XRV 127 COMPRESSOR
SERVICE MANUA M ANUAL L
INDEX TO SECTIONS Page Number 2
SECTION 1
FOREWORD
SECTION 2
DESCRIPTION DESCRIPTI ON 2.1 Compressor 2.2 Compression Cycle 2.3 Gas System 2.4 Oil System 2.5 Recommended Oils
4 5 6 7 7 9
SECTION 3
INSTALLATION INSTALLATIO N 3.1 Alignment of Compressor Couplings 3.2 Conventional Alignment Method 3.3 Double Clock Alignment Method 3.4 Piping
10 11 12 13 15
SECTION 4
FIRST START UP 4.1 First Start
16 17
SECTION 5
NORMAL OPERATION 5.1 Normal Start 5.2 Normal Stop
18 19 19
SECTION 6
PROCEDURES PROCEDURE S DURING SHUTDOWN 6.1 Precautions Precauti ons During Shutdown 6.2 Recommended Inhibiting Inhibiti ng Oils
20 21 21
SECTION 7
MAINTENANCE MAINTEN ANCE 7.1 General Comments
22 23
SECTION 8
OVERHAUL 8.1 Preparation for Dismantling 8.2 Dismantling Dismantli ng 8.3 Checking Clearances During Assembly 8.4 Final Assembly
24 25 25 45 55
SECTION 9
SPECIAL INSTRUCTIONS INSTRUCTI ONS 9.1 Torque Specifications Specific ations 9.2 Procedures for fitting Lockwashers Lockwashers 9.3 Special Tool List 9.4 Procedure for Refitting Inlet Casing
75 76 76 77 78
SECTION 10
RECOMMENDED RECOMMEND ED SPARES LISTS 10.1 Recommended Spares Lists
79 80
1
SECTION 1
FOREWORD
2
READ CAREFULLY BEFORE INSTALLING AND ST ARTING YOUR COMPRESSOR
These instructions have been prepared to ensure that your compressor gives long and satisfactory service. The entire manual should be read before reverting to any one section for specific information. One copy should be given to the personnel responsible for installing and operating the compressor.
All requests for information, information, services or spares should should be directed to: Howden Compressors Compressor Business Unit 133 Barfillan Barfill an Drive Glasgow, G52 1BE United Kingdom Telephone: Fax: e-mail: Web Site:
or
Howden Compressors LLC 1850B N Gravers Road Plymouth Meeting PA 19462 USA
+44 (0)141 882 3346 +44 (0)141 883 5901 hcl@aftersales@how hcl@
[email protected] den.com www.howden.com www.howden.com
+1 610 313 9800 +1 610 313 9215 sales@howdenco
[email protected] mpressors.com www.howden.com www.howden.com
All enquiries should be accompanied by the Howden Contract Number and the Compressor Serial Number, Number, taken from the nameplate on the side of the compressor body.
3
SECTION 2
DESCRIPTION
4
2.1
THE XRV COMPRESSOR The Howden XRV Oil Injected Compressor is a positive displacement, capacity controlled, oil flooded, rotary m achine. A feature of the XRV compressor range is the f acility to alter t he volume ratio by altering the size of the discharge port. port. This is done by the setting setting of a screw to obtain the desired desired ratio in the range 2.6:1 to 5.0:1. Clockwise Clockwise for Vi = 2.6, anti-clockwise anti-clockwise for Vi = 5.0. Compression is achieved by the meshing of two helical rotors on parallel shafts housed in a casing. The accurately machined machined helical rotors are called Male Male and Female. Female. The Male (driving) rotor has has four lobes which mesh with six flutes in the Female (driven) rotor, both rotors having the same outside diameter. Each rotor is supported by two cylindrical cylindri cal roller bearings. Lubrication is achieved whilst in the running condition by use of the differential pressure between the suction and discharge discharge pressure of the compressor. compressor. The bearing spaces spaces are at suction pressure and oil is forced into t he compressor compressor from the oil/gas separator separator by discharge pressure acting on the oil in the separator. separator. On startup, it may be necessary to use an an auxiliary oil pump to force oil to the bearings until sufficient differential pressure is developed by the compressor to sustain its own oil pressure. This will depend on how long is taken to achieve achieve the required differential differential pressure in the system. Rotor end thrust is accommodated by angular contact ball bearings on both male and female rotors and balance balance pistons at both ends of the male rotor. One side of each balance balance piston is subject to pressure from lubricating lubricati ng oil and the other side at suction pressure. The balance pistons therefore theref ore oppose the normal rotor end thrust, and as a result, the angular contact bearings are lightly loaded and have a long life. The male rotor has lobes formed helically along the rotor length and these mesh with corresponding flutes flut es on the female rotor. The meshing and disengaging of the lobes and flutes within the compressor casings creates enclosed spaces which expand in volume (the suction phase) till a point determined by by the shape of of the suction port port where the interlobe space space is sealed. As the rotors continue their rotation and the rotor lobes and flutes remesh, the gas now trapped in the interlobe spaces is compressed. At a point determined by the discharge port shape the decreasing interlobe space is opened to discharge and the gas escapes at pressure. (See Section 2.2) Capacity control is achieved by means of a slide valve in the casing operated by a piston in a hydraulic cylinder mounted mounted on the compressor. Movement of of the slide sli de valve alters the point at which gas compression begins by allowing the gas from the start of the compression phase to re-circulate back to suction. This in effect decreases the volume of gas compressed. At the same time, the slide valve alters the size of the outlet port in order to keep the compression compression ratio constant. By this means, capacity can be controlled from 100% down to 10%, with an approximately proportionate saving in power. The piston is actuated by lubricating oil fed from the lubricating oil manifold to the outboard side of the piston acting against against spring pressure. pressure. As oil is fed to the cylinder, the slide slide valve will move on load (towards the inlet end). When the oil feed is stopped, stopped, the slide valve will be “locked” in position. To offload the compressor, compressor, the oil trapped in the cylinder cylinder is allowed to escape escape to the compressor oil drain and the slide valve will move off load (towards the outlet end) under a combination of spring and gas pressure. Various methods of hydraulic cylinder control are possible and Howden Compressors Limited are able to provide assistance in this f ield if required . 5
2.2
THE COMPRESSION CYCLE (DIAGRAMMATIC ONLY)
1. Gas is drawn in to fill the interlobe interl obe space between adjacent lobes on top side of rotors at Inlet End.
2. As the rotors rotate, the interlobe space moves past the inlet port so sealing the interlobe space. Viewed from the top side of rotors at Inlet End.
3. Continued rotation progressively reduces the space occupied by the gas causing compression. Viewed from underside of rotors at Discharge End.
4.
6
When the interlobe interl obe space becomes exposed to the outlet port the gas is discharged. Viewed from the underside of rotors at Discharge End.
2.3
DESCRIPTION DESCRIPTI ON OF A GAS SYSTEM FOR A TYPICAL REFRIGERATION REFRIGERATI ON COMPRESSOR SET Gas is drawn into the compressor through a non-return valve and strainer fitted directly on the inlet flange and discharged discharged into an oil tank/separator. tank/separator. The non-return valve is necessary necessary to prevent the compressor being “motored” in the reverse direction when it is stopped with high gas pressure at the outlet. If necessary, a second non-return valve is positioned at the outlet of the tank to prevent the entry of gas or liquid refrigerant. Primary separation of the oil mixed with the gas is achieved in the tank, secondary separation takes place in a wire mesh element separator positioned close to the tank outlet. In some separator designs, the wire mesh is replaced by a separator cartridge. The separated separated oil drains into the oil oil tank. A further secondary secondary separator vessel may also be be fitted where a very high separation separation efficiency efficiency is required. The oil separated separated is usually drained into the compressor through a small bore pipe which can be fitted with a protective filter and an isolating valve.
2.4
DESCIPTION DESCIPTI ON OF AN OIL SYSTEM FOR A TYPICAL TYPIC AL REFRIGERATION REFRIGERATI ON COMPRESSOR SET If necessary, an auxiliary oil pump would be used to supply sufficient lubricating oil to the compressor during startup (for the reasons detailed in the compressor description, Section 2.1). Once running, the lubricating oil pressure would be self sustaining and the pump could be shut down. Discharge pressure will now force lubricating oil oil through a cooler cooler and micronic filter(s) to the manifold where it is introduced to the compressor via the appropriate connections. When liquid refrigerant is used there is no oil cooler. If the compressor is to be run on a continuous duty duplex duplex micronic filters should be fitted i n parallel, allowing one filter element to be changed while the other is in operation. Approved lubricating lubricating oils for refrigeration compressors compressors are listed under under Section 2.5.
7
2.4
A SYSTEM FOR A TYPICAL TYPIC AL REFRIGERATION REFRIGER ATION COMPRESSOR SET
8
2.5
APPROVED LUBRICANTS FOR REFRIGERATION REFRIGERATIO N COMPRESSORS COMPRESSO RS
AMMONIA AND R22
VISCOSITY CENTISTOKES MANUFACTURER
TYPE
ISO GRADE
40°C
SPECIFIC GRAVITY
100°C
SPECIFIC HEAT
POUR POINT
FLOC POINT
FLASH POINT
(15°C) KJ/Kg°C
°C
°C
°C
(15°C) B.P.
ENERGOL LPT 68
68
68
7.3
0.902
1.829
-33
-42
173
CLAVUS 68
68
68
7.3
0.898
1.838
-27
-24
193
CLAVUS G68
68
65
7
0.894
1.838
-36
-50
205
ESSO
ZERICE 68
68
65
7.4
0.894
1.838
-37
-34
224
MOBIL
ARTIC 300
*
57
6.4
0.925
1.834
-34
-40
190
GULF
ESKIMO 68
68
65.5
7.2
0.898
1.834
-33
-50
212
CHEVRON
REFRIGER ATION OIL 68
68
68
6.7
0.93
1.85
-30
-40
180
CPI
CPI 009 -68
68
73
8
0.87
2.09
-37
-30
216
SHELL
Fig.3 NOTES 1. 2. 3. 4.
* The viscosity viscosi ty of these oils is between ISO 46 Grade and ISO 68 Grade. 1 KJ/Kg°C KJ/Kg° C = 0.239 Btu/LB°F = 0.239 Kcal/Kg°C. The existence of this list does not exclude the use of other oils, but approval for oils not included above must be obtained from Howden Compressors Limited before use. An oil should be selected to be compatible with system components and conditions.
9
SECTION 3
INSTALLATION
10
3.1
ALIGNMENT OF COMPRESSOR COUPLINGS Misalignment causes a vibration which affects other parts of the compressor leading to premature failure of bearings, bearings, seals, etc. Drive couplings fitted to XRV XRV compressors must be aligned aligned using one of the methods described below. The coupling alignment tolerance figures can be seen under Section 3.2. Coupling gap dimensions should be set with the couplings held in a repeatable position, i.e. hard together or hard apart. apart. This ensures that each coupling coupling half is moved to the same axial position as each check is made. The actual coupling gap should be correct when the shafts are in their normal running condition. When When setting the gap, the axial float of each shaft should be determined and the “hard together” or “hard apart” dimension calculated. Example:
Compressor Compressor driven directly by a turbine. Compressor Compressor shaft float Turbine shaft float
0.000mm (0.000”) 0.250mm 0.250mm (0.010”)
The normal running position of the compressor compressor shaft is thrusting towards the turbine t urbine and the turbine runs thrusting towards the compressor. compressor. Required coupling gap
3.175mm (0.125”)
If the gap is checked with the couplings “hard apart” it sh ould be: Required coupling gap Plus Compressor Compressor shaft shaft float Plus Turbine shaft float = “Hard apart” gap
3.175mm 0.000mm 0.250mm 3.425mm
(0.125”) (0.000”) (0.010”) (0.135”)
If the gap is checked with the couplings “hard together”, ie in the normal running condition, it should be equal to the required coupling gap: gap: 3.175mm (0.125”).
11
3.2
CONVENTIONAL ALIGNMENT METHOD 1.
Checking Vertical Alignment Begin by setting up a dial indicator as in Fig. 4. Commence alignment by setting the faces of the coupling halves parallel in the vertical plane. When achieved, the shaft axes will be parallel in the horizontal plane. Set the dial to zero.
Fig. 4 Rotate both half couplings together from 0° to 180° and record readings of facial alignment. (TIR) (TIR = Total Indicator Indicator Reading). Reading). Add shims to either both front or both back feet to achieve a TIR as close to zero as possible. NOTE: Turning both half couplings together (Half couplings must not be bolted together or have spacer fitted) ensures that readings are recorded at the same point on each half coupling, thus eliminating the effect of any irregularities on the outside diameters or faces of the half couplings.
12
3.2
CONVENTIONAL CONVENTIO NAL ALIGNMENT METHOD (Continued) 2.
Setting the Centre Height Set up a clock gauge B as in Fig.5.
Fig. 5 Fig. 5
Set the dial to Zero. Rotate both half couplings together from 0° to 180° and record readings of radial alignment TIR. To obtain the correct centre heights will require equal shimming under each foot of the unit being adjusted. The amount of shimming required will be equal to half the TIR. 3.
Setting Lateral Alignment Lateral alignment is done by moving the machine in the horizontal plane using the same clock gauge techniques as for steps 1. and 2. and reading at 90° and 270° until facial and radial readings on the clock gauges are within tolerance. Check that the coupling gap is within tolerance (see Section 3.1).
3.3
“DOUBLE CLOCK” ALIGNMENT METHOD ALIGNMENT METHOD Two clock gauges should be set up as per Fig.6 below.
Fig. 6
13
3.3
“DOUBLE CLOCK” ALIGNMENT METHOD (CONTINUED) 1.
Checking Lateral Alignment This check should be done before setting the vertical ali gnment as any lateral misalignment will result in an error in the t he calculation of of shim sizes. Set the clock gauges gauges to zero at the 90° and and 270° positions. Then by rotating the coupling through half a revolution, check the readings at 270° and 90° position. These readings are the total indicator readings (TIR). The centre of shaft alignment is half TIR. Adjust the clock gauges gauges so that they indicate half half TIR, eg if indicator indicator was at +20, adjust to show +10. By using jacking screws the compressor can now be moved laterally until both clock gauges are at zero. The compressor is now aligned laterally, both peripheral and axial.
2.
Checking Vertical Alignment The clock gauge which which records at the fixed machine should should be in the 0° position. The clock gauge which records at the machine which is to be moved to correct alignment should be at the 180° position. Both clocks should should be set to indicate zero. Then by rotating the coupling coupling through through half a revolution, check and record the readings at the 180° and 0° positions. From the measurements recorded, the amount of shimming required under the Drive End (DE) and Non Drive End (NDE) feet, see Fig. 7, can be calculated as follows: SHIMS TO BE ADDED AT DRIVE END
= A – (A-B) D 2 2C
SHIMS TO BE ADDED AT NON DRIVE END = A - (A-B) E 2 2C If answer to calculation is positive - add shims. If answer to calculation is negative - remove shims.
14
Fig. 7
3.3
“Double Clock” Alignment Alignment Method (Continued)
3.
Alignment Alignmen t Tolerance And Allowance For Coupling Gap The clock gauges should give the same readings, ie if the right hand gauge reads +5 at 270° then the left hand gauge should read +5 at 90°. The difference in reading between the two gauges indicates the radial misalignment of the coupling halves. An allowance of 0.025mm (0.001”) should be made for every every 250mm (10”) of coupling gap, eg if the overall alignment tol erance is 0.10mm (0.004”) TIR TIR and the coupling gap is 500mm (20”) then the following tolerances apply (metric calculation shown). shown). Allowable Allowable difference between between the two gauges: Coupling Gap X 0.025 250 Ie:
500 X 0.025 = 0.05mm 250 Allowable Allowable TIR ± 0.10mm 0.10mm
1. 2. 3. 4.
Clock A +0.05mm - 0.10mm +0.04mm +0.12mm
Clock B +0.10mm - 0.05mm - 0.04mm +0.12mm
Difference 0.05mm 0.05mm 0.08mm 0mm
TIR Result 0.10mm Acceptable 0.10mm Acceptable 0.04mm Not Acceptable 0.12mm Not Acceptable
Example readings 3 not accepted because difference = 0.08mm Example readings 4 not accepted because TIR = 0.12mm 3.4
PIPING Before installing the piping, the compressor inlet and outlet ports should be inspected to ensure no dirt is present. Note that the pipes and fitti ng used should not restrict flows. To avoid this, always use piping with a bore ¼” larger than the thread dia meter of the compressor compressor port, eg connection thread thread is ¾” BSP and so a 1” OD pipe OD pipe should be used. supported so that no strain is transmitted transmitted to the compress compressor or casings. NOTE: All piping should be supported The piping should should be inspected for cleanliness before before installation. As each pipe is connected connected to the compressor, the coupling alignment should be checked to ensure that no alteration has taken place. If alignment has altered, the compressor is being strained and the piping supports must be adjusted. It is not sufficient merely to re-align the drive unit as this will not correct the t he strain being imposed on the compressor. Oil injected refrigeration compressors must have a suction strainer permanently fitted directly on the compressor compressor inlet.
15
SECTION 4
FIRST START UP
16
4.1
FIRST START Installation of the compressor will have been carried out in accordance with Section 3 of this manual. The Commissioning Engineer should however ascertain that the correct procedures have been followed, in particular the coupling alignment must be checked, then proceed as follows: 1.
Disconnect the coupling between the drive and the compressor and check that the motor rotation is correct to drive the compressor in a clockwise direction for the R1 type and anticlockwise for the gear driven R3, R4 and R5 type, looking on the compressor input shaft.
2.
Fill the oil tank with lubricating oil of the correct grade to the required level as indicated on the tank level sight glass.
3.
Ensure that the pipe from the oil filter to the manifold, manifold, the manifold and oil pipes to the compressor are clean and, if fitted, start the auxiliary pump to circulate the oil.
4.
The lubricating oil pressure pressure relief valve, if fitted, should be set to give a differential differential of 4 bar (60 psi) above gas suction pressure measured at the oil manifold, at the correct operating temperature and with clean oil filter elements elements fitted.
5.
Check the operation of any safety trips fitted by running the drive unit disconnected disconnected from the compressor compressor and mechanically operating operating the trips. Check that the trips are set to act at a point which will protect protect the compressor from damage. damage. If an auxiliary oil pump is fitted, the lubricating oil differential trip can be set at 2 bar (30 psi) by partially closing the oil filter outlet isolation valve to reduce the differential differential oil pressure pressure to the point where the trip operates. As the filters become dirty the differential oil pressure will drop to this figure, which is the minimum acceptable pressure.
6.
Check that the compressor compressor turns freely by hand and reconnect reconnect the coupling between between the drive unit and the compressor.
7.
Check that the cooling water is turned on to the lubricating oil cooler, if fitted.
8.
Check that all gas inlet and outlet isolating isolati ng valves are open.
9.
Start the auxiliary lubricating oil pump motor, if fitted. NOTE: NOTE: The compressor should be unloaded prior to start up. If the compressor is started without first being unloaded a higher starting torque will be required.
10.
Start the drive unit and check that all gauges are indicating indicati ng correctly. correctl y.
11.
Run the compressor compressor for 30 minutes at minimum gas flows and check that all all readings readings are normal, then operate operate the capacity control valve to the required position. position. This position will be indicated on the dial mounted on the hydraulic cylinder.
12.
If possible, possible, check the slide valve control over the full range of capacity.
17
SECTION 5
NORMAL OPERATION
18
5.1
NORMAL START 1.
Check the level of the oil in the tank.
2.
Check that all the necessary gas, oil and water valves valv es are open.
3.
Ensure the capacity control valve is in the fully unloaded unloaded position and the Volume Ratio Vi screw set. Clockwise for 2.6. Anti-clockwise for 5.0.
4.
Start the drive unit and check that all gauges are indicating indicati ng normal readings.
5.
Load compressor – oil to cylinder activates compressor slide valve to go to “on load” position.
NOTE: A log should be kept of the instrument readings readings so that deviations from normal running conditions can be easily seen by the Engineer in charge of the installation.
5.2
NORMAL STOP 1.
Stop the drive unit.
2.
After the compressor compressor stops, the control system should be operated to move the slide valve into the off load position unless unless the control system does this automatically.
3.
After the compressor compressor stops rotating, stop the lubricating oil pump motor, if fitted.
4.
Close all gas and water isolating valves.
The compressor is now ready for the next start up sequence.
19
SECTION 6
PROCEDURES DURING SHUTDOWN
20
6.1
PRECAUTIONS DURING SHUTDOWN The Howden XRV Screw Compressor operates on an oil/gas mixture and short periods of shutdown will not adversely affect the t he unit. If the compressor is shut down for an extended period the lubricating oil pump, if fitted, should be operated for approximately ten minutes weekly, to distribute oil throughout the set. Turn the compressor compressor driveshaft a few times every week by hand. hand. This will help to avoid Brinelling of the anti-friction bearings. bearings. If the shutdown period is three months or more, the above procedure should be continued, and in addition, the compressor set should be run for one hour every three months. Alternatively, for greater corrosion protection, the normal lubricating oil can be drained off, replaced with inhibiting oil, and the oil pump run for one hour initially, then one hour every three months. NOTE:
Before the compressor set is returned to normal operation, the inhibiting oil must be removed and the system filled with regular oil.
During a shutdown period in cold conditions any water cooled items of plant should be drained, or the cooling water flow maintained to prevent frost damage.
6.2
INHIBITING OILS APPROVED FOR USE WITH HOWDEN SCREW COMPRESSORS A list of approved approved inhibiting oils suitable for use on the Howden Screw Compressor prior to a prolonged shutdown is shown in Fig. 8. If you have any doubts about the compatibility of these oils with your gas please contact the manufacturer or your dealer.
SHELL
ENGINE OIL 30
ESSO
RUST-BAN RUST-BA N 335 OR 337
MOBIL
ARMA 524
CALTEX
CALTEX PRESERVATION PRESERV ATION OIL 10W Fig.8
21
SECTION 7
MAINTENANCE
22
7.1
GENERAL COMMENTS The compressor is designed to give long periods of trouble free operation with the minimum of maintenance. A yearly inspection is recommended for f or all Howden Howden compressor compressor installations. Some installations may require an annual statutory insurance survey. The purpose of the yearly inspection survey is to check if there is any significant wear of the journal and thrust bearings, balance pistons and seals, and if any wear is found, for these components to be renewed. It is not anticipated that a major overhaul will be required for approximately three years of operation. After this time, the thrust and journal bearings bearings must be renewed. The bearings may still be perfectly serviceable, but all bearings have a finite lifespan and replacement at this point may forestall an expensive compressor breakdown at a later date. When the compressor is being inspected or overhauled it must be dismantled in a clean area. All fasteners should be torqued to the value specified in Section 9.1 using appropriate torque wrenches. All lockwas l ockwashers hers and ‘O’ rings ri ngs must be renewed on re-assembly. re-assembl y. Section 9.2 describes lockwasher assembly procedure. procedure. Special tools to ease dismantling dismantl ing and re-assembly re-assembl y can be provided, as listed in Section 9.3. Details of these can be obtained obtained from the Compressor Compressor Business Unit, Unit, Howden Compressors. Compressors. Section 10 details all Part Numbers of normally replaceable components.
23
SECTION 8
OVERHAUL
24
8.1
PREPARATION FOR DISMANTLING Before dismantling the compressor, precautions should be taken in the interests of safety:
8.2
1.
Isolate the drive unit.
2.
Depressurise and purge the system.
3.
Disconnect Disconnect the drive unit coupling from the compressor. compressor.
4.
Place a receptacle under the outlet end of the compressor compressor to catch any oil which may drip from the hydraulic cylinder when the cylinder cover is removed or when the casings are separated.
5.
Ensure all lifting lifti ng equipment, ie eye bolts, slings and shackles are safe and serviceable.
DISMANTLING Note that the compressor slide valve is spring loaded and so, to avoid injury, the operator should ensure that all spring spring tension is released prior to dismantling. This can be done by ensuring that the slide valve is fully off load (the piston should be at its limit towards outlet) and the volume ratio adjustment is at its minimum. (The Vi adjustment screw should should be turned to its limit in the clockwise direction). Disconnect/remove Disconnect/remove any electrical equipment fitted if it is going to obstruct f urther dismantling. dismantling. 1.
Place a receptacle under the inlet end casing, remove the hex headed headed plug from the bottom of the inlet end casing and allow allow the oil to drain. (Fig.10)
Fig.10
25
8.2
DISMANTLING DISMANTLI NG (Continued) Removing the Vi Indicator Assembly 1.
Slacken and remove the 2 cap screws holding the indicator support support plate in position and slide this this plate off. (Fig.12)
2.
The sleeve retaining ring can then be removed by slackening the two socket set screws and pulling from the slide stop stem. (Fig.13)
3.
Both the indicator and screw sleeve are then free to be removed. Remove the indicator post by extracting the socket cap screw.
Fig.12
Fig.13
26
8.2
DISMANTLING DISMANTLI NG (Continued)
Removing the Input Shaft Seal 4.
Remove the input shaft coupling key from the input (drive) shaft. shaft. Extract the 4 cap screws (Fig.14) and withdraw the seal housing (Fig.15). Collect the seal housing ‘O’ ring seal, the stationary seat will remain in the seal housing.
5.
Slacken the 3 grub screws holding the shaft shaft seal to the shaft (Fig.16).
6.
Carefully remove the shaft seal from the input shaft shaft (Fig.17). Remove the stationary drive shaft seat and ‘O’ ring from the seal housing.
Fig.14
Fig.15
Fig. 16
Fig. 17
27
8.2
DISMANTLING DISMANTLI NG (Continued) Gearbox Cover 7.
Slacken off the gearbox cover socket cap screws. (Fig.18)
8.
Insert M10 guide rod. (Fig.19)
9.
Pull away the gearbox cover supporting both the drive shaft and gear wheel. (Fig.20)
10.
Collect the ‘O’ ring seal. (Fig. 21)
Fig. 18
Fig. 19
Fig. 20
Fig. 21
28
8.2
DISMANTLING DISMANTLI NG (Continued) Removal of Pinion and Pinion Key 11.
Remove the pinion cap screw and washer from the end of the male rotor (Fig. 22).
12.
Remove the pinion from the male rotor using extraction extracti on tool XR12008J (Fig. 23).
13.
Remove the pinion key (Fig. 24).
Fig. 22
Fig. 23
Fig. 24
29
8.2
DISMANTLING DISMANTLI NG (Continued) Capacity Control Limit Switch Assembly Removal 14.
Unscrew the two cap screws (Fig.25) securing the limit switch cover and remove the cover (Fig.26). This will give access to the microswitches microswitches and potentiometers. potentiometers.
15.
Remove the four socket cap screws securing the cylinder end cover (Fig.27) and withdraw the actuator spindle/limit switch assembly assembly (Fig.28).
NOTE: The indicator spindle has to clear a dowel pin which moves along the spiral groove in the spindle, therefore this assembly must be kept in axial position when withdrawing until the spindle clears the dowel pin. IMPORTANT – IMPORTANT – it it is essential that the spiral groove engaging the dowel pin is marked for correct reassembly to avoid damage to the potentiometer.
Fig. 25
Fig. 26
Fig. 27
Fig. 28
30
8.2
DISMANTLING DISMANTLI NG (Continued) Actuator Piston Removal 16.
With the actuator piston in the fully unloaded position, bend back the tab on the lockwasher (Fig.29).
17.
Slacken and remove the locknut (Fig.30) and the lockwashers lockwashers (Fig.31).
18.
The actuator piston can then be removed with the aid of extraction extracti on tools (Fig.32). (Fig.32) .
Fig. 29
Fig. 30
Fig. 31
Fig. 32
31
8.2
DISMANTLING DISMANTLI NG (Continued) Rotor End Cover Plate Removal 19.
Remove the 6 socket set adjusting screws (Fig.33).
20.
Slacken and remove the 6 socket cap screws that hold the rotor end cover plate plate in position position (Fig.34 & 35).
21.
Remove the rotor end cover plate to give access to both male and and female rotors (Fig.36).
Fig. 33
Fig. 34
Fig. 35
Fig. 36
32
8.2
DISMANTLING DISMANTLI NG (Continued) Rotor Thrust Cover Removal 22.
Identify and remove both male and female rotor thrust covers using suitable M6 screwed screwed rod as extraction tool (Fig.37).
23.
Both the male and female disc springs will now be exposed (Fig.38). (Fig. 38).
24.
Identify and collect the disc springs (Fig.39).
Female Spacer Removal 25.
Remove the female spacer (Fig.40).
Fig. 37
Fig. 38
Fig. 39
Fig. 40
33
8.2
DISMANTLING DISMANTLI NG (Continued) Balance Piston Removal There are 2 methods of locking rotors when you wish to either tighten or loosen rotor locknuts: 1. Insert a nylon wedge wedge between rotors (through inlet end port). 2. Use special special spanner spanner XR12012J XR12012J fitted onto onto male rotor input input shaft shaft (Fig.43). 26.
With the rotors locked release the lockwasher lockwasher (Fig.41) and remove the locknut from the male rotor using tool XR12005J (Fig.42).
27.
Remove the balance piston using a suitable M6 screwed rod as an extraction extr action tool and discard ‘O’ ring seals seals (Fig.44). (Fig.44).
Fig. 41
Fig. 42
Fig. 43
Fig. 44
34
8.2
DISMANTLING DISMANTLI NG (Continued) 28.
Remove balance piston sleeve, complete with labyrinth labyrint h insert using the jacking plate XR12008J XR12008J (Fig.45 & 46).
Fig. 45
Fig. 46
35
8.2
DISMANTLING DISMANTLI NG (Continued) 29.
Unlock both male and female lockwashers lockwashers (Fig.47). A special locknut spanner spanner XR12006J XR12006J has been manufactured f or these locknuts shown in Fig. 48.
30.
Remove the male locknut (Fig.49) while remembering to employ a suitable method to stop rotors rotating (Fig.50).
Fig. 47
Fig. 48
Fig. 49
Fig. 50
36
8.2
DISMANTLING DISMANTLI NG (Continued) 31.
Remove the female locknut (Fig.51) and remove both male and female lockwashers. The rotors are now ready to be removed from the inlet end of the compressor following the removal of the gearbox assembly.
Removal of the Gearbox 32.
Remove the two internal socket cap screws. screws. (Fig.53) ( Fig.53)
Fig. 51
Fig. 52
Fig. 53
37
8.2
DISMANTLING DISMANTLI NG (Continued) 33.
Slacken and remove only twelve of the external socket cap screws from the inlet end leaving one adjacent to each of the 2 dowel dowel pins. (Fig.54)
34.
Using extraction tool XR12010J XR12010J (Fig.55) the dowel dowel pins should be pulled clear of main casing but still remain in the gearbox.
35.
Screw two M12 x 200 long guide rods into the selected holes and run two hexagonal nuts down. (Fig.56)
Fig. 54
Fig. 55
Fig. 56
38
8.2
DISMANTLING DISMANTLI NG (Continued) 36.
Support the weight of the gearbox at the lifting point and extract extr act the remaining socket cap screws.
37.
By evenly slackening the hexagonal nuts along the guide rods, draw the gearbox from the rotor casing until slide valve valv e spring pressure has been relaxed. (Fig.57)
NOTE: As the inner inner race of the angular angular contact thrust thrust bearing is also removed, the support support offered by the guide rod is essential. 38.
The gearbox gearbox will will come come away complete with slide valve stop, nut-slide stop stem, slide stop stem, retaining cap screw and washer. washer. (Fig.58) (Fig. 58) Remove slide valve spring.
Fig. 57
Fig. 58
39
8.2
DISMANTLING DISMANTLI NG (Continued) Rotors 39.
The rotors are now free to be removed. (Fig.59) Jacking plate XR12007J is mounted on the rotor end cover plate position (Fig.60) and pressure applied to the female rotor using a jacking screw. screw. (Fig.61) The rotor will rotate rotate as it is axially axially displaced. (Fig.62)
Fig. 59
Fig. 60
Fig. 61
Fig. 62
40
8.2
DISMANTLING DISMANTLI NG (Continued) Continue to apply pressure via this jacking screw until rotors are fully clear of the thrust bearings. bearings. The rotor can then be withdrawn withdrawn by hand. (Fig.63) 40.
Repeat with the male rotor. (Fig.64)
Slide Valve Removal 41.
Pull the slide valve out through the rotor casing. (Fig.65)
Fig. 63
Fig. 64
Fig. 65
41
8.2
DISMANTLING DISMANTLI NG (Continued) Discharge End Angular Contact Bearings, Cylindrical Roller Bearings and Floating Bush 42.
The angular contact bearings, bearings, (Fig.67 (Fig.67 & 68) outer track and bearing race of the cylindrical roller bearing (Fig.69) and floating bush (Fig.70) can then be be readily removed from both male and female side of the discharge casing.
Fig. 67
Fig. 68
Fig. 69
Fig. 70
42
8.2
DISMANTLING DISMANTLI NG (Continued) Removal of Gearwheel 43.
Support the gearbox cover horizontally with the input shaft downwards. downwards. Remove the cap screw and bearing washer. washer. (Fig.71)
44.
Apply a load to the shaft to push the cylindrical cylindri cal roller bearing inner race, the input shaft spacer and the gearwheel from the input shaft. shaft. (Fig.72)
Fig. 71
Fig. 72
43
8.2
DISMANTLING DISMANTLI NG (Continued) 45.
The gearwheel key can then be removed.
46.
The angular contact bearing can be removed by applying a load to the input shaft. (Fig.73)
Removal of Bearings from Inlet End Casing 47.
Withdraw the 3 cylindrical cylindri cal bearings after removing the retaining socket cap screw and washer. Fig. 73
44
8.3
CHECKING CLEARANCES DURING ASSEMBLY Input Shaft, Gearbox Cover and Gearwheel Assembly 1.
Apply protective protectiv e tape to the shaft seal area.
2.
Heat both angular contact bearings on a suitable induction heater to a temperature of 80 C – 90 C and apply anti-seize compound to the input shaft. (Fig.74)
3.
With the circlip in position, locate bearings. bearings. By referring to the assembly drawing, ensure that they are positioned back to back. (Fig.75)
4.
Using bearing pre-load jig XR12009J to confirm that the bearings are fully located next to the
input shaft circlip. Fig. 74
Fig. 75
45
8.3
CHECKING CLEARANCES DURING ASSEMBLY (Continued) (Continu ed) 5.
The shaft and thrust bearing assembly should then be assembled into the gearbox cover (Fig.76) along with the seal housing. housing. (Fig.77)
NOTE: At this stage, it is not necessary to fit the ‘O’ ring seals or shaft seal. Gearwheel 6.
Support the gearbox cover horizontally with the input shaft downwards and assemble assembl e the gearwheel key onto the shaft.
7.
Heat the gearwheel to a temperature temperatur e of 80 C - 90 C and apply anti-seize compound to the shaft. (Fig.78) Push the gearwheel home onto the shaft. (Fig.79)
Fig. 76
Fig. 77
Fig. 78
Fig. 79
46
8.3
CHECKING CLEARANCES DURING ASSEMBLY (Continued) (Continu ed) Input Shaft Spacer, Cylindrical Roller Bearing Inner Race and Retaining Washer/Cap Screw 8.
Heat both the input shaft spacer and cylindrical roller bearing inner race to a temperature of 80 C - 90 C, apply apply anti-seize compound to the shaft. (Fig.80)
9.
Push both the spacer (Fig.81) (Fig. 81) then the cylindrical cylindri cal roller bearing inner race home. (Fig.82) ( Fig.82)
10.
Ensure that all the components components on the shaft shaft between between the circlip and the roller bearing inner race are hard up up to each other. The end of the shaft should should be slightly under the cylindrical cylindrical roller bearing inner inner race. Assemble the bearing bearing washer and cap cap screw with Loctite 242 onto the end of the shaft shaft and torque to 20Nm. (Fig.83)
Fig. 80
Fig. 81
Fig. 82 Fig. 83 Check the bearing pre-load pre-load by applying a hand side load load to the shaft. If excessive play exists then the bearing has not been successfully pre-loaded and this should be corrected by the following method. (0.15 radial max. 0.1 axial axial max.) max.) Remove M8 cap screw and washer from gear end and replace washer with a thicker washer approximately approxim ately 2 x times thickness. Fit a longer cap screw and tighten to 20Nm. With the shaft in t he vertical position and drive end on a “Safe” flat surface, apply a sharp blow to the perimeter of the thick washer via a tube. Re-torque the Re-torque the capscrew to 20Nm. Repeat this hammer-torque sequence until cap screw does not require further tightening. If the axial and radial play is acceptable rebuild the drive shaft housing using original washer and cap screw tightened to 20Nm.
47
8.3
CHECKING CLEARANCES DURING ASSEMBLY (Continued) (Continu ed) Slide Valve 11.
Ensure that the actuator spindle guide dowel is in position. (Fig.84)
12.
We recommen recommend d that when fitting the slide valve (Fig.85/86) (Fig.85/86) into the main casing that it is pushed fully through to the outlet port (Fig.87) as a test to ensure that there is no sticking.
Fig. 84
Fig. 85
Fig. 86
Fig. 87
48
8.3
CHECKING CLEARANCES DURING ASSEMBLY (Continued) (Continu ed) Female Rotor Bearing Spacer and Dummy Bearing 13.
Grease and insert the dummy bearing XR12002J XR12002J into the discharge casing to simulate both angular contact and cylindrical bearings (Fig.88) . Leave the dummy bearing in position.
14.
Position the female bearing spacer onto its shaft. Lubricate the rotor and carefully refit into the main casing (Fig.89). It is usually easiest to fit the female rotor first.
NOTE: The male and female bearing spacers are used to set the rotor outlet end clearance.
Fig. 88
Fig. 89
Fig. 90
49
8.3
CHECKING CLEARANCES CLEARANCES DURING ASSEMBLY (Continued) (Continued) Male Rotor Bearing Spacer with Dummy Bearing 15.
Position Positi on male bearing spacer on male shaft (Fig.91 & 92).
16.
Grease and position the male dummy bearing in the discharge casing (Fig.93). dummy bearing in position.
17.
Rotate the male rotor to locate with female rotor and push through casing (Fig.94). (Fig. 94). Ensure the rotors mesh with their serial number meeting together. Please note that some rotors do not have serial numbers imprinted on the lobes.
Fig. 91
Fig. 92
Fig. 93
Fig. 94
50
Leave
8.3
CHECKING CLEARANCES DURING ASSEMBLY (Continued) Assembly – Assembly – Gearbox Gearbox to Main Casing 18.
Gearbox to be fitted with with Male and Female Cylindrical Roller Bearing Outer Race and Slide Valve Stop Assembly. Support the weight of the gearbox at the lifting point (Fig.95) and carefully locate gearbox onto main casing. (Fig.96)
NOTE: At NOTE: At this stage, there is no need to install the actuator spring. 19.
Secure the gearbox using a number of the M12 socket cap screws and push home the gearbox dowel pins to ensure correct alignment of casings.
Fig. 95
Fig. 96
51
8.3
CHECKING CLEARANCES CLEARANCES DURING ASSEMBLY (Continued) (Continued) To Find Total Rotor Clearance (0.725 max – max – 0.325 0.325 min) 20.
Set a dial indicator to zero on the inlet end of each rotor in turn. (Fig.97) Move the rotor axially its full f ull length, the reading on the indicator gives the total cl earance between between rotor end face and casing.
21.
Repeat with the other rotor.
Fig. 97
Fig. 98
52
8.3
CHECKING CLEARANCES CLEARANCES DURING ASSEMBLY (Continued) (Continued) Rotor End Face to Casing Outlet End Clearance (0.090 max – 0.065 – 0.065 min) 22.
Replace the male rotor locknut (Fig.99) and torque to 200Nm (Fig.100). ( Fig.100).
23.
Repeat with female rotor locknut.
NOTE: The NOTE: The torque applied should be the same as on the final assembly to ensure correct clearance cl earance readings. 24.
Set the dial indicator to zero on the inlet end of the male rotor (Fig.101). Move the rotor axially (Fig.102). The axial movement noted on the indicator gives the male rotor end face to casing outlet end clearance.
25.
Repeat with the female rotor.
Fig. 99
Fig. 100
Fig. 101
Fig. 102
53
8.3
CHECKING CLEARANCES CLEARANCES DURING ASSEMBLY (Continued) (Continued) Dummy Bearing Removal 26.
The dummy bearings bearings are removed (Fig.103) with the bearing spacer (Fig.104) stuck to the grease.
27.
Any modifications modific ations can now be made to the recorded clearances by grinding grindi ng these spacers. When clearances are correct final assembly can now begin.
Remove gearbox and rotors following dismantling procedures.
Fig. 103
Fig. 104
54
8.4
FINAL ASSEMBLY Cylindrical Roller Bearing Inner Race onto Male Rotor 1.
Heat the inner race of the male rotor cylindrical roller bearing on an induction heater to a temperature of 80 C - 90 C and coat the rotor shaft with anti-seize compound (Fig.105).
2.
Push the race onto the shaft (Fig.106). Apply a load of of 20kg to ensure ensure inner track is fully fully seated (Fig.107). (Fig.107). Do not remove until parts are cool.
Fig. 105
Fig. 106
Fig. 107
55
8.4
FINAL ASSEMBLY (Continued) Male Floating Bush 3.
Ensure both ‘O’ ring and locating pin are installed correctly and insert into male side of the discharge casing. (Fig.108)
Male Cylindrical Roller Bearing Outer Race into Discharge Casing 4.
Insert the male cylindrical roller bearing outer track and bearings (Fig.109).
5.
Push the male dummy bearing in to ensure that both the bearing and floating fl oating bush are fully full y in the correct position (Fig.110). Leave Leave in i n position until male rotor is assembled into position. position.
Fig. 108
Fig. 109
Fig. 110
56
8.4
FINAL ASSEMBLY (Continued) Female Floating Bush 6.
Fit the female cylindrical roller bearing inner track to rotor following the procedure for fitting the male cylindrical roller bearing track (8.4 line 1-2).
7.
Lubricate and fit the ‘O’ ring seal and anti -rotation location pin into the female floating bush (Fig.111) align the pin with the hole in the discharge casing (Fig.112).
8.
Insert the female cylindrical roller bearing outer race and bearings (Fig.113).
9.
Insert the female dummy bearing to ensure correct positioning of the floating bush (Fig.114). Leave Leave this dummy bearing in place until female rotor is assembled into position.
Fig. 111
Fig. 112
Fig. 113
Fig. 114
57
8.4
FINAL ASSEMBLY (Continued) Female Rotor 10.
With the female bearing spacer in position lubricate the female rotor and carefully refit refit into into the main casing (Fig.115). With the aid of the dummy bearing, ensure that the floating bush remains in position (Fig.116).
Male Rotor 11.
With the male bearing spacer in position lubricate lubricat e and rotate the male rotor to locate with female rotor (Fig.117) ensuring the rotors mesh with their serial numbers meeting together. Utilise the dummy bearing to ensure that the male floating bush remains in position.
Fig. 115
Fig. 116
Fig. 117
58
8.4
FINAL ASSEMBLY (Continued) Stainless Steel Actuator Spring 12.
During final assembly assembly the spring is assembled assembled with the actuator stop assembly assembly (Fig.118).
Gearbox ‘O’ Ring 13.
Lubricate and fit the gearbox gearbox ‘O’ ring ring seal (Fig.119) .
Fig. 118
Fig. 119
59
8.4
FINAL ASSEMBLY (Continued) Gearbox 14.
Support the weight of the gearbox at the lifting lifti ng point. Use the M12 x 200 guide rods during assembly of gearbox to main casing to ensure proper location onto (and as a safeguard against damaging the) bearing races.
15.
Locate the gearbox to the casing entering spring into stop (Fig.120). (Fig.120) . Use hexagonal nuts on the guide rods and tighten evenly until gearbox and casing come together ensure dowels are aligned and push home (Fig.121). Use Loctite 242 on the two inner M12 socket cap screws.
16.
Fit the two internal M12 socket cap screws and torque to 95Nm (Fig.122). (Fig.122) .
17.
Fit the outer cap screws where possible possi ble then remove the guide rods (Fig.123). (Fig.123) . Torque these socket cap screws to 95Nm.
Fig. 120
Fig. 121
Fig. 122
Fig. 123
60
8.4
FINAL ASSEMBLY (Continued) Male Angular Contact Bearing 18.
Heat and push both the male and female side angular contact bearings into discharge casing (Fig.124 & 125). Refer to the assembly drawing to ensure correct alignment.
Fig. 124
Fig. 125
61
8.4
FINAL ASSEMBLY (Continued) Angular Contact Bearing Assembly (Locknut/Lockwasher)Male and Female The rotors will now require to be locked by eit her method described described previously in order to tighten the locknuts. locknut s. The method employed employed shown in Fig.128 is to fit a special spanner onto male rotor shaft. 19.
Locate the lockwasher and locknut onto the male rotor (Fig.126). (Fig.126) . Torque locknut to 200Nm 200Nm (Fig.127). Refer to Section 9.2 9.2 for correct procedure.
20.
Repeat with female rotor locknut (Fig.128).
21.
Bend tab on both male and female lockwashers lockwasher s to lock using tool XR12001J (Fig.129) .
Fig. 126
Fig. 127
Fig. 128
Fig. 129
62
8.4
FINAL ASSEMBLY (Continued) Balance Piston Sleeve (including Male Labyrinth Insert) 22.
Lubricate the male bore with oil and insert the balance piston sleeve. (Fig.130 & 131) Take care not to damage the ‘O’ ring seal especially on the oil feed hole where it may snag. (Fig.132)
Fig. 130
Fig. 131
Fig. 132
63
8.4
FINAL ASSEMBLY (Continued) Balance Piston, Locknut and Lockwasher 23.
The balance piston can now be inserted into the bore. (Fig.133) ( Fig.133)
24.
With the lockwashers in place (Fig.134) refit the locknut and tighten to the required torque of 130Nm. (Fig.135) Bend tab to lock. (Fig.136)
Fig. 133
Fig. 134
Fig. 135
Fig. 136
64
8.4
FINAL ASSEMBLY (Continued) Male Disc Spring 25.
Place the male disc spring in position ensuring that it is well oiled. Refer to drawing for the correct orientation (Fig.137).
Male Rotor Thrust Cover 26.
Lubricate and position the male rotor thrust cover (Fig.138). (Fig.138).
Female Spacer 27.
Lubricate Lubricat e the female end bore and insert female spacer (Fig.139) into position (Fig.140).
Fig. 137
Fig. 138
Fig. 139
Fig. 140
65
8.4
FINAL ASSEMBLY (Continued) Female Disc Spring 28.
Lubricate and insert female disc spring. (Fig.141) (Fig.141)
Female Rotor Thrust Cover 29.
Lubricate and position the female rotor thrust cover into position. (Fig.142)
Rotor End Cover Plate 30.
Assemble rotor end cover plate to discharge casing (Fig.143) (Fig. 143) and evenly torque socket cap screws and washers to 30Nm each. (Fig.144)
Fig. 141
Fig. 142
Fig. 143
Fig. 144
66
8.4
FINAL ASSEMBLY (Continued) 31.
Set a dial indicator onto the end of each rotor in turn at gearbox end.
32.
Apply Loctite 242 to each of the the 6 adjusting socket set screws and screw into the cover (Fig.145).
At this stage check check that the rotors are are free to turn. 33.
Tighten each of the adjusting screws evenly until a resistance is felt. Torque to 20Nm (Fig.146) and then slacken them them by 2 full turns, the rotors will now move axially onto the end face of of the casing. Gradually turn each set of three three to approximately approximately 1Nm. This compresses the disc disc spring by 1.2mm. This will also pre-load the angular angular contact bearings approximately approxim ately 300N. The rotors will will have been displaced axially axiall y by at least 0.007mm as a result of this pre-load. Check the rotors for freedom freedom of movement.
Fig. 145
Fig. 146
67
8.4
FINAL ASSEMBLY (Continued) Actuator Piston 34.
Lubricate Lubricat e both the actuator piston cylinder and the actuator piston. Lubricate Lubricat e and fit a new actuator piston lip seal. seal. Ensure that this seal seal is fitted the correct way round by by referring to the assembly drawing. drawing. Lubricate and fit a new ‘O’ ring seal seal onto the slide valve. Fit piston seal to piston and press firmly on the outer edge of the entire seal circumference until the seal is heard heard to “click” into position. Failure to do so will will result in premature failure failure of the piston seal and incorrect compressor operation.
35.
Refit the actuator piston seal assembly onto the slide valve using the extraction rods taking care not to damage damage the lip seal (Fig. 147). Apply Loctite 243 to the locknut and slide slide valve insert thread. Use special special tool to centralise piston in cylinder cylinder bore, fit support bracket and secure with capscrews. capscrews. Insert locknut socket socket through support bracket bracket and torque locknut locknut to 80 Nm. Align slot in nut nut with M5 tapped tapped hole in piston. piston. Apply Loctite 243 to the anti-rotation grub screw and tighten into piston. Torque to 10Nm. 10Nm.
Fig. 147
68
8.4
FINAL ASSEMBLY (Continued) Limit Switch Assembly 36.
Making sure that the actuator spindle dowel is in position locate and assemble the indicator indicat or assembly to the discharge casing (Fig.148). Take care to engage the dowel into the correct spiral groove which should have been marked during dismantling.
37.
Fit the four socket cap screws into the cylinder end cover and torque to 30Nm.
Fig. 148
69
8.4
FINAL ASSEMBLY (Continued) Pinion Assembly 38.
Heat the pinion to a temperature temperatur e of 80 C - 90 C (Fig.150).
39.
Re-assemble the pinion key onto the male rotor shaft, shaft, apply apply anti-seize compound compound and locate the pinion onto the shaft (Fig.151).
40.
Apply Loctite 242 and tighten tight en the cap screw and bearing washer to the required torque of 20Nm (Fig.152).
Fig. 150
Fig. 151
Fig. 152
70
8.4
FINAL ASSEMBLY (Continued) Gearbox Cover 41.
Lubricate and position the gearbox cover ‘O’ ring seal. Using the guide rod to ensure ensure correct alignment with the input shaft cylindrical roller bearing assemble the gearbox cover to the gearbox. (Fig.153)
Fig. 153
71
8.4
FINAL ASSEMBLY (Continued) Shaft Seal and Cover 42.
The shaft seal can now be fitted by by first removing removing the seal housing that was fixed in position during the gearbox input shaft to cover assembly. Remove the protective tape from the input shaft. Carefully oil the shaft and the carbon face of the input shaft seal and slide over the input shaft until it is hard against against the circlip. circlip. (Fig.154)
43.
Apply Loctite 242 to each of the three cup point grub screws. Lightly tighten up the screws evenly against against the shaft while holding the seal against against the circlip. Finally torque torque up the screws to 3.5Nm. (Fig.155)
44.
Lubricate the seal seat and ‘O’ ring seal and fit into the recess in the seal housing (if it was removed).
Fig. 154
Fig. 155
72
8.4
FINAL ASSEMBLY (Continued) 45.
Lubricate and position ‘O’ ring around the angular contact bearing in the triangular groove. Lubricate and fit the small ‘O’ ring round the oil feed supply hole.
46.
Finally replace the seal housing (Fig.156) and insert the 4 socket cap screws and washers, washers, tighten evenly to compress both shaft seal and ‘O’ ring seal to 55Nm.
Fig. 156
73
8.4
FINAL ASSEMBLY (Continued) Vi Indicator Assembly 47.
Check that the the slide valve Vi stop is in the 2.6 position position by turning the slide stop stem fully clockwise. Screw the indicator pointer onto the screwed sleeve and check for freedom of movement. Position the sleeve retaining ring onto the screwed sleeve, ensure that the holes line up and push onto the slide stop stem. Position the indicator between the indicator pointer, align and secure to the gearbox using the single socket cap screw. Align the indicator pointer on the screwed sleeve with the Vi = 2.6 marking and tighten the two screws to secure the screws sleeve to the stem. Use the square drive to check the operation of the stop over its full travel for smoothness. smoothness. Fit the indicator support plate with two cap screws and washers.
74
SECTION 9
SPECIAL INSTRUCTIONS
75
9.1
TORQUE SPECIFICATIONS SPECIFICATIO NS COMPRESSOR TYPE XRV 127
FASTENER Locknut 25mm Locknut 30mm Locknut 40mm M8 Capscrew
TOOL Special XR12006J Special XR12006J Special XR12005J 6mm Hex Drive
M10 Capscrew M10 Capscrew M10 Capscrew
8mm Hex Drive 8mm Hex Drive 8mm Hex Drive
M10 Capscrew M12 Ca[screw
8mm Hex Drive 10mm Hex Drive
APPLICATION APPLICAT ION OE Balance Piston Actuator Actuat or Piston OE Thrust Bearing Gearwheel and Pinion Retaining Screws Seal Housing Cover Screws Gearbox Cover Screws Actuator Actuat or Cylinder End Cover Plate Rotor End Cover Plate Gearbox Screws
TORQUE Nm 130 Nm 80 Nm 206 Nm 20 Nm 55 Nm 55 Nm 30 Nm 30 Nm 95 Nm
Fig.157 9.2
PROCEDURES FOR FITTING LOCKWASHERS LOCKWASHERS This instruction applies to all lockwashers used on Howden compressors for the purpose of locking shaft locknuts in place, place, eg thrust bearing locknuts, locknuts, piston rod locknuts, locknuts, etc. A typical example example is shown below. (Fig.158)
Fig. 158 Assembly Method: When using this type of lockwasher, the locknut should be assembled to the shaft without the lockwasher and torqued torqued to the prescribed value. The locknut must then be removed, removed, the lockwasher lockwasher dipped in oil and fitted to the shaft, and the locknut replaced and again torqued to the prescribed value. This assembly process limits the amount of relative movement between the locknut and lockwasher and avoids the possibility of the inner tang being damaged during assembly. 76
9.3
SPECIAL TOOL LIST COMPRESSOR TYPE XRV 127 Description of Special Tool
Part Number
Quantity
Lockwasher Tab Bending Tool
XR12001J
1
Dummy Bearing Assembly
XR12002J
2
Locknut Spanner M40
XR12005J
1
Locknut Spanner M25
XR12006J
1
Rotor Jacking Tool
XR12007J
1
Rotor Anti Rotation Tool
XR12012J
1
Gearwheel Jacking Jacki ng Plate R3, R4, R5
XR12008J
1
Bearing Preload JIG R3, R4, R5
XR12009J
1
Dowel Pin Extractor
XR12010J XR12010J
1
Locknut Spanner M30
XR16006J
1
XRV127/163 30MM Locknut socket
XR12021J
1
XRV127 Actuator Piston Centralising Tool
XR12022J
1
XRV127 Locknut Socket Support
XR12023J
1
Dummy Thrust Bearing (MK4)
XR12003J XR12003J
77
1
9.4
PROCEDURE FOR TORQUING CASING TAP SCREWS 1.
Ensure that the inlet and outlet casing flanges are free from dirt and metal burrs.
2.
Install the ‘O’ rings without using grease or jointing compounds.
3.
When replacing the cap screws, ensure they are free of dirt and grit, and always fit washers.
4.
Tighten the cap screws in two stages, following foll owing the sequence shown in Fig.159 below in both stages.
Initial Torque Final Torque 5.
GEARBOX COVER 25 Nm 55 Nm
GEARBOX 45 Nm 95 Nm
On completion, give the cap screws a final check for tightness, tightness, working round the flange in a clockwise direction.
Fig. 159
78
SECTION 10
RECOMMENDED SPARES LISTS
79
10.1
RECOMMENDED RECOMMEN DED SPARES Spares are available for all XRV Compressors Compressors in the form of the f ollowing ollowing Kits: Shaft Seal Kit Shaft seal and cover ‘O’ Ring. Annual Inspection Kit All ‘O’ Rings and and seals required required for Annual Annual Inspection. Inspection. Overhaul Kit All ‘O’ Rings, seals seals and bearings bearings requi required red for complete strip and rebuild of compressor. When undertaking a compressor overhaul, all of the above Kits are required. NOTE: Suction and Discharge joints are not part of of Inspection Kit. These are availabl available e at extra cost as required.
80
RECOMMENDED SPARES LIST HOWDEN COMPRESSOR MODELS Mk2, 2A & 2B XRV 127/165 R1 Replacement Shaft Seal Kit – Kit – KXDS127 KXDS127 PART NUMBER DESCRIPTIO N XR12096-3 Input Shaft Seal G44059 O’Ring – Inlet Cover
QUANTITY 1 1
Annual Inspection Kit – Kit – KX127-2 KX127-2 PART NUMBER G44059 XR12059-3 XR12106-3 XR16102-3 XR16515-3 XR16522-2 M0905010
QUANTITY 1 1 2 1 1 1 1
Overhaul Kit – Kit – KXD127-2 KXD127-2 PART NUMBER G33001 G33002 G33003 G33008 G51001 G57057 G60004 G60005 M1701008 M1701010 M1701012 M1701020 Q4273 Q5163 XR12014-2 XR12032-2 XR12033-2 XR12060-3 XR12457-3 XR12097-3 XR12101-3 XR16295-3 XR12101 - OK
DESCRIPTIO N O’Ring – Inlet Cover Actuator Piston Seal O’Ring – Actuator Cyl. Cover O’Ring - Piston/Slide Valve Locknut M30 (S/Lock) Indicator Pin Grub Screw
DESCRIPTIO N Bonded Seal 3/8” BSP Bonded Seal ½” BSP Bonded Seal ¾” BSP Bonded Seal ¼” BSP Deep Groove Ball Bearing Microswitch Retaining Ring Retaining Ring Washer – Washer – 8mm Dia. Washer – Washer – 10mm Dia. Washer – Washer – 12mm Dia. Washer – Washer – 20mm Dia. Lockwasher S Lockwasher 40mm Labyrinth Insert Floating Bush Bearing Spacer Disc Spring Cylindrical Roller Bearing Cylindrical Roller Bearing Angular Contact Bearing Potentiometer (1k OHM) O’ Ring Kit G44005 – G44005 – O’Ring – Indicator Spindle G44059 - O’Ring – G’ Box Cover G44076 - O’Ring – G’ Box/Main XR12106-3 - O’Ring – Covers XR12107-3 - O’Ring – Gas Seal XR16102-3 – XR16102-3 – O’Ring – Piston/Slide Valve XR12109-3 - O’Ring – Man. Vi Spindle XR12112-3 - O’Ring - Main/Outlet
81
QUANTITY 2 1 1 3 1 2 1 1 1 10 26 4 1 2 1 2 2 2 3 1 4 1 1 Kit containing: 1 1 1 6 2 1 2 1
RECOMMENDED SPARES LIST HOWDEN COMPRESSOR MODELS Mk2, 2A & 2B XRV 127/165 R3-5 Replacement Shaft Seal Kit – Kit – KXGS127 KXGS127 PART NUMBER DESCRIPTIO N XR12124-3 Input Shaft Seal (Short Seat) XR12105-3 O’Ring – Shaft Seal Hsg. XR12110-3 O’Ring – Shaft Seal Hsg.
QUANTITY 1 1 1
Annual Inspection Kit – Kit – KX127-2 KX127-2 PART NUMBER G44059 XR12059-3 XR12106-3 XR16102-3 XR16515-3 XR16522-2 M0905010
QUANTITY 1 1 2 1 1 1 1
Overhaul Kit – Kit – KXG127-2 KXG127-2 PART NUMBER G33001 G33002 G33003 G33008 G51001 G57057 G60004 G60005 G60156 M1701008 M1701010 M1701012 M1701020 Q4273 Q5163 XR12014-2 XR12032-2 XR12033-2 XR12060-3 XR12457-3 XR12101-3 XR12103-3 XR12116-3 XR16295-3 XR12102 - OK
DESCRIPTIO N O’Ring – G’Box Cover Actuator Piston Seal O’Ring O’Ring – Act. Cyl Cover O’Ring – Piston/Slide Valve Locknut M30 (S/Lock) (up to Mk2) Indicator Pin Grub Screw
DESCRIPTIO N Bonded Seal 3/8” BSP Bonded Seal ½” BSP Bonded Seal ¾” BSP Bonded Seal ¼” BSP Deep Groove Ball Bearing Microswitch Retaining Ring Retaining Ring Circlip Washer – Washer – 8mm Dia. Washer – Washer – 10mm Dia. Washer – Washer – 12mm Dia. Washer – Washer – 20mm Dia. Lockwasher Lockwasher 40mm Labyrinth Insert Floating Bush Bearing Spacer Disc Spring Cylindrical Roller Bearing Angular Contact Bearing Cylindrical Roller Bearing Angular Contact Thrust Bearing Potentiometer (1k OHM) O’ Ring Kit G44005 - O’Ring – Indicator Spindle G44059 - O’Ring – G’Box Cover G44076 - O’Ring – G’Box/Main XR12105-3 - O’Ring – Shaft Seal Hsg. XR12106-3 - O’Ring – Covers XR12107-3 - O’Ring – Gas Seal XR16102-3 - O’Ring – Piston/Slide Valve XR12109-3 - O’Ring – Man.Vi Spindle XR12110-3 - O’Ring – Shaft Seal Hsg. 82
QUANTITY 2 1 1 3 1 2 1 1 1 1 10 26 4 1 2 1 2 2 2 4 4 1 2 1 1 Kit containing: 1 1 1 1 6 2 1 2 1
XR12112-3 - O’Ring – Main/Outlet
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Our Compressor Business Unit can offer you a comprehensive range of facilities to ensure the continued reliable operation of your Howden compressor. We can supply: 1.
A comprehensive comprehensiv e range of direct replacement compressors, supplied with a warranty.
2.
Approved parts and technical information inform ation to allow urgent repairs to be carried out on site.
3.
A field engineer engineer to service or supervise supervise the installation and commissioning of compressors. compressors.
4.
Quotations for price and delivery of spare parts.
5.
A comprehensive comprehensive service contract or survey incorporating full vibration analysis tailored specifically to meet customer requirements requirements and time schedules. schedules.
For further information and details of the above, please contact our Compressor Business Unit directly.
Howden Compressors Compressor Compressor Business Unit 133 Barfillan Drive Glasgow G52 1BE Scotland, UK Telephone: Fax: E-mail: Website:
or
+44 (0) 141 882 3346 +44 (0) 141 882 8648 hcl@
[email protected] www.howden.com
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Howden Compressors LLC 1850B N Gravers Road Plymouth Meeting PA 19462 USA +1 610 313 9800 +1 610 313 9215
[email protected] www.howden.com
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Printed in the UK – UK – Issue Issue HCL/September 2013 © Howden Compressors Limited
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