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EZ-CAL™ HIGH PRESSURE CUT-OUT
TEST BLOCK & CALIBRATION KIT
Form 160.100-IO (APR 2018)
INSTALLATION - OPERATION
File: SERVICE MANUAL - Section 160
Replaces: 160.100-IO (FEB 2018)
Dist: 3, 3a, 3b, 3c
Revised:
Please check www.johnsoncontrols.com/frick for the latest version of this publication.
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.
160.100-IO (APR 2018)
Page 2
EZ-CAL™ HIGH PRESSURE CUT-OUT TEST BLOCK & CALIBRATION KIT
INSTALLATION - OPERATION
Indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
Indicates a potentially hazardous situation or practice which, if not avoided, will result in death or
serious injury.
SAFETY PRECAUTION DEFINITIONS
Indicates a potentially hazardous situation or practice which, if not avoided, will result in damage
to equipment and/or minor injury.
Indicates an operating procedure, practice, etc., or portion thereof which is essential to highlight.
Contents
GENERAL INFORMATION
Preface ..............................................................................3
Design Limitations ............................................................. 3
Unit Inspection .................................................................. 3
Transit Damage Claims ...................................................... 3
Kit Maintenance ................................................................ 3
Test Block Dimensional Outline & Port Locations .............. 4
INSTALLATION
Retrot Installation ............................................................ 5
OPERATION
Operation Instructions & Testing ....................................... 7
Principles of Operation ......................................................7
Operation Procedure Example ...........................................8
WARNING
CAUTION
DANGER
NOTICE
160.100-IO (APR 2018)
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EZ-CAL™ HIGH PRESSURE CUT-OUT TEST BLOCK & CALIBRATION KIT
INSTALLATION - OPERATION
General Information
PREFACE
This manual has been prepared to acquaint the owner and
serviceman with the INSTALLATION and OPERATION pro-
cedures as recommended by Frick® Industrial Refrigeration
for the EZ-CAL™ High Pressure Cut-out Test Block and
Calibration Kit.
Both ASHRAE 15 and IIAR-2 safety standards prohibit the use
of an intervening stop valve in the compressor discharge line
leading to the high-pressure-limiting device (High Pressure
Cut-out, or HPCO).
The IIAR-6 standard will require testing of the HPCO yearly
to show the function of the device to shut down an operating
compressor. The standard does not allow removal and bench
testing of the HPCO or testing on a shutdown compressor.
There is a safe, simple calibration solution that complies
with safety standards.
The Frick EZ-CAL™ test block is designed to be installed be-
tween the compressor discharge connection and the HPCO.
The unit provides a simple calibration method in compliance
with safety standards, while reducing the risk of prematurely
lifting a safety relief valve with a resultant ammonia release.
It is most important that these units be properly applied to an
adequately controlled refrigeration system. Your authori zed
Frick® representative should be con sulted for their expert
guidance in this determination.
Proper performance and continued satisfaction with these
units is dependent upon:
CORRECT INSTALLATION
PROPER OPERATION
REGULAR, SYSTEMATIC MAINTENANCE
To ensure correct installation and application, the HPCO unit
should be connected to a properly designed and installed
system.
NOTICE
Trained personnel are required for
handling and installation.
DESIGN LIMITATIONS
The compressor units are designed for operation within the
pressure and temperature limits as shown in Frick® publica-
tion 070.610-SED.
UNIT INSPECTION
Immediately upon delivery examine the box and components
for dam age. Unpack all items and check against shipping lists
for any discrepancy. Examine all items for damage in transit.
TRANSIT DAMAGE CLAIMS
All claims must be made by consignee. This is an ICC re-
quirement. Request immediate inspection by the agent of
the carrier and be sure the proper claim forms are execut ed.
Report damage or shortage claims im mediately to John-
son Controls, Frick® Sales Ad ministration Depart ment, in
Waynes boro, PA.
KIT MAINTENANCE
If, in the course of regular use, any component in the
EZ-CAL™ block or calibration kit fails to work or any com-
ponent becomes damaged, the damaged component should
be discarded and replaced with a new one.
160.100-IO (APR 2018)
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EZ-CAL™ HIGH PRESSURE CUT-OUT TEST BLOCK & CALIBRATION KIT
INSTALLATION - OPERATION
EZ-CAL™ TEST BLOCK DIMENSIONAL OUTLINE & PORT LOCATIONS
NOTES:
1. Dimensions are in inches unless indicated otherwise.
2. Constructed of 316/316L ASTM A479.
3. Max. Press./Temp. Rating: 2,500 psi from -55°F to 150°F (-48°C to 65°C), 1,000 psi up to 300°F (148°C).
4. Recommended tubing from EZ-CAL™ block to the compressor is stainless steel, minimum 3/8".
(3 7/8)
(1 5/8)
1/4 NPT
INLET
(7/16)
(1 3/16)
1/4 NPT PRESSURE
TRANSDUCER PORT
2X (
5/16)
MOUNTING HOLES (1 1/8)
(1 1/8)(1 1/4)
(5 7/8)
(3)
(2 1/2)
QUICK CONNECT
WITH BODY PROTECTOR
(
3/8) LATCH LOCK
(LOCKS IN THIS
POSITION ONLY)
Figure 1. Test Block Dimensional Outline
160.100-IO (APR 2018)
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EZ-CAL™ HIGH PRESSURE CUT-OUT TEST BLOCK & CALIBRATION KIT
INSTALLATION
Installation
PE
MOTOR
COMPRESSOR
SUCTION
DISCHARGE
PI
C
R
EZ-CAL™ HPCO
CALIBRATION BLOCK
DISCHARGE PRESSURE & HPCO
TRANSDUCER
LOCKABLE '2' POSITION
VALVE (RUN/CALIBRATE)
TEMPORARILY INSTALLED
FOR FIELD CALIBRATION
PERMANENTLY
INSTALLED
TEST PORT CONNECTION
MASTER GAUGE
HAND OIL PUMP
REFRIGERATION
OIL SUMP
CONNECTION HOSE
TO TEST PORT
HIGH PRESSURE CUT-OUT CALIBRATION DIAGRAM
RUN POSITION
CALIBRATE POSITION
DISCH PRESSURE
RETROFIT INSTALLATION
During installation of the test block, care should be taken
to minimize total system volume from the test block to
the HPCO. Directly installing the HPCO discharge pressure
transducer on the test block will keep the volume low, and
be much easier to pressurize during testing.
WARNING
This section must be read and un der stood before
installing or performing any main tenance or service
to the unit.
When installing or performing service you must take several
precau tions to ensure your safety:
1. If unit is running, press [stop] key.
2. Disconnect power from unit before performing any
maintenance.
3. Wear proper safety equipment when compressor unit
is opened to atmosphere.
4. Ensure adequate ventilation.
5. Take necessary safety precautions required for the re-
frigerant being used.
WARNING
Close all compressor package isolation valves prior to
servicing the unit. Failure to do so may result in seri-
ous injury.
NOTICE
Recommended tubing from the EZ-CAL™ block to the
compressor is stainless steel, minimum 3/8".
Figure 2. HPCO Calibration Diagram
160.100-IO (APR 2018)
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EZ-CAL™ HIGH PRESSURE CUT-OUT TEST BLOCK & CALIBRATION KIT
INSTALLATION - OPERATION
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160.100-IO (APR 2018)
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EZ-CAL™ HIGH PRESSURE CUT-OUT TEST BLOCK & CALIBRATION KIT
OPERATION
Operation
OPERATION INSTRUCTIONS & TESTING
The Frick® EZ-CAL™ test block, 720B0129H01, is designed to
be installed between the compressor discharge connection
and the discharge pressure limiting device, (the high pressure
cut-out, or HPCO).
Figure 3. Test Block in Test & Run Position
Figure 4. Test Block in Run Position
The valve is lockable in the RUN position.
PRINCIPLES OF OPERATION
TEST BLOCK
The test block functions as a low pressure drop check valve,
not a stop valve, in the line from the discharge pressure
source to the HPCO. In the RUN position the HPCO is fully
open to the discharge pressure source.
In the TEST position an external pressure source is con-
nected to the test connection quick connect and when the
valve is switched to TEST position, the external source is
connected directly to the HPCO. This allows the function of
the HPCO and pressure setting to be conrmed by applica-
tion of external pressure while comparing the compressor
discharge pressure reading to a master gauge.
Once the HPCO is conrmed to trip the compressor at the
correct set point, the valve is switched back to run mode and
any high pressure trapped above the check valve is relieved
back to the system. Should an actual high pressure event
occur, even during testing, the check valve in the test block
will open and expose the HPCO to the high pressure level,
still allowing protection of the compressor during testing of
the HPCO.
One EZ-CAL™ test block should be installed permanently on
each compressor and only be used when the HPCO is to be
tested. They can be locked in the RUN position during normal
operation, but the compressor is still protected from a high
pressure event in either operational position.
NOTICE
Leaving the test block valve in the TEST position after
testing is complete can trap the external pressure be-
tween the HPCO and the test port.
The only risk by leaving the test block valve in the TEST posi-
tion after testing is complete is trapping the external pressure
between the HPCO and the test port. The discharge pressure
reading on the control panel would not see the decrease in
discharge pressure as the system is returned to normal op-
eration. Returning the test block valve to RUN position after
test opens a direct two-way connection between discharge
pressure and the HPCO transducer or switch.
During installation of the test block, care should be taken
to minimize total system volume from the test block to the
HPCO. Directly installing the HPCO on the test block will
keep the volume low, and be much easier to pressurize
during testing.
TEST PUMP CALIBRATION KIT (720B0129G01)
Figure 5. Calibration Kit in Hard Case with Hose
The test pump calibration kit comes complete with hydraulic
test pump, a 15 foot quick connect hose, oil reservoir, and
calibrated master gauge – all suitable for use with refrigera-
tion oil as the pressurizing media.
The pump is used to connect to the quick connect test port
on the test block. Once the test block is switched to the TEST
position, operation of the test pump will allow the technician
to raise the pressure measured at the HPCO until the run-
ning unit is proven to stop at the correct cut-out pressure.
The actual cut-out pressure can be compared between the
pressure display on the control panel and the master gauge
included with the test pump. If the reading is beyond the
permissible tolerance (generally 2.5% of cut-out pressure),
the control panel should be recalibrated to read correctly
at the set point.
160.100-IO (APR 2018)
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EZ-CAL™ HIGH PRESSURE CUT-OUT TEST BLOCK & CALIBRATION KIT
OPERATION
If used to test a pressure switch, and the switch does not
function to stop the compressor at the correct set point,
the switch should be properly adjusted or replaced, and
re-tested to show proper cut-out within tolerance. Once
testing is complete the pump can be removed at the quick
connect to the block, and the block can be switched back
to the RUN position.
Any test refrigeration oil used during the testing will drain
harmlessly into the compressor sump without introducing
non-condensable gas to the system. The test pump is then
ready to calibrate the next compressor HPCO.
OPERATION PROCEDURE EXAMPLE
1. Each technician that is using this test block and test
pump for calibration should be trained in general ammonia
refrigeration safety practices (or other refrigerants used).
All technicians need to be aware they are dealing with high
pressure toxic or ammable gases and due caution is es-
sential to assure safety. We suggest that each facility review
this example procedure and modify as necessary to assure
safety in their facility.
NOTICE
The test block and calibration kits are refrigerant spe-
cic and the refrigerant to be used must be specied
at time of order. O-ring material will vary between
different refrigerants.
2. The test block and calibration kits are refrigerant specic
and must be ordered with the refrigerant to be used specied.
O-ring material will vary between different refrigerants.
3. Remove test pump from hard carrying case. Inspect for
any damage.
4. Familiarize yourself with the components and operation
of the pump and gauge.
GAUGE
ZERO MAX
MIN
CONFIG
ENTER
Needle Bleed Valve
Vernier Control
Top Port 1/4” FNPT
Gauge Display
Side Port 1/8” FNPT
for optional Relief
Valve only (P/N 1010050)
Fill Port and Cap
Media
Reservoir
Stroke Limiter
Fill Line
Figure 6. Calibration Kit Pump and Gauge
5. Select an oil that is compatible with the refrigeration
system being calibrated and with the MECP10K pump. Frick
oils 3, 9, 9S, 11, and 11S are all suitable for ammonia systems,
but it is not recommended to change the oil used in the
pump back and forth. Pick an oil for the pump and always
use the same oil and pump together to avoid O-ring swell
or shrinkage issues.
6. The pump is equipped with a safety relief valve set to
500 psi to avoid overpressure of the pump or hose during
the test. This safety valve is adjustable with an allen wrench.
It is advisable to test the function of the safety valve with
CAUTION before the rst time the pump is used to be sure it
will not open at a normal test pressure. The hose and pump
are designed for operation pressures well above normal
refrigeration pressure.
7. Fill the reservoir to the ll line with clean refrigeration oil
then reinstall the ll plug nger tight. During use do not let
the reservoir drop below 50% of the reservoir capacity. (Do-
ing so may allow air to be introduced into the test system).
Figure 7. Oil Reservoir and Fill Plug
160.100-IO (APR 2018)
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EZ-CAL™ HIGH PRESSURE CUT-OUT TEST BLOCK & CALIBRATION KIT
OPERATION
8. Use only the provided hose between the pump and block.
The provided hose is rated for the system pressures it will
be exposed to, and has internal check valves to prevent
leakage of refrigerant into the pump or from the hose once
disconnected.
Figure 8. Adjust gauge to zero
9. Press enter to turn on the gauge. If the reading is not
zero, press zero to adjust for atmospheric pressure.
10. The male-end of the hose connects to the test block.
Figure 9. Hose Connection (Male End)
11. The female-end of the hose connects to the test pump
and gauge unit.
Figure 10. Hose Connection (Female End)
12. Close needle bleed valve on pump, clockwise, and posi-
tion Vernier dial about middle position. Insert quick connect
tting labeled “pump end” into the hand pump quick connect
at red guide sleeve. It should “click” into place.
Figure 11. Calibration Pump Vernier Dial
13. The hose can trap high pressure oil or gas between the
pump and the check valve. Read the gauge reading to see
if internal pressure is trapped in the hose from the last use.
The pressure can be “carefully” bleed off to the reservoir by
slowly opening the bleed valve. If air or refrigerant is trapped
in the hose it can foam the oil in the reservoir, so open the
bleed slowly if pressure is shown on the gauge. Once pres-
sure is relieved close the bleed valve, (turn clockwise).
14. On rst use the hose should be lled with oil to avoid
pushing air into the system. Push the stroke limiter into the
prime mode position to allow the handles to have maximum
travel. Hold the center post of the block end quick connect
in while working the pump handles until oil comes out of the
hose end.
NOTE: this can take many strokes of the pump depending on
the volume of the hose and whether the pump has been used
in a while. It is important to hold the reservoir reasonably
level to allow the pump to properly ll between strokes. Slow
operation of the pump is more effective than fast operation,
to give the plunger time to properly ll on each pump stroke.
15. See image below.
GAUGE
ZERO MAX
MIN
CONFIG
ENTER
Figure 12. Avoiding air in the hose/system
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EZ-CAL™ HIGH PRESSURE CUT-OUT TEST BLOCK & CALIBRATION KIT
OPERATION
16. Once uid starts to exit the end of the hose switch the
valve on the test block to test position and connect the hose
to the test port on the test block.
Figure 13. Block in TEST Position
17. Insert the hydraulic hose (block end) into the test port of
the test block.
Figure 14. Attaching Hydraulic Hose
18. Equipment is now ready for testing. The block valve is
shown in the test position.
Figure 15. Block remains in TEST Position
19. Squeeze the pump handles until the master gauge starts
to show a sharp rise in pressure.
Figure 16. Checking Reading on Gauge
20. The person conducting the test should be able to see the
reading from the discharge pressure sensor on the control
panel begin to rise and follow the pressure increase created
by the test pump once the pump pressure exceeds the dis-
charge pressure. As the test pressure begins to approach the
cut-out set-point, the stroke limiter button can be pushed in,
(from the back side of pump), while the handles are squeezed
together to put the pump in “pump mode” where the pres-
sure increase can be controlled more precisely. NOTE: Failure
to use the stroke limiter will greatly reduce the mechanical
advantage the user has and will limit the maximum pressure
that can be generated with reasonable handle pressure.
21. See below.
Figure 17. Using the Stroke Limiter
22. As the test pressure approaches the cut-out set point, the
nal pressure adjustment can be made by turning the Vernier
dial. The Vernier is capable of ne pressure adjustment but
only a few psi.
160.100-IO (APR 2018)
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EZ-CAL™ HIGH PRESSURE CUT-OUT TEST BLOCK & CALIBRATION KIT
OPERATION
23. See below.
Figure 18. Vernier Dial Adjustment
24. If the HPCO fails to stop the compressor from operating
when the HPCO reaches its set point, repairs will be required.
The transducer on discharge pressure will need to be re-
calibrated to the master gauge, within allowable tolerance,
(IIAR-6 proposes a maximum disagreement of 2.5% of set
point pressure). A HPCO switch will need to be adjusted (if
possible), or replaced.
25. See nal image on 23.
26. Once the HPCO is proven to stop the compressor within
allowable tolerance at set point, the calibration is complete
and should be documented.
27. The block end of the test hose can be removed from the
test block while the test valve is still in the test position.
Internal check valves are used to prevent oil leakage in either
direction.
Figure 19. Detaching Hydraulic Hose
28. The test block valve can then be switched back to run
position, You should observe the panel reading dropping
back to the normal discharge pressure reading once the
valve position is switched to run. The compressor can be
restarted, as necessary, and the test block can be locked in
run position with the lock ring in the handle.
Figure 20. Block in RUN Position
29. There is still oil pressure trapped in the hose after the test.
This can be left in the hose if it will be used immediately to
calibrate another compressor. If not being used immediately,
the pressure can be slowly bled off by opening the bleed valve
on the pump. There should be no refrigerant trapped in the
hose if the above procedure was followed. But, use CAUTION
when bleeding the hose in case any gas is in the hose, as it
will cause bubbles in the oil reservoir which can spray oil
out of the reservoir, Unless a check valve fails to function
there should never be ammonia vapor in the test hose, but
always open the bleed valve cautiously as any vapor in the
hose will be fed back to the reservoir.
30. Once the testing and calibration is complete the pump
and hose can be drained of oil and safety quick connect plugs
can be inserted in the test port connectors on the block and
pump to keep the connections clean.
Figure 21. Using Safety Quick Connect Plugs
31. To assure the master gauge is accurate to NIST (National
Institute of Standards and Technology) it should be calibrated
to a dead weight tester or master calibration gauge on a
scheduled basis with certicate and date maintained.
JOHNSON CONTROLS
100 Cumberland Valley Avenue
Waynesboro, PA 17268-1206 USA
Phone: 717-762-2121 • FAX: 717-762-8624
www.johnsoncontrols.com/frick
Form 160.100-IO (2018-04)
Supersedes: 160.100-IO (2018-02)
Subject to change without notice
Published in USA • 04/18 • PDF
© 2018 Johnson Controls Int'l PLC - ALL RIGHTS RESERVED
April 2018 Form Revisions
p.4 – Added block dimensions and port locations
p.5 – Added tubing notice
– Added Figure numbers throughout
/
