allowed to be run through

the Frick RTF electrical panel. All wiring must be in

accordance with Frick published specications and

must be performed only by qualied Frick personnel.

Frick will not be responsible for damages/problems

resulting from improper connections to the controls

or application of improper control signals. Failure to

follow this will void the manufacturer’s warranty and

may cause serious damage to property or injury to

persons.

200.108-IOM (OCT 2022)

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RTF Rooftop Freezer Systems

Installation - Operation - Maintenance

General information

Receiving the shipment

Inspecting the shipment

Do not accept the delivery until you inspect the shipment

on arrival. This is to ensure that all required parts are

present and free of shipping damage. Unpack all items and

compare them with the shipping lists. Contact your sales

representative to report any missing items.

Signature acceptance of equipment implies that the RTF

unit and all loose components are complete and free from

defects.

Inspect the following parts:

• Roof curb

• Discharge plenum

• Enclosure plugs for the lifting lug locations

• Transition ducts

• Roof ashing

• Miscellaneous hardware

In addition, check the motor supports, fan, and fan guard

fasteners for tightness. Some fasteners may have loosened

during transportation.

Checking for a leak

Check the coil to see that the internal gas holding charge

remains intact (15 psi to 25 psi). You must maintain this

charge until connecting the refrigerant piping to the unit.

A coil that does not have a charge may have been dam-

aged during transit.

If the charge is not present when the unit is received, you

must pressure test the coil with dry nitrogen gas to con-

rm that it is free of leaks. To leak check the unit, com-

plete the following steps:

1. Install a pressure gauge with a range of 200 psi to

400 psi.

2. Apply a 100 psi to 150 psi charge of dry nitrogen.

3. Hold the charge for 24 hr and observe any signicant

changes in pressure.

Note: The nitrogen charge may change 1 psi to 2 psi each

10°F change in temperature.

Transit damage and shortage claim

The consignee must make all damaged freight claims. This

is an ICC requirement. Request immediate inspection by

the agent of the carrier and be sure all the correct docu-

mentation is executed. Send a copy of the damage claim

to the Frick Service and Warranty department.

Send shortage claims directly to the Frick sales represen-

tative and the Frick factory sales department

For either claim, include the RTF unit model number, the

serial number, and the Frick sales order number. Refer to

the RTF unit nameplate for all of this information.

Safety

Because rooftop unit installation, operation, and mainte-

nance involves operating at high speed and high voltage,

safety is a top priority.

The customer is responsible for providing qualied and

trained personnel to install and operate the equipment.

Consult all local building, occupational safety, electrical,

gas, and other codes applicable to the installation.

A variety of optional safety features are available from

the manufacturer. It is the responsibility of the owner to

determine if the unit is equipped with all of the safety

devices required for the particular application.

Be aware of the following safety considerations:

• Accessibility of the equipment to non-service

personnel.

• The provision of electrical lockout switches.

• Maintenance procedures.

• Automatic control sequences.

CAUTION

Users and installers of this equipment should be aware

of all recommended safety procedures and information

such as AMCA publication 410-90 Safety Practices.

CAUTION

Never open an access door while air unit is in operation.

CAUTION

A fan, even though locked out electrically, can rotate

in a seemingly insignicant air ow. During mainte-

nance the fan blades should be secured to restrict

rotation. Verify that the restrictive device is removed

before putting the fan back into service.

CAUTION

Equipment wired to automatic control devices may

start without warning, resulting in personal injury or

property damage. In many instances, a unit will have

multiple elec trical connection points. To prevent un-

foreseen start-up before beginning work on an RTF

unit, always lock out all power supplies.

CAUTION

Always replace any protective covers removed for

servicing.

CAUTION

Always replace bolts or locks on latches of access

doors that provide access to areas with moving

parts. This mechanical protection from moving parts

is required by UL 1995.

CAUTION

A number of additional safety issues are discussed

throughout the manual. Read the complete manual

before installing, operating, or servicing the equipment.

200.108-IOM (OCT 2022)

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RTF Rooftop Freezer Systems

Installation - Operation - Maintenance

Warranty

NOTICE

For warranty support with the Frick RTF unit, contact

Frick Service at 717-762-2121.

Pre-installation requirements

Training and safety considerations

The Frick RTF evaporator design uses the nest materi-

als and corrosion protection to deliver dependable and

consistent cooling for coolers and freezers. To ensure the

longest possible system life and dependable, consistent

performance follow the instructions and guidelines in this

manual.

CAUTION

Frick suggests that only experienced industrial re-

frigeration contractors, operators, and maintenance

technicians be used to install, operate and maintain

the RTF unit. Before working on the RTF unit, it is

further recommended that they be provided formal

training on the RTF’s design and features that incor-

porates reading and understanding this manual.

Installing, operating, and maintaining the Frick RTF unit

involves rotating machinery operating at high speed and

high voltage. Normal operations and maintenance pro-

cedures may require working at elevations, entry into

enclosed spaces, and the use of hand and power tools. As

a result, safety is the top priority.

Frick suggests that every site installing an RTF unit analyze

and develop an installation-specic safety regime that

takes into account specic site and unit features, person-

nel qualications, hazard identication, and other safety-

related considerations.

NOTICE

Congure all power switches and controls to provide

an open, safe circuit before and during maintenance

pro cedures, until the system is cleared by manage-

ment for normal online operations. For extended

shutdowns, it is recommended that a qualied tech-

nician remove fuses from fused-disconnect panels

or otherwise open the circuit in an accepted, secure

manner.

Frick suggests incorporating the following operational-

safety elements into every client's RTF safety requirements

and safety program.

Fans: all fan covers, guards, and shaft retainers, if any,

must be in place before applying power to an RTF unit.

Always disengage and lock out power before allowing

interior inspections. To prevent foreign objects from being

sucked into rotating fan blades, never allow operation with

the doors open.

Enclosed space inspections: inspecting coils, drain pans,

guards, or other components in an enclosed space, require

machinery lockout and another colleague to look out, at

a minimum. Consult your internal safety policy and OSHA

requirements for additional safety procedures.

Vibration and noise: discontinue or stop machinery that

emits unusual vibration and noise. Investigate and identify

the source of the disturbance and correct before testing or

placing the system back in operation.

Wet surface precautions: poorly maintained and wetted

machinery requires care to avoid electrical shocks from

inadequate or loose eld wiring and connections. All per-

sonnel must lock out and tag machinery before working on

the unit. Correct safety precautions such as using insulat-

ing soles and gloves and a trained colleague to look out

are indispensable.

Ice formation in cold weather can present slip and fall haz-

ards around a rooftop penthouse unit. Ensure ice-related

safety procedures are mandatory when the daily ambient

temperature falls below 40°F.

RTF units operates in a continuous-duty capacity so it is

important that unit installers correctly locate, install, and

connect the units in the eld. It is also imperative to ad-

equately size and correctly install the electrical power and

control wiring, refrigerant lines, and air duct.

Preliminary site layout considerations

Locate all RTF units for accessibility on the roof and air

ow in and out of the cold space. The Frick RTF enclosure

has two access doors, one on either side of the unit. En-

sure there is access for service and maintenance to both

of these locations.

Air is drawn into the RTF unit along one side, enter-

ing upward through the bottom of the unit. Colder air is

discharged downward along the opposite side of the unit.

Adequate free ow area must be available for returning air

to enter the bottom of the RTF unit. Excessive restriction

reduces air ow and in turn the cooling capacity of the

RTF unit.

It is the owner’s responsibility to correctly locate the RTF

unit in consultation with a qualied engineer before laying

out structural supports and installing the penthouse unit.

Ensure Frick RTF units are uniformly supported around the

perimeter either by roof curb or building structural steel

under roof decking.

Preliminary eld piping design considerations

Before nalizing the refrigerant piping plans for the new

RTF unit, discuss related plans for potential expansion of

the refrigeration system and building with your refrigera-

tion system designer and Frick sales representative. Incor-

porating appropriate pipe and opening sizes now, in light

of existing and future needs, is often the most economical

long-term strategy.

200.108-IOM (OCT 2022)

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RTF Rooftop Freezer Systems

Installation - Operation - Maintenance

CAUTION

Avoid hydraulic lockup caused by trapped liquid.

When there is an increase in ambient temperature

and liquid refrigerant conned in rooftop piping, the

resulting expansion pressure has the potential to

cause refrigerant lines to burst.

CAUTION

All Frick RTF units require strongly supported and

properly anchored eld piping. NO eld piping is to

be supported by the RTF unit enclosure itself. Wind

loading, temperature variation, etc., must be con-

sidered to allow for movement between the rooftop

unit, adjoining building, and eld piping. A qualied

cooling system design engineer should provide nal

eld-piping plans and specications.

Electrical power

Frick RTF units usually require both 120 V/1 ph/60 Hz and

3-phase electrical power.

• The 3-phase power drives the evaporator fans. Frick

may or may not supply factory-installed switch gear

and disconnects. Consult the specic order details when

designing the electrical power system.

• Separate 120 V single-phase power is required to both

sides of the RTF unit for internal service light, GFI con-

venience outlet, and heated freezer door seals.

• An additional 120 V power circuit may be required to

heat trace the condensate drain pan outlet and p-trap.

• The refrigeration system design engineer must provide

separate electrical controls and instrumentation infor-

mation.

Refrigeration

Frick equips the RTF unit with a cooling coil based on a

specied refrigerant and a specied type of liquid feed.

Each cooling coil is shipped with a low-pressure nitrogen

charge to prevent moisture from collecting inside the

circuits.

It is the refrigeration design engineer’s responsibility to lay

out the refrigerant piping and control valves to service the

RTF cooling coil. Do not use the RTF unit or the cooling

coil pipe stubs to support the refrigerant piping system.

The RTF insulated enclosure is not designed to support

concentrated roof loads. If the cooling coil is serviced by a

ooded surge drum, unit installers must provide separate

supports to transmit the weight of the vessel and piping to

the foundational structure.

Condensate drain

Each RTF unit is designed with a condensate drain pan

under the cooling coil. The drain pan is internally sloped to

channel the water to the connection end of the RTF unit.

A threaded male pipe stub is run to the outside of the RTF

enclosure. Pipe this stub with a p-trap to prevent air mi-

gration through the drain line. In addition, environmental

conditions may make it necessary to heat trace this drain

line.

When planning the installation of the penthouse unit, the

elevation of this drain connection and the need for a drain

trap are often important when determining the unit sup-

port and the possible benets of a roof curb.

200.108-IOM (OCT 2022)

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RTF Rooftop Freezer Systems

Installation - Operation - Maintenance

Figure 1: Standard RTF arrangement

Callout Description Callout Description

A Field junction box power connection for

120 V/1 ph/60 Hz

F Lifting lug opening removable plug, Type 4

B Door canopy G 110 V duplex GFI outlet

C Termination bar for roof membrane H Light switch

DRefrigerant connection, order specic I Solid service door

E Approximately 13 in. - -

200.108-IOM (OCT 2022)

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RTF Rooftop Freezer Systems

Installation

Installation safety guidelines

Electric

Check the unit nameplate to verify that the power be-

ing provided corresponds with the requirements of the

equipment.

Ensure

that only qualied electricians install

the power supply and xtures, and that they conduct all

electrical work in accordance with local codes.

All electrical conduits entering the RTF enclosure walls

must be non-metalic inside the wall to minimize heat

transfer. After the electrical conductors are run inside

those conduits, thoroughly seal the inside of the conduits

with electrical putty or caulk to prevent moisture migra-

tion. Failure to follow these guidelines may result in the

accumulation of water or ice in the electrical boxes and

conduits inside the RTF.

It is important to congure all power switches and controls

to provide a safe circuit. Poorly installed, maintained, or

wetted machinery could lead to electrical shocks.

Fans

Ensure all fan covers, guards, and shaft retainers, if any,

are in place before applying power to the unit. Always turn

off electrical power and use lock-out/tag-out procedures

before interior inspections, testing, or starting the RTF unit.

Vibration and noise

Immediately stop machinery that emits unusual vibra-

tion or noise. Investigate the source and resolve the issue

before placing the unit back in operation.

Support structure information

The Frick RTF unit consists of the penthouse enclosure

assembly and possibly a roof curb for mounting. You must

anchor these components to a suitable support structure

such as building structural steel or roof decking. Ensure

the structure is capable of supporting the dry shipping

weight of the unit plus any refrigerant within the coil; any

frost or ice that may accumulate on the coil, the weight

of any ancillary items attached to the unit enclosure, such

as electrical panels, and any live loads imposed due to

operating fans and moving air. The weight that the sup-

port structure must support and the associated anchoring

requirements also varies as a result of externally imposed

loads, such as expected snow or ice buildup, seismic, and

wind loading.

Ensure the structure is designed for at least 110% of the

operating weight of the RTF unit distributed as a uni-

form load around the perimeter of the enclosure support

surface.

Ensure the support structure where you are locating the

RTF units is rigid and level, and shim if necessary. Place

shims, as required, at intervals no greater than 3 ft apart

and do not use them to compensate for signicant surface

slope. Ensure the sum total of any individual stack of shims

does not exceed 1/2 in. and only use them to compensate

for surface irregularities.

Secure the RTF unit to the support structure. It is the

installer’s responsibility to ensure the unit is secured in

accordance with applicable building and earthquake codes.

If the support structure is in the form of parallel steel

beams, size the beams in accordance with standard engi-

neering practices.

Figure 2: RTF supported directly on building steel

Callout Description Callout Description

A RTF unit D Supporting steel

B Steel base E Roof or insulation, existing

C Load bearing location F Roof ashing and insulation, completed by unit

installers

200.108-IOM (OCT 2022)

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RTF Rooftop Freezer Systems

Installation

RTF supported by roof curb

Figure 3: RTF supported by roof curb

Callout Description Callout Description

A Penthouse panels C Roof curb upper lip

B Gasket material provided with the roof curb D Roof curb height

Suggested roof to curb nish

Figure 4: Suggested roof to curb nish

Callout Description

A RTF base frame

B Roof curb

C Building steel or roof deck

D Roof insulation, completed by unit installers

ERoof ashing and insulation, completed by

unit installers

F Seal strip, completed by unit installers

Note: Roof ashing to extend up to the seal strip covering

the RTF enclosure to the roof curb joint.

Figure 5: RTF support layout dimensions, in.

Table 1: RTF support layout dimensions, in.

Model A AA B BB

201 88 96 89.5 9 7.5

302 144 152 89.5 9 7.5

422 144 152 93.5 101.5

453 168 176 89.5 97.5

603 168 176 99.5 107.5

703 168 176 99.5 107.5

604 216 224 89.5 9 7.5

734 216 224 93.5 101.5

904 216 224 99.5 107.5

755 243 251 93.5 101.5

905 243 251 99.5 107.5

1005 249.5 257.5 99.5 107.5

1155 249.5 257.5 99.5 107.5

1245 249.5 257.5 99.5 107.5

Note: Dimensions assume 4 in. thick Insulated enclo-

sure panels. Add 2 3/4 in. to the above AA and BB

dimensions if 5 3/8 in. thick panels are used.

200.108-IOM (OCT 2022)

Page 10

RTF Rooftop Freezer Systems

Installation

Roof curb

Preparing the roof curb

Unless specifically indicated on the project drawings, Frick

provides the roof curbs for use with the RTF unit fully as-

sembled.

1. Check the roof curb for any damage that may have oc-

curred during shipment: corner welds, bottom resting

surfaces, upper RTF unit mating surfaces, and anges.

2. Check the roof curb for square by comparing the two

diagonal measurements.

3. Check that the rooftop mounting surface and any

opening in decking and insulation is adequate for ac-

cepting the curb dimensions.

4. Locate the gasket material that is shipped loose with

the curb. Apply this to the curb just before setting the

RTF unit on the curb.

Rigging the roof curb

The roof curb is provided with an interior perimeter ange

that contains slotted holes for attaching the RTF unit to

the roof curb as well as a number of circular holes near

each corner. Use these circular holes to attach rigging

clevises for lifting the curb into place as shown in Figure 6.

Figure 6: Lifting holes in roof curb

Callout Description

A Lifting hole

Figure 7: Roof curb load bearing region

Callout Description

A Insulated panels

B Potential stitch weld location

C Support structure

D Load bearing point

NOTICE

If you are not setting the RTF on a roof curb, proceed

to Rigging and lifting the RTF unit.

Setting the roof curb

The roof curb is designed to set directly on support steel.

The load bearing region of the roof curb is the interior

perimeter of the curb as indicated on Figure 7.

The roof curb needs to be supported uniformly around the

entire interior perimeter. Apply shims as necessary. Space

shim packs no more than 36 in. apart and do not exceed

1/2 in. thickness. Do not use shims and blocking to adapt a

curb to roof pitch.

It is the responsibility of the installing contractor to secure

the roof curb to the supporting structure in accordance

with local building codes. If welding is used, place the

light stitch welds along the outside perimeter of the 11

gauge lip as shown in Figure 7. Welding along the inside

perimeter may result in damage to the thermal barrier and

insulation.

200.108-IOM (OCT 2022)

Page 11

RTF Rooftop Freezer Systems

Installation

WARNING

When lifting the RTF unit, weight may not be evenly

distributed causing the unit to be unbalanced or top

heavy. See Figure 10 for recommended lifting proce-

dure.

Rigging and lifting the RTF unit

1. Using the lifting lugs provided, attach spreader bars

and rigging as shown in Figure 10. Spreader bars are

required to prevent damage to the cabinet and pro-

truding components during a lift.

2. Cooling coil is not centered inside the enclosure and is

likely offset the center of mass. Adjust the tension in

each line for the correct load distribution.

Figure 10: Standard rigging conguration

Callout Description

A Lifting point

B Fan side

C Center of gravity, approximate location

D Spreader bar

Lift the air unit only in an upright position. Never lift or

move a unit on its side or upside-down.

3. After the RTF unit can be lifted, remove the protective

sheet metal angles under the perimeter of the enclo-

sure. If mounting the unit on a roof curb, keep the bolts

and nuts because these are required to secure the RTF

unit to the roof curb. See Figure 11. If mounting the

RTF unit directly on structural steel proceed to Setting

the RTF unit without a roof curb.

RTF unit

Preparing the RTF unit

The RTF unit arrives fully assembled as a single unit.

1. Inspect the RTF unit enclosure for any visible damage.

2. The RTF unit is shipped with lifting lugs in place. These

lugs may be used to secure the unit during transport as

well. Check to be sure that all of the lug mounting bolts

are in place and secure before attempting to lift the

unit onto the roof. See the following gure.

Figure 8: Standard lifting lug for mounting bolts

Callout Description

A Standard mounting bolt for the lifting lugs (4)

WARNING

When lifting, use all lifting lugs to avoid damage and/

or personal injury. Lifting lugs are shown in Figure 8.

There are a number of items that may be shipped loose

inside the RTF unit. Identify and inspect these items before

lifting the unit into place. See the following gure.

Figure 9: Ship loose items placed in fan side of RTF

200.108-IOM (OCT 2022)

Page 12

RTF Rooftop Freezer Systems

Installation

Figure 11: Enclosure protective perimeter base

Callout Description

A Protective base

B Base

Note: Store attachment bolts and nuts inside the base

CAUTION

If you do not rig or lift the unit carefully, you could

damage the unit, hurt yourself or others.

Setting the RTF unit

1. When setting the RTF unit on a roof curb, rst apply

two strips of 1 7⁄8 in. wide neoprene gasket material

around the top surface of the roof curb. Position the

inside strip of gasket material a third of the way inside

the load bearing point of the mating surface. Ensure

the outside strip is approximately 1/4 in. from the out-

side edge of the curb nailer. See the following gure.

Figure 12: Applying roof curb gasket

Callout Description

A Two 1 7/8 in. x 1/2 in. neoprene gaskets

B Support structure

C Load bearing point

2. As the RTF unit is being positioned overhead, it may

be benecial to spray the neoprene gasket with a light

mist of water. This allows slight adjustments while the

RTF unit is aligned for nal positioning. The use of drift

pins also facilitates positioning the RTF unit on the

roof curb so that the attachment bolts can be installed

easily.

3. Install the ange bolts around the inside perimeter

ange. Insert the bolts downward with the nuts being

installed on the bottom side of the ange. Space the

attachment bolts uniformly around the inside perim-

eter ange with no more than 14 in. between adjacent

bolts. See Figure 3 and Figure 6.

Setting the RTF unit without a roof curb

1. When setting the RTF unit without a roof curb it is

unnecessary to apply a sealing gasket. The RTF base

structure may be set directly on supporting steel.

2. The RTF base needs to be supported uniformly around

the entire interior perimeter. Apply shims as necessary.

Space shim packs no more than 36 in. apart and do not

exceed 1/2 in. thickness. Do not use shims and blocking

to adapt the RTF base to a pitched roof.

Figure 13: RTF set directly on site structural steel

Callout Description

A Factory-supplied bolt holes

B Insulated panels

C Load bearing point

D Support structure

E Potential weld location

3. It is the responsibility of the installing contractor to

secure the RTF unit base to the supporting structure in

accordance with local building codes. If welding, place

light stitch welds along the inside perimeter of the base

lip as shown in Figure 13. Alternatively, the interior

base lip also has factory-supplied holes through which

bolts may be used to secure the unit.

200.108-IOM (OCT 2022)

Page 13

RTF Rooftop Freezer Systems

Installation

Installing optional sloped roof paneling

For sloped roof applications, refer to the suppliers

instructions for installing sloped roof paneling, which you

install before the roof membrane.

Installing the roof membrane

You must protect the RTF units with a membrane roof

cover, which consists of the following components:

• Membrane roof cover

• Termination trim, plastic

• Black Phillips head metal screws

• 2 in. truss plates

• Caulking

Before you install the membrane, keep the following points

in mind:

CAUTION

The membrane is very slippery when wet.

• Keep sharp objects such as nails or screws off the

roof. Someone stepping on them could puncture the

membrane.

• Do not allow hot objects to touch the membrane.

• You can temporarily repair any punctures or holes that

occur during installation with duct tape or caulking.

However, you need to make any nal repairs using a

heat gun.

For correct weather protection, complete the following

steps:

1. Unpack the membrane roll, being careful not to cut the

membrane.

2. Unroll the membrane over the roof area, ensuring the

tabs are on the underside and that the roof area is free

of debris.

3. Maneuver or shift the membrane so it ts squarely over

the roof area, allowing equal amounts of membrane

to overhang at least 6 in. on the edges of the roof. In

windy conditions, place a heavy object, such as con-

crete blocks or tires, around the perimeter to keep the

wind from lifting the membrane.

4. After centering the membrane on the roof, either fold

or roll the membrane back towards the center of the

roof so the underside tabs are exposed. The roll or fold

must be parallel to the factory seam and tab.

5. Stop rolling or folding when you reach the tab going in

the opposite direction.

6. Begin to roll or fold the membrane back until a tab is

exposed and the tab is at on the roof deck.

7. Install the 2 in. truss plates along the fastening tab us-

ing the Black Philips screws, keeping them spaced 12

in. O.C.

Note: Do not screw directly over a ceiling panel seam.

Stay 6 in. away from any of these seams.

8. Continue to roll the membrane until the next tab is

exposed and in place, ready for fastening.

9. Pull the tab tightly to reduce any wrinkle that may oc-

cur. After pulling the tab, hold it in position until you

can secure it with a couple of fasteners.

10. Install the fasteners along the tab 12 in. O.C.

11. Complete steps 9 and 10 for every tab.

12. Hold the membrane that is overhanging the edge of the

roof tight and install the termination bar at least 5 in.

below the horizontal roof. If the termination bar has a

caulking lip, ensure the lip is on the upside.

13. Fasten the termination bar using the pilot holes with

the Black Philips head screws.

Figure 14: Fastening the termination trim

14. After attaching all termination bars, trim any excess

membrane that is exposed under the termination bar

with a sharp knife, using the bottom edge of the bar as

a cutting guide.

15. Caulk the top edge of the termination bar.

200.108-IOM (OCT 2022)

Page 14

RTF Rooftop Freezer Systems

Installation

Callout Description Callout Description

A Fastening tab F Factory welds, staggered equidistant

between factory welds of adjacent roles

27 in. O.C.

B Approved fastener with barbed stress plate G Approved fastener with barbed stress plate

approximately 27 in. O.C.

C Factory weld H Side lap roll to roll minimum 4 1/2 in.

D Paneled roll I Side lap

E Factory tab - -

Figure 15: Membrane roll out and fastener placement

200.108-IOM (OCT 2022)

Page 15

RTF Rooftop Freezer Systems

Installation

Sealing the RTF enclosure

The RTF enclosure insulated panels may have shifted dur-

ing transit. It is important to inspect all panel seams and

reset the cam-locks as necessary.

1. Inspect all panel seams to ensure that the sealing gas-

ket is visibly compressed. If it is not, remove the snap

plugs at the cam-lock, use an allen wrench to com-

pletely unlock the cam latch and then reset and relock

it. Reinstall the snap plugs.

2. Inspect all panel corners to be sure that adjacent pan-

els are not racked; loosen the required cams, adjust the

panels then reset and relock the cam-locks.

3. Although the RTF enclosure is completely sealed when

assembled at the factory, additional caulk may be

required on either interior and exterior panel seams.

Frick suggests the use of a silicone DOW RTV-732 food

grade caulk for any interior seams. Use rainbuster 1200

for resealing any external seams.

4. Use caulking or insulating sealant to nish the exterior

joint between the RTF enclosure and the roof curb

before the surrounding roong is sealed to the unit

5. Inspect each of the RTF enclosure freezer door rain

hoods. Tighten any loose attachment screws and caulk

as necessary.

6. Remove all of the lifting lugs by removing the mounting

bolts in each one. Discard the lifting lugs and bolts.

7. Insert the lifting lug plug into the opening. Take care

not to damage the inner and outer seal strips. Attach

the plug into place using the screws provided. Plug all

of the factory-drilled screw holes.

8. Seal the building roof insulation to the RTF enclosure

or the roof curb. Use a cant or radius around the pe-

rimeter of the enclosure or curb.

For installations involving a roof curb, it is necessary to

use roof membrane or ashing to cover the exterior of the

curb including the curb to RTF enclosure joint. Ensure the

nal nish includes a caulked seal strip as shown in Figure

If you don't use a roof curb, the location of the seal strip

is subject to the discretion of the installer that installs and

seals the roof.

Figure 16: Lifting lug enclosure plug

11 in.

1 1/2 in.

16 in.

Callout Description

A1/8 in. pre-drilled holes for eld mounting

B White stucco aluminum cover plate

C Double-beaded gasket

D High-density urethane perimeter

200.108-IOM (OCT 2022)

Page 16

RTF Rooftop Freezer Systems

Installation

Discharge air plenum

The discharge air plenum and interconnecting circular

ducts components ship separately from the RTF unit.

It is intended that the RTF discharge air plenum be sup-

ported independently of the RTF unit or its supporting roof

curb.

Preparing the discharge plenum

1. Inspect the air discharge plenum for any obvious ship-

ping damage.

2. Install a prefabricated circular duct transition to each

plenum air inlet orice using tapper screws. The RTF

fans are provided with a transition duct attachment.

See Figure 17.

Figure 17: Fan discharge nozzle integral to module

3. The interconnecting duct material is provided as pieces

of at stock. Take one piece of at stock, roll it into a

tube that is approximately 33 in. in diameter. Secure it

with a strap to prevent it from unrolling. Stand the roll

inside one of the plenum air inlet openings. Repeat this

process for each fan discharge duct.

Installing the discharge plenum

1. Lift the plenum into position taking care that the coiled

duct material does not get damaged. Mount the

plenum using support rods as indicated on the Frick

RTF plenum drawing. See Figure 18 for an example.

Note that each plenum hanger rod must pass through

the upper alignment bracket and support the assem-

bly by the lower bracket. Use the double nuts jammed

together to secure the nal adjustment.

2. Each fan discharge must be connected to the plenum

using the coiled at stock material. Carefully measure

the distance between the RTF fan discharge nozzle and

the plenum transition duct inlet. Mark the outside of

the coiled duct at stock so that approximately 50%

of the excess is available for insertion and attachment

into the fan discharge nozzle. Ensure that the remaining

50% is available to extend into the plenum transition

for attachment.

3. Carefully lift the coiled duct material and insert it into

the fan discharge nozzle. Allow it to uncoil and attach

it to the fan nozzle using tapper screws. Install screws

spaced approximately 18 in. apart.

4. Attach the coiled duct material to the lower plenum

duct transition assembly using tapper screws, again

spaced approximately 18 in. apart.

5. Secure the vertical duct seam using tapper screws

spaced a maximum of 12 in. apart.

Figure 18: Discharge plenum assembly

Callout Description

A Transition duct assembly

B Discharge plenum

200.108-IOM (OCT 2022)

Page 17

RTF Rooftop Freezer Systems

Installation

Figure 20: Standard RTF enclosure indicating 120 V eld power connection

Callout Description Callout Description

A Field junction box power connection for

120 V/1 ph/60 Hz

D Light switch

B Door canopy E Solid service door

C 110 V duplex GFI outlet

Electrical

The Frick RTF unit may be provided with a variety of

factory power wiring options. See Figure 19 for an ex-

ample.

• Fan motors are not factory wired

• Fan motors wired to a disconnect

• Fan motors factory wired to an ATL starter

• Fan motors factory wired to a VFD

See Figure 21 and Figure 22 for standard suggestions

for wiring multiple parallel fans. When power wiring the

fans on the installation site, it is the installing contrac-

tor’s responsibility to ensure that the electrical design and

installation meet the applicable codes.

For RTF units with factory wired motors, refer to the

order-specic wiring drawings provided.

120 V service power

Each Frick RTF units is provided with internal lights,

exterior light switches and external convenience outlets

located by each access door. For RTF units designed to

operate below 32°F, the access door seals are also heat

traced. Each access door and associated components are

internally wired and require 120 V eld supplied power to

an external electrical junction box. See Figure 20.

Figure 19: Standard RTF 120 V factory-installed service

wiring diagram

BRONZE TERMINAL

(120 VAC/60 Hz/1Ø POWER)

(GROUND FAULT

CIRCUIT INTERRUPTER)

DOOR

HEAT ER

BACK VIEW

LOAD

GREEN

GRAY

DOOR

FRAME

HEAT ER

SILVER TERMINAL

(NEUTRAL)

LINE

GFCI

BLACK

WHITE

SINGLE

EXTERIOR

SWITCH

RED

WHITE

BLACK

GREEN

VAPOR PROOF

LIGHTON

DOOR FRAME

BLACK

GREEN

WHITE

GREEN

TAN

RED

GREEN

WHITE

BLACK

GREEN GREEN

BLACK

WHITE

FIELD CONNECT

120VAC/60 Hz/1Ø

#12 AWGTHHN STRANDED Cu

GRAY

FIELD CONNECTION BOX

Note: Two independent circuits for each RTF unit, standard

NOTICE

The electrical specications information provided

here is standard for each of two tie-in points, one for

each side of the RTF enclosure.

200.108-IOM (OCT 2022)

Page 18

RTF Rooftop Freezer Systems

Installation

Figure 21: Standard power wiring involving ATL starters

Figure 22: Standard power wiring involving a VFD

Electrical Specifications

120VAC/60 Hz/1Ø

Light and heated door frame

FLA 2.4 amps

GFCI rating

20 amps

Factory-installed wire

#12 AWG THHN stranded Cu

Figure 23: Electrical specications

200.108-IOM (OCT 2022)

Page 19

RTF Rooftop Freezer Systems

Installation

Refrigeration

The Frick RTF unit may be provided with a cooling coil de-

signed for any direct or secondary refrigerant. Refer to the

original order documentation for specic information.

The RTF cooling coil is provided with a nitrogen charge.

This charge prevents moisture from migrating inside the

refrigerant circuits, collecting and contaminating the future

cooling system.

CAUTION

Care must be taken when initially opening the ends

of the refrigerant pipes to make eld connections

as injury could occur due to the positive nitrogen

charge.

NOTICE

Once the cooling coil refrigerant piping has been

opened, maintain a dry nitrogen charge in the pip-

ing system if the coil is not charged with refriger-

ant immediately. Failure to do so could result in the

collection of moisture inside the coil circuits and

the possible contamination of the future refrigerant

charge.

Refrigerant piping

CAUTION

The unit connections are not designed to support the

weight of piping, valves, or ttings.

The cooling coil refrigerant connections are weldable pipe

stubs, anges, or threaded pipe caps. The project submit-

tal drawings indicate the coil connections for a specic

unit. It is important to correctly size and orientate the

refrigerant lines servicing the cooling coil in order for the

coil to function correctly.

Refrigeration piping design and line size selection are the

responsibility of the unit installers. Conrm that the system

design parameters comply with the coil design parameters

stated on the certied submittal drawings. Before con-

necting the refrigerant lines to the coil, verify that the pip-

ing and control valves on the unit are correctly supported.

Design all piping to minimize the transfer of vibration to

the unit and allow for thermal expansion of piping.

CAUTION

Avoid hydraulic lockup caused by trapped liquid.

When there is an increase in ambient temperature

around conned liquid, the expansion pressure could

cause refrigerant lines to burst.

When the Frick RTF unit is provided with hot gas drain pan

heat, the pan coils are not factory piped to the evaporator

refrigeration piping. Design of the refrigerant control valve

group and the interconnecting pan and coil piping must

be done by a qualied refrigeration engineer. The required

refrigeration piping must be done in the eld by qualied

pipe tters.

CAUTION

Use of a refrigerant other than that stamped on the

nameplates may cause damage to the refrigeration

coils. Coils must not be subjected to higher pressure

than the design pressure stamped on the nameplate.

In ammonia systems, be sure to use refrigerant

grade, not agricultural grade ammonia.

Flooded surge vessels support

The Frick RTF enclosure and pipe stubs are not designed

to support a ooded surge vessel. A separate support

structure is required for ooded evaporator applications.

Evaporator condensate drain piping

The cooling coil condensate drain pan is provided with a

male pipe thread (MPT) pipe stub out the end of the pan

and extending through the RTF enclosure.

Although the height may vary from model to model, in

general the drain pan drain connection is centered ap-

proximately 13 in. above the bottom of the RTF enclosure

panels. If the unit is mounted on a roof curb, this is ap-

proximately 13 in. above the top of the roof curb.

Due to static pressures inside the RTF unit enclosure, it is

necessary to trap the condensate drain. This is generally

done with a P-trap. It is the responsibility of the installing

contractor to be sure that the condensate water is piped

according to applicable codes.

Figure 24: MPT condensate drain

Callout Description

A Drain pan drain connection

NOTICE

When mounting a Frick RTF unit directly on building

steel, be sure to allow enough elevation to properly

trap the condensate drain pipe. See the project sub-

mittal drawings for available height.

RTF units are designed for freezer applications and may be

installed in climates that have low outdoor temperatures

during the winter. If either of these conditions apply it is

advisable to provide heat trace of the condensate drain

piping. Consult a refrigeration design engineer for selec-

tion and application of the heat trace product.

200.108-IOM (OCT 2022)

Page 20

RTF Rooftop Freezer Systems

Operation

Start-up

Before start-up

Do not start the unit until the following you inspect and

verify operational readiness. You can avoid accidents or

equipment failure by rectifying any unsatisfactory

condition.

WARNING

Do not attempt any inspections or maintenance un-

less the electrical power to the fans has been com-

pletely disconnected and locked out.

1. Inspect the general condition of the unit:

• Enclosure integrity: ensure that the seams are all

sealed, the doors operate and seal correctly, and the

roof membrane is correctly installed.

• RTF unit is secured correctly, roof curb, if used, is

secured correctly

• Discharge air plenum and ducts are secured and

installed correctly

2. Inspect fans and motors for condition and alignment:

• Verify that all fan mounting bolts are secure and all

fan motor mounting bolts are tight.

• Rotate fans by hand to ensure rotation free of ob-

struction.

• Verify the rotation of the fans

3. Clean up any excessive dust or remains of material

used during installation:

• Inside the drain pan

• Top of the cooling coil housing

• Inside of the discharge air plenum

4. Check the refrigerant pipe penetrations of the RTF

enclosure wall and the pipe insulation:

• Pipe insulation is sealed

• Pipe insulation to the RTF enclosure interface is

sealed correctly

• Check the cooling coil ns. Use a n comb to

straighten any bent ns that may block air ow.

5. Touch up scratches in galvanizing with cold galvanized

paint.

WARNING

Do not allow the access door heat tape to be en-

ergized unless the freezer / cooler refrigeration is

operating. Allowing the heat tape to be energized

without cooling inside the RTF unit may allow the

heat tape to overheat and destroy itself.

WARNING

Do not remove safety equipment or warning labels

from equipment. Removal could result in serious

injury or death.

NOTICE

When starting the RTF unit, due to the RTF enclosure,

the temperature pull-down rate is unrestricted down

to 45°F. Below 45°F, restrict the temperature pull-

down rate to 10°F per 24-hr period.

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Model: RTF Roof-Top Freezer Systems

Type: Installation Operation and Maintenance Guide

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Frick RTF Roof-Top Freezer Systems Installation Operation and Maintenance Guide

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