CC150

F.L.Smidth, Inc. 2040 Avenue C Bethlehem, PA 18017-2188 Telephone: 610-264-6011 Fax: +1-610-264-6701 www.flsmidth.com

Parts and Service Call 1-800-795-6825

Instruction Document No.: C66-A446 Version: 15.0 Page 1 of 51

Instruction Manual

Ful-Vane Compressors, Vacuum Pumps And Boosters

Single Stage Rotary Sliding Vane

Air And Gas Service

Version Signed by Release Date

15.0 Tom Krulick 10/05/2004

Caution

Read this instruction manual before performing any installation, operation or maintenance procedure.

All equipment must be operated and maintained in accordance with all applicable

governmental safety and health laws and regulations, generally recognized industrial standards, and the users plant standards.


F.L.Smidth

2

CONTENTS Page INTRODUCTION ...............................................................................................................3 RECEIVING AND STORAGE...........................................................................................4 INSTALLATION Location ...............................................................................................................................4 Foundation ...........................................................................................................................4 Erection & Alignment..........................................................................................................5 Cooling System....................................................................................................................6 Water Piping ........................................................................................................................7 Air Piping.............................................................................................................................8 Accessories .................................................................................................................... 9-10 OPERATION Before Start ........................................................................................................................11 Start-Up..............................................................................................................................12 Operation Notes .................................................................................................................12 Stopping .............................................................................................................................13 Lubrication................................................................................................................... 14-15 Maintenance Guide ............................................................................................................16 INSPECTION AND SERVICE Internal Inspection ....................................................................................................... 17-18 Dismantling........................................................................................................................19 Assembly............................................................................................................................19 Descriptive Views........................................................................................................ 20-22 Cylinder Head Gaskets ......................................................................................................23 Rotor End Clearances .................................................................................................. 23-25 Doweling and Bottom Clearance ................................................................................. 25-28 Renewal Parts.....................................................................................................................29 SPECIAL NOTICE PARTS ...........................................................................................30 PARTS LIST................................................................................................................ 31-34 APPENDIXES A. Cog Belt Tension Adjustment......................................................................................35 B. Lubrication Feed Rate ..................................................................................................36 C. Re-machining Procedure ........................................................................................ 37-38 D. Rotor Slot Criteria........................................................................................................39 E. Clearance Setting Methods..................................................................................... 40-41 F. Reconditioning Limits ............................................................................................ 42-47 G. Trouble Shooting Chart................................................................................................48 H. F.L.Smidth Exchange Programs ..................................................................................50


F.L.Smidth

3

Here's Why You're Ahead with F.L.Smidth Ful-Vane Rotary Compressors

LIGHTER FOUNDATIONS NEEDED No reciprocating motion to set up vibration. Air flow is free from pulsations. You can install F.L.Smidth rotaries on much lighter foundations even on balconies. SIMPLER PIPING, TOO Intake and discharge openings are on horizontal plane on opposite sides of cylinder-avoiding reversal of air flow, simplifying piping, making easier access to rotating parts. DIRECT DRIVE, COG BELT DRIVE, OR GEAR REDUCER . . . FOR VERSATILITY ECONOMY AND SAFETY SLIDING FUL-VANE EFFICIENCY F.L.Smidth rotary compressors, vacuum pumps and boosters are of the multivane type. Each unit consists of a water-jacketed cast iron casing in which a forged steel rotor revolves. Its axis being eccentric to that of the casting. Arranged in milled slots on the rotor is a series of composition blades, free to slide by centrifugal force, against the interior wall of cylinder as the rotor turns, forming numerous crescent-shaped cells that trap the air being compressed. Since these rotor blades are free riding in their rotor slots, they automatically compensate for blade wear, maintaining perfect cylinder with contact through centrifugal force. UNDERCUT BORE F.L.Smidth's exclusive undercut bore is a key to higher volumetric efficiency of the F.L.Smidth rotary compressor. After boring the cylinder to size, the boring bar is dropped to the point of rotor eccentricity and a second cut is taken at bottom only and at same radius as the rotor. After the bore intersections are blended this undercut section of the cylinder is parallel to the rotor surface for approximately 30 circumference and, with close running clearance, acts as an effective seal between discharge and suction pressures.

High quality F.L.Smidth circular bore type compressors are also available. These units provide rotary compressor advantages of higher speeds and capacities in competitive cylinder sizes.


F.L.Smidth

4

RECEIVING AND STORAGE Before and after uncrating, look for damage that may have occurred in transit. Check for shortages by comparing each item received with those listed on the shipping manifest. If damage or shortage is noted, advise carrier within fifteen (15) days of receipt and request an inspection report. Make proper claim with carrier and order replacement part/s from F.L.Smidth. If unit is not used immediately, place equipment in a clean, dry storage area protected from inclement weather. The compressor interior has been serviced with a special anti-corrosion agent which will allow storage for a reasonable period of time but, consult F.L.Smidth if storage periods are extended. INSTALLATION Location the unit should be installed in a clean, dry, well-ventilated area adjacent to points of use. Ample space and facilities should be provided for convenience in servicing and inspection The Air Intake should be located where the atmosphere is:

Clean because dirty, gritty air quickly chokes filters and if allowed to pass into the compressor, causes rapid wear. Cool - because the cooler the intake air, the more air is compressed per revolution. Free from Chemical Fumes - which cause corrosion in compressor mains and tools-exhaust gases from engines and furnaces come under this heading. Dry - because wet intake conditions will wash cylinder lubrication, pit bearings, and cause abnormal precipitation of moisture in receiver or distribution system. Keep intakes clear of steam exhausts and outlets from dryers or cooling towers. An outdoor

intake must be protected from severe weather conditions. If unusually dirty or dusty conditions exist, consult F.L.Smidth Company for information about special filters or cleaners. FOUNDATION - concrete foundations, extending to firm bearing and with moderate steel rod reinforcing, are recommended. However, installations on balconies or steel supports are also satisfactory providing that sufficient stiffness is designed into the supports to maintain coupling alignment. Ful-Paks must be mounted on a solid foundation for noise containment. Simple slab type foundations are normally used to raise the compressor unit to reasonable height above floor for convenient servicing and/or inspection. Basic design should be for static loadings only. The foundation drawing indicates the necessary dimensions for the construction of these foundations and gives anchor bolt and pipe sleeve locations.

CC300 Ful-Paks


F.L.Smidth

5

ERECTION AND ALIGNMENT - the unit should be placed on foundation, leveled carefully with wedges located as close to foundation bolts as possible. The driver, with the coupling half assembled, should be placed on foundation and aligned with the unit. All anchor bolt nuts must be sufficiently tight to hold unit firmly on wedges or plate. Check for proper shaft gap (refer to general arrangement drawing) and proceed with coupling alignment. For a unit with driver on combination base and factory assembled, alignment has already been made but, must be reestablished at installation. Set entire unit in place on foundation bolts, and using wedges at each bolt, level in both directions. Keep nuts only finger tight until coupling alignment has been rechecked and reestablished. Do not spring base. One method to check coupling alignment is with a dial indicator having magnetic bases or clamps and as follows: With one coupling pin in place, turn both coupling halves through 360 to check parallel alignment. See Fig. 1. Readings are taken at four points; top, each side and bottom. The difference between the two side radial readings

indicates the motor must be shifted sideways and the difference between top and bottom radial readings indicates that the driver must be raised or lowered by adding or removing the same thickness of shims under all four feet. The amount of correction to make in each case is one-half of the difference between the two indicator readings. Align to within .003" (.076mm) actual or .006 (.152mm) total indicator reading.

To check angular alignment, mount indicator as shown in fig. 2 with pickup against coupling face. With one coupling pin in place, turn through one revolution. A reading on the dial will show amount of misalignment and location. Correct this to within .003 (.075mm) by shimming under front or rear feet, as required, of the driver or cylinder. The straight edge-taper gauge method can be used as an alternative to the foregoing procedure with following variations:

Use feelers and straight edge and check coupling parallel alignment at four positions turning the rotor by hand 90 for each step and align by shimming under all four feet of driver. See Fig. 3.

Use a taper gauge and check coupling angular alignment. Align by shimming under front or rear feet, where required, of driver or cylinder. See Fig. 4.

Figure 2

Figure 3

Figure 4

Figure 1


F.L.Smidth

6

After alignment is complete, proceed as follows:

Use a cement grout and grout in thoroughly around and well under the base, filling all anchor bolt sleeve openings.

After grout is set, tighten all anchor bolts firmly. Be sure to recheck coupling alignment and if necessary to

realign, use shim stock between cylinder and base.

Where required, mount the lubricator on its support and locate as shown on general arrangement drawing.

The driver should be checked for rotation, making sure that it agrees with the compressor rotation arrow. Do not put in the coupling pins for this check.

For V-belt driven units, check the alignment of the sheaves before final grouting. Locate sheaves as

dimensioned on the general arrangement drawing. Install driver and its base with allowance for lateral motion to install V-belts and provide proper tension during operation. In adjusting tension of V-belts, follow instructions of the V-belt manufacturer.

Cog belts are not to be tensioned as a V-belt. They should be installed with snug fit, neither too taut nor

loose. See Appendix A: Cog Belt Tension Adjustment Chart.

The balance of the erection should be completed by following the general arrangement and special drawings supplied.

NOTE! Coupling halves are bored for a medium push fit to shaft and must be securely locked to shafts with set screws over keys. Coupling halves should be mounted to clean and thoroughly oiled shafts with a soft lead hammer by lightly tapping into position. COOLING SYSTEM-the water supply should be clean and ample. Dirty, scale-forming cooling water coats and clogs water passages, thereby reducing cooling effect. Ample cooling water to cylinder jackets is necessary, but excessive cooling is not advantageous. The temperature of cooling water at cylinder outlet should range between 80F (26C) and 110F (43C). Check coolant temperature/flow thru open sight funnel under full load conditions. To minimize sweating and condensation inside compressor, it is always recommended that the cooling water be shut-off as soon as compressor is stopped. To do this automatically, it is suggested that a solenoid-operated water valve be used in cooling water supply line. Connect valve to open, only when compressor is running.

The minimum cooling water requirements per 100 hp input (75 kw) to produce exit water temperature of 110 F. are as follows: 2.4 gpm (9 lpm) for 50F (10C) Incoming Water 3.7 gpm (14 lpm) for 70 (21C) Incoming water 7.5 gpm (28.5 lmp) for 90 (32C) Incoming Water At no time should water pressure in the cylinder jackets exceed 70 psig (4.2 bar).


F.L.Smidth

7

WATER PIPING-The supply line valve should be located conveniently for use of the operator. An open sight funnel for gauging water flow and temperature is supplied with every unit. Provide connections at the lowest elevation of the water piping to allow complete drainage of the cooling water from the compressor. See Fig. 5.

Compressors are sometimes furnished with a self-contained water cooling system consisting of an air-cooled radiator, water pump and complete re-circulating piping system. A fan is used to pass atmospheric air through the radiator core and to cool the water. Locate the system so there is an unrestricted flow of cool, clean air through the radiator. In freezing weather, drain or be sure to add suitable anti-freeze solution. Follow instructions given on special drawings for installation and operation. See Fig. 6 and 6A.

Figure 6

Figure 5

This two stage gas compressor package uses a radiator for intercooling, aftercooling and for cooling the jacket cooling water.

This compressor package uses a radiator to cool the cooling water.

Note: For gas services, it is recommended that a thermostatic control valve be installed on the water exit to avoid condensing liquids that may be present in the gas stream.

Figure 6A


F.L.Smidth

8

AIR PIPING-piping can be cast iron, black iron or galvanized steel pipe. With welded piping, be sure to provide a removable flanged connection at the compressor proper. Provide adequate supports for piping and align carefully to remove all strains on the compressor. The intake air filter-silencer (normally supplied with each compressor) should be located to provide a source of cool, dry, clean air and convenient for easy servicing and frequent inspection. HVAC ducting is not recommended for inlet piping. Pipeline type filters are recommended for the intake line of vacuum pumps and gas boosters. Intake air/gas must be free of all dirt, scale, slugs of liquid, etc.

The intake piping should be cleaned thoroughly before final connection and if necessary, acid pickled and wash cleaned prior to initial operation. Do not install any stop valves in the intake line of compressors. Large vacuum pumps require a vacuum limiting device between any stop valves and pump inlet. See drawings furnished with unit for specific instructions.

A flanged non-return valve is furnished each unit, automatically preventing any back flow created by discharge pressure when unit is not running. Normal mounting is horizontal. A simple drop-leg should be provided after the non-return valve, to trap all excess lubricant or moisture entrained in the air or gas. All compressors and boosters should be protected against overpressure in the discharge line with a safety valve. Be sure no stop valve is placed between compressor and safety valve. Vacuum pumps are normally supplied with discharge silencers. See Figures 7 through 9 for typical installation arrangements.

Figure 7

Figure 8

Figure 9


F.L.Smidth

9

ACCESSORIES Many accessories are available and necessary for use on a well-designed compressor system. The important ones are listed as follows: Protective Controls - the following controls are typical and available for use. However, check drawings furnished for individual unit. Discharge temperature switch-in discharge flange of unit and set to operate when the discharge temperature

reaches temperatures equivalent to the internal clearances in unit. Pressure switch-used by boosters and gas compressors to control either or both the discharge and intake

pressure by actually starting and stopping the motor. Solenoid flow valve-in the water supply line to open and close with operation of motor. Cooling water flow switch-in water discharge line to operate on water failure or inadequate flow. Flow control valve-in water supply line and its temperature bulb in discharge line which controls amount of

water flow. Solenoid drain valve-installed in water piping low point to drain compressor jackets when motor stops.

Protection during freezing weather.

Lubricator low oil level switch and lubricator belt failure switch are some of the other controls available to stop the motor or sound an alarm on lubrication failure.


F.L.Smidth

10

Figure 10 Single Stage Typical Gas Compressor Package

Oil and Moisture Separator-on installations where aftercoolers are not used, a separator such as impingement type, change of direction of flow type, cyclonic action type, or coarse mesh screen type can be used to remove any condensation which may occur. Adequate drainage facilities should be provided. It should be located in the discharge line as far from the compressor as possible. Aftercooler and Separator-on air compressors, the discharge air contains atomized oil and moisture from the atmosphere. The amount of moisture is considerable and cooling, during transmission in the discharge piping, causes unwanted condensation. An aftercooler will cool the compressed air close to the cooling water temperature. This will reduce the water and oil vapor to a liquid for easy removal in the separator. Adequate drainage facilities should be provided. By-Pass Regulator-furnished for special applications to vary the final delivery of the unit and to control either the discharge of the intake pressure. A pressure-operated valve by-passes excess capacity from the discharge to the inlet or atmosphere. When by-passing to inlet, the air or gas is cooled to its approximate inlet temperature to prevent overheating during continuous maximum by-passing. Special instructions and drawings are submitted for these arrangements. Air Receiver-the chief function of a receiver is to furnish reserve air capacity and should be sized large enough to avoid frequent operation of the regulating device. They also act as excellent separators and remove a good percentage of any condensate in the air stream. Therefore, adequate drainage facilities should be provided. It is important that receivers be equipped with a safety valve sized to meet the compressor capacity.


F.L.Smidth

11

OPERATION The following checkpoints are mandatory and are to be made before initial start or after any repairs. They are general in nature and applicable to single stage compressors, vacuum pumps and boosters: BEFORE START: Recheck coupling alignment, direction of rotation. all piping connections, water and air, and adjust as required. Fill the lubricator with oil. Loosen the tubing nuts at the oil line check valves. Be sure each oil line is purged

of all entrapped air and retighten the nuts. Follow instructions in the lubricator manual. Fill the oil bath filters with oil to the proper level per the instructions shown on filter. If filter is installed

outdoors, use SAE 10-30 in cold weather and SAE 30-50 in hot weather. Check dry type filters for any blanks or strapping used for shipment. Where a bag-type dust collector intake filters is used, on an installation at heavy dust loads such as a cement

plant, be sure to check all features from the special instructions furnished. In any event, recheck that no shipping protector or blind flange is blocking the intake line or filter. Important-disconnect piping at intake of unit and install a 16 mesh screen between flanges, folded twice, and

reconnect piping firmly. This dirt catching screen is temporary and should be removed after the intake line is clean. Rap entire intake line thoroughly, at start up, to dislodge all loose material. Repeat until line is clean!

Check all protective devices or controls making sure they are properly connected electrically and/or

mechanically.

Figure 10A Ful-Pak


F.L.Smidth

12

START-UP PROCEED WITH START-UP AS FOLLOWS: Open cooling water supply valve fully to check the adequacy of the discharge facilities. Throttle the flow to a

moderate rate. Where the unit has a recirculating cooling system, make sure the system is filled. Start the driver and bring unit up to full speed. When starting boosters, be sure intake line valves are fully open. Boosters can usually be started against normal

discharge pressure; however, some boosters are piped with a manually valved by-pass, from discharge to suction, for pressure equalization during startup and shutdown.

When starting vacuum pumps, the discharge line is open to atmosphere and the intake line valve fully open. For

large vacuum pumps, the inlet valve can be closed to reduce starting power and then slowly opened after the vacuum pump is at full speed.

Adjust the flow of cooling water so that the final discharge ranges from 80F (26 C) to 110F (38 C). Check and adjust lubricator feed rates to the drop rate indicated on the lubricator nameplate. Check all protective devices or controls making sure they are working properly. Check and adjust shaft packing, where used so that there is small amount of leakage of air and oil. Normal

operating temperature will range from 110F (43C) to 180F (82C). Packing running too tight will overheat excessively. Where mechanical seals are used, no adjustment is required, and cover temperature will operate at from 125F (52C) to 210F (99C).

MISCELLANEOUS OPERATING NOTES: Excessive discharge temperature-for normal operation, the discharge temperature will vary over a definite range

as determined with a thermometer. A sudden or gradual rise above this range is indicative of trouble such as inadequate cooling, faulty lubrication, dirty intake filter, etc. The unit should be stopped and inspected. Any continuous operation involving discharge air/gas temperatures exceeding 325/350F (163/177C) range severely affects lubrication and blade strength promoting excessive wear and breakage.

Dirty cooling water causes cooling inefficiency by clogging the jackets. Unit must be dismantled and jackets

scraped and hosed clean. If clean water is not available, suggest back flushing jackets with high pressure air through the connections on the bottom of cylinder heads.

Loss of cooling water-stop unit immediately and DO NOT turn on unit until unit is completely cool. Condensibles can cause severe blade wear on special gas boosters or "wet" vacuum pumps and require careful

throttling of jacket water or preheat of suction to maintain internal temperatures above the dew" point.


F.L.Smidth

13

STOPPING PROCEDURE: On standard compressors and vacuum pumps, stop the motor or driver. Shut off water. Continuous flow of water can cause condensation in bearing chambers. Drain cooling system if

freezing is possible. Where unit is on standby service, run weekly for three to four minutes or turn rotor over by hand with full

lubrication adjustment.


F.L.Smidth

14

LUBRICATION

F.L.Smidth Company now has as standard an innovative FUL-LUBE Lubrication System...that greatly reduces risk of rotary compressor damage due to lubrication failure. An advanced distribution block design with a high-capacity reservoir in a self-contained package is the key to: increased compressor protection decreased maintenance man-hours

FUL-LUBE Lubrication System is standard for single-stage, two-stage and duplex compressor arrangements. See Figures 11 and 11A.

1. 15 and 30 Gallon Storage Tanks allow approximately one month of continuous operation between refills...reducing maintenance man-hours and risk of water contamination. 2. Direct-Driven Pumping Unit with 110-volt enclosed 1/3-HP motor eliminates risk of compressor failure due to belt breakage and lubrication loss. Three

phase motors are available as an option. 3. 20-Micron Filter removes entrained impurities in the lubricant. 4. Distribution Block meters precise amount of lubricant to each compressor lube point while eliminating the need for constant monitoring and adjustment. 5. Digital No Flowtimer (DNFT) monitors movement of divider valve piston for dependable timed shutdown protection.

Oil is fed to cylinder walls, bearings and mechanical seal with a force-feed, positive-pressure, lubricator. Each connection on the unit is equipped with a check valve to prevent leakage of air or gas to the lubricator. See Fig. 12.

Adjust lubricator feed rates to the drop rate indicated on the lubricator nameplate. On units with mechanical seals, be sure to hand pump oil to the seal face at startup. Never exceed the 3 to 4 drops/minute rate recommended for the seal.

Whenever unit is disassembled, add approximately 1/2 pint (.231) of oil to each bearing cavity through pipe tap on top of each bearing retainer at reassembly.

During the first internal inspection, determine if the proper oil is being used. Bearings, cylinder walls, rotor slots and blades should show a polished surface with a light film of oil. Hard, baked deposits indicate inferior oil, dirt or excessive temperature.

Where excessive moisture is present, use suitably compounded oil having the ability to wet metal surfaces in preference to water.

Gas compressors and boosters are lubricated similar to air compressors except when special gases are being handled. Special material and lubrication is required.

Figure 12

Figure 11

Figure 11A


F.L.Smidth

15

The following are the characteristics of an oil which will be suitable for units operating on straight air service in normal room temperatures of 60F (16C) to 90F (32C).

TYPICAL CHARACTERISTICS FOR A PARAFFINIC OIL WITH ADDITIVES: 9 Normal discharge air temp, range: 250 F (121 C) to 325 F (163 C) 9 Grade: SAE 40 9 70 to 90 SSU viscosity @ 210 F (99 C) 9 Gravity: 25 API minimum 9 Viscosity index: 87 min. 9 Flash: 450 F (232 C) 9 0.5% max. carbon residue of base stock (Conradson).

Must meet performance level of former MIL-L-2104A suppl. #1. For abnormal discharge air temperatures above 325 F (163 C) a 90 to 110 SSU @ 210 F (99 C) viscosity oil is required.

TYPICAL BRAND NAME OILS OF NATIONAL SUPPLY SUGGESTED ARE: Chevron: Chevron Delo 100 Motor Oil

SAE 40

Mobil: Delvac 1640

Cities Service: Citgo C-340 Shell: Shell Morlina / NA150

Compounded oil for wet vacuums:

Texaco: URSA Oil C 150 or Chevron

Marine Oil 150X

Exxon: XD-3 SAE 40 Texaco: URSA ED40 or URSA Extra

Duty SAE 40

For wet compressor service:

Chevron EP Industrial 220X

See Appendix B for Oil Feed Rates We do not recommend the use of kerosene, gasoline, or any other volatile cleaning agent in the cylinder during operation. Their use can cause a temporary lack of proper lubrication. Contact FL Smidth Inc. for synthetic lubricants.


F.L.Smidth

16

MAINTENANCE GUIDE Set up a schedule along the following lines: Daily Fill and/or check lubricator. Drain airlines of condensate including drain on pilot valve, where furnished.

Monthly Replace oil in oil-bath filter silencers and note if more frequent servicing is needed. Check operation of safety valves and controls for proper operation. Check shaft packing take up as required. Check lubricator drop rate or count rate.

Yearly Inspect unit as outlined under Inspection and Service Clean lubricator, oil lines and check valves. Where furnished, clean regulator and pilot valve. Clean filter and element. Recheck alignment and shaft gap.

MULTIPLE LUBRICATOR PUMP SYSTEM OPERATION To Regulate the Feed:

To increase the feed, place a screw driver in the slot of the feed regulator and turn to the left until the desired amount is being supplied. To decrease turn to the right.

Crank for Hand Operation: The hand crank on the end of the lubricator is for use before starting, or for momentarily increasing the oil supplied while the machine is in operation. The hand crank operates all of the feeds at one time. Its use does not affect the feed regulation.

Check 'V'-Belt Drive: Lubricator belts are of the 'endless' variety and require removal of a link to adjust tension. Check belt periodically for wear and proper adjustment.

Keep Lubricator Clean-

Use only new or filtered lubricant. Periodic cleaning of the lubricator is recommended since lubricant is subject to fouling from atmospheric dusts and additives. To do this, remove all pumping units; clean them and the reservoir by dipping and brushing in a cleaning solvent.

To Remove a Pumping Unit-

Any single unit may be removed from the reservoir by removing the two screws, which hold it to the cover. After the screws have been taken out, pry up the front end of unit with a screwdriver, pull unit forward as far as possible, at the same time tilting the front end upward, and the unit will readily lift out.

Ful-Lube System

Read the instruction manual for proper installation, operation and maintenance of this type system

Figure 13

Force feed oiling to cylinder wall (as shown) on intake quill on other size machines; assures proper oil distribution to all surfaces. Bearing oiling connections on cylinder heads are always located on discharge side.


F.L.Smidth

17

INSPECTION & SERVICE INTERNAL INSPECTION A new unit should be inspected internally during its first year of operation.

Normally, an internal inspection requires removal of the rear end cylinder head only. See Fig. 13A. The expansion bearing, hub seal ring, blades, rotor slots, cylinder bore and cylinder jacketing can then be examined. If all items appear reasonably clean and unworn, further dismantling is not required. The head gaskets can be reused if not damaged at dismantling. Should they require replacement, see section on cylinder head gaskets. However, if preliminary inspection indicates closer examination is required, proceed to dismantle unit as outlined in following sections and check items on front or fixed end. NOTE! Refer to paragraph concerning inspection under lubrication section to assure proper lubricant is being used.

Cylinder bore must provide a smooth and true surface for smooth blade action thru each revolution of rotor. Rotor slots must provide full, even support to blades from end to end and top to bottom. See illustration on page 18. Clean all carbon build-up, flush jackets, stone any minor corrugations in bore and clean up head faces for a good gasket surface. Clean out dirt and carbon in the bottom and sides of rotor slots so the blades can retract in slots freely. When new blades are fully retracted in slots, the top of blades should be flush with the top of the rotor. Excessive slot wear or major bore corrugations can be repaired in the field; however, a complete factory reconditioning is recommended. Occasionally the dowel pins will become offset, which is difficult to determine visually without their complete removal. This usually happens after blade breakage. Offset dowels can cause premature bearing failure and rotor damage through contact with heads or cylinder bottom. To check a dowel pin, insert a # 10 drill in the center hole. A straight dowel pin allows the drill to pass completely through the dowel. Some machines are built with solid dowel pins. These should be pulled and replaced. Complete and modern rebuilding facilities exist at F.L.Smidth's manufacturing plant at Manheim, Pennsylvania. Your compressor can be rebuilt by experienced craftsmen to new machine standards with a six-month warranty on materials and workmanship. In addition, cylinder assemblies, rebuilt to factory specifications including new wearing parts, and carrying a six-month factory warranty on material and workmanship from date of shipment, are available for immediate shipment on an exchange basis. If major reconstruction in the field is mandatory, special service can be extended for parts. See the following appendix for special field instructions. Appendix C: Procedure for remachining cylinder Appendix D: Rotor slot criteria Appendix E: Indicator method of setting rotor end clearance Appendix F: Instructions for reconditioning of cylinder rotor

and head

Figure 13A


F.L.Smidth

18

Blades-the maximum recommended blade wear in width can be roughly checked by measuring the distance between the top of the rotor and top of worn blade(s) with blade seated in bottom of slots - See Fig. 15. Blades should be checked also for charring, splitting or chipping on the running edge and for concave wear in thickness at point of rubbing contact with rotor slot. For any wear other than a 'polish', replace with new blades. Before installing new blades, thoroughly clean rotor slots using keystock as wide as slot width. Bevel one side to chisel point and work back and forth in slot removing all carbon. Be sure new blades are lightly oiled and fit freely in slot. File away any metal tending to bind blade from free movement. New B3000 blades are slightly longer and thinner than other blades, but are interchangeable. Do not modify. The B3000 may also have cosmetic blemishes and spots on the surface, which will not affect blade performance. If blade containers are cracked or damaged, blade dimensions will not change with exposure to air and moisture. Bearings - Any rough, pitted or irregular markings on the bearing running surfaces will cause noise and vibration and careful examination of the inner race and rollers will indicate when replacement is required. Use a torch to apply quick heat to the bearing inner race for removal. Note-race temper will be destroyed and bearing is not reusable. Shaft Seal-Packing or Mechanical Seal - replace packing if worn or if rotor shaft shows signs of scoring. If unit has mechanical seal, examine carefully and if face is worn or chipped and ring torn, replace complete seal. Check the seal cover to assure a smooth mating surface for the seal face and be sure lubricating oil hole is open. Hub Seal Rings - replace if any signs of wear or breakage are noted. Replacement rings are split for easy assembly.

Blade Wear Compressor Size SS / LP HP CC15 (12.7mm) N/A

C30-40 (12.7mm) (12.7mm) C50 (6.3mm) (6.3mm) C60 (12.7mm) (12.7mm) C70 (9.5mm) (9.5mm) C80 (12.7mm) (12.7mm) C100 (9.5mm) (9.5mm)

C110 thru C350 (12.7mm) (12.7mm) C375 (12.7mm) N/A C400 (12.7mm) N/A C450 (12.7mm) N/A C508 (12.7mm) N/A C608 (9.5mm) N/A Figure 15 Measure blade wear as shown and

replace blades when wear exceeds limits indicated above.


F.L.Smidth

19

DISMANTLING Remove Rear End Cylinder Head: Drain water jackets and disconnect oil tubing to head. Remove cylinder head stud nuts. Use two hexagon set screw wrenches and turn into cylinder head to force head equidistant off the dowel pins and away from the cylinder end. Return hexagon screws to original position after head is free to be lifted off the studs. Try to preserve cylinder head gaskets. Remove Front End Cylinder Head: For units without spacer coupling, remove piping, hold down bolts, lubrication tubing and swing entire cylinder assembly so the coupling can be removed. Remove fixed bearing retainer. Use a long drift pin and hammer to loosen bearing locknut. Look for rotation direction arrow on locknut since they are furnished with right or left hand threads*. Remove the locknut, lock washer, spacer and fixed bearing thrust ring. Then, jack off the head following procedure outlined under rear end head removal. The bearing shims, used to establish the fixed end clearance, should be carefully removed for reuse on reassembly. Again, try to preserve the cylinder head gaskets. *On certain, older machines ASSEMBLY Bearings and Seal Ring Retainers to Rotor-

Place rotor on "v" blocks, clean shaft thoroughly and oil lightly. The hub seal retainers and inner race of the bearings are furnished for a shrink fit and must be heated in an oil bath before assembling to shaft. Heat the bearing inner races to 200F (93C) or 225F (107C) for 15 minutes and ring retainers to 450F (235C). Do not heat with a torch and do not overheat.

Retainers are usually furnished in a one-piece construction. The rings are split for replacement since they can be extended over the assembled bearing race and retainer and slipped into the ring groove. Bearing inner races are not alike. The fixed bearing inner race, assembled on shaft end nearest driver, has a shoulder and separate collar to hold rotor axially. See Fig. 17.

Figure 16 Installing pre-heated bearing inner race

Figure 17 Fixed bearing parts with inner race assembled.

Inner Ring

Outer Ring Collar


F.L.Smidth

20

Interior view of cylinder showing intake and discharge ports. Note smooth intersection of main and undercut bores.


F.L.Smidth

21

View showing rotor slots. Note parallel side walls to provide proper blade support.


F.L.Smidth

22

CYLINDER HEAD STUD BOLT INFORMATION

Compressor

Size

Torque Ft-Lbs / Newton

Meters Qty. Per Set Stud Dia.

50 / 68 12 1/2 (12.7 mm) 11-12-13 100 / 135 12 5/8 (15.8 mm) 15 to 25 100 / 135 12 5/8 (15.8 mm) 30-40-50 165 / 224 12 3/4 (19.1 mm)

165 / 224 12 3/4 (19.1 mm) 60 to 100 265 / 304 12 7/8 (22.2 mm) 265 / 304 16 7/8 (22.2 mm) 110 to 150 400 / 542 16 1 (25.4 mm)

175 to 225 400 / 542 20 1 (25.4 mm) 175H to 300H 400 / 542 20 1 (25.4 mm) 250-300 400 / 542 20 1 (25.4 mm) 350 400 / 542 24 1 (25.4 mm) 350H 400 / 542 24 1 (25.4 mm) 375-608 650 / 881 28 1-1/8 (28.5 mm)

Rotor End Clearances (cold)

Rotor End Clearances (hot)

When the machine is cold, free end clearance is greater than fixed end clearance. The rotor expands from the fixed end and clearances will become equalized when hot.

Rotor end clearances must be held to a minimum to prevent air leakage and the resultant decrease in compressor volumetric efficiency.


F.L.Smidth

23

CYLINDER HEAD GASKETS In replacing gaskets, first measure by micrometer the total thickness of gasket material formerly employed under each cylinder head, then replace with new gaskets under same total thickness as before, plus .002" (0.5mm) for each layer of gasket used. This is to allow for compression of new gasket material, which amounts to about .002" (.05mm) for each sheet.

For new parts or if machine work has been done on cylinder, rotor, or heads or if old gaskets cannot be measured, see section on rotor end clearances. Two gaskets should be used at each end of the cylinder and if greater thickness is required to secure proper rotor end clearance, the extra may be made of paper. In this case put the gasket in contact with the cylinder proper and the paper next to the head. This will preserve the life of the paper. The center of the gasket has purposely not been cut out. This is because it is necessary to match the edge of cylinder wall with the edge of the gasket as nearly as possible. Place gasket over the head studs, cutting proper openings for dowels, then with the

gasket pressed against the end of the face of the cylinder, run a sharp knife blade around to match the edge of cylinder wall all the way around. See Fig. 17. Gasket must NOT extend inside the edge of cylinder bore as that will interfere with the action of the rotor blades. ROTOR END CLEARANCES- LEAD WIRE/FEELER METHOD (See Appendix E for alternate indicator method) Front and Rear Heads (See clearance plates on compressor and illustration on page 22.) Determine fixed end clearance at front head as follows: Place three bearing shims and outer race of front bearing into housing of cylinder head. Shims are available in

thicknesses of .003" (.076mm), .005" (.125mm) and 0.10" (.25mm). Place cylinder head over front end of rotor assembly. Care should be taken

to hold bearing outer race and head central to rotor to prevent damaging bearing inner race and hub seal retainer surfaces.

Assemble the fixed bearing locating collar, fixed spacer and locknut. Do

not assemble lock washer at this time. Tighten locknut firmly. Assemble front retainer and fasten tightly to cylinder head. Do not use the

retainer gasket at this time. Check for maximum clearance by using three feelers, of equal thickness,

inserted between face of cylinder head and end of rotor at three equally spaced points. See Fig. 19. Be sure cylinder head is pulled away from rotor face so that the clearance obtained is maximum. Actual clearance may vary plus .002" (.05mm), minus .000".

Figure 18 Trim cylinder head gaskets to suit cylinder bore

Figure 19 Checking fixed-end clearance between rotor and front head.


F.L.Smidth

24

If clearance obtained is more than required amount, the cylinder head must be removed and extra shims added. If less, necessary shims must be removed.

Check minimum clearance by pushing cylinder head against rotor and inserting .005" (.125mm) minimum feeler

at three equally spaced points. If doweling is required, establish bottom clearance as indicated in next section. If doweling is not required, complete fixed end assembly as follows: Remove bearing retainer, locknut, bearing locating collar and cylinder head with bearing outer race assembled.

Place two synthetic fiber gaskets next to cylinder face, trim to suit and reassemble head. Be sure hub seal ring is in place. Assemble lock washer to rotor at this time and bend locking ear into nut groove after tightening locknut firmly.

Tighten nuts on studs evenly and tightly. Be sure backing-off screws and pins are in place in head. Do not install

front bearing retainer.

Proceed to establish expansion end clearance at rear head as follows: Place straight edge across face of cylinder at rear end and with feelers, measure clearance back to face of rotor as shown on Fig. 20. Subtract this clearance from the sum of the fixed-end clearance, expansion-end clearance and .002" (.05mm) for each gasket estimated to be used. This gives the total gasket thickness required at expansion end between rear head and cylinder. NOTE: Where rotor extends beyond end of cylinder, add this clearance dimension to the

sum of the fixed end clearance, expansion end clearance and .002" (.05mm) for each gasket to give the' total gasket thickness. Install the quantity of gaskets as estimated above with the synthetic

fiber placed next to the cylinder and trim to suit. Check for proper gasketing by installing a lead wire with a

diameter slightly greater than the sum of the fixed end clearance, expansion end clearance and .002" (.05mm) for each gasket and hang from the top of the rotor with two ends extending in an arc around the expansion end face of the rotor. See Fig, 21.

With bearing outer race assembled, install rear head on studs and

tighten firmly and evenly. Then, remove head, using backing-off screws and pins to pull clear of dowel pins. Remove lead wire and measure. If lead measurement exceeds sum of fixed end clearance, expansion end clearance and .001" (.025mm) for each gasket for future compression; remove sufficient head gaskets to correct. If less, add sufficient gaskets. Tolerance on this total clearance is plus .005" (.125mm), minus .002 (.05mm) for machines over 700 cfm (1189m/hr) capacity and plus .003" (.075mm), minus .001" (.025mm) for smaller units.

If doweling is required, establish bottom clearance as indicated in next section.

Figure 21 Checking total rotor end clearance with lead wire to verify expansion end clearance at rear head. Wire measurements must be uniform to .002 (.05mm). If not, invert some asbestos gaskets used.

Figure 20 Checking clearance between rotor and cylinder face at rear end.


F.L.Smidth

25

If doweling is not required, complete final assembly as follows: Install blades from rear end and be sure they are lightly oiled and fit freely in slots. Install hub seal rings. Reassemble rear head and tighten nuts on studs evenly and tightly. Be sure backing-off screws and pins are in

place in head. Push rotor towards rear end and assemble both bearing retainers, installing retainer gaskets or "0" rings as

required. Be sure to tighten retainers evenly and firmly to heads. Replace the packing gland and packing or mechanical seal as required. If packed, install ring by ring, push each

firmly into stuffing box, and tighten with gland after each ring. Install last ring in same manner and then back off approximately one-half turn. Install split seal In gland.

Replace the rotor half coupling, which is bored for medium push fit, and lock in place with set screw over key.

Some units are equipped with spacer type couplings for ease in making inspections and repairs. Set unit back on base, shim and realign, connect all external oil, water and air piping. Be sure to recharge bearing

cavity with oil. Refer to operation section and proceed with start-up accordingly. DOWELING AND BOTTOM CLEARANCE- (See page 21 and clearance plate on compressor.) Bolt cylinder feet to firm support. Insert rotor (with bearing inner races

assembled) into cylinder and place on shim stock or feeder located approximately 1-1/2 (38mm) from each end. Rotor is assumed to have been indicated and runs true within .001" (.025mm), body to bearing journals, and .003" (.075mm) for shaft at coupling.

Select shims or feelers that

are .001" (.025mm) to .002" (.05mm) thicker than bottom clearance specified on name plate and equivalent in length to about half of rotor diameter.

Place fixed end of rotor flush with cylinder face. Insert rotor

'jacks' (between top of rotor and cylinder bore) directly above feelers and wedge tightly to cylinder bore. (See Fig. 22.) NOTE-If an assembled nut and bolt is used as a rotor 'jack,' be sure to protect rotor and cylinder surfaces with brass or aluminum sheet stock. Brass or hardwood wedges can also be used.

Verify bottom clearance at center and both ends of cylinder with

long feeler gauges inserted thru inlet and/or discharge ports. Be sure feelers are inserted far enough to carry down over cylinder undercut and underneath rotor body. (See Fig. 23.)

Figure 22 Wedge rotor against shim stock laid across bottom of cylinder bore at each end to establish bottom clearance.

Figure 23 Check bottom clearance using long feeler gauge through inlet or outlet ports.


F.L.Smidth

26

Tolerances on bottom clearances shown in table below: Compressor Size Bottom Clearance Tolerance 15 to 100 + 001 (.025mm), -0 110 to 350 +.002 (.050 MM), -0 375 to 608 +.003 (.076 mm), -0 Install cylinder head gaskets as determined by section on rotor end clearances. Use a minimum of two gaskets at

fixed end-I.E. (1) synthetic fiber & (1) paper with synthetic fiber gasket next to cylinder. Do not trim center to suit bore at this point.

Assemble the heads to cylinder (with bearing outer races in

place) and centralize on studs. Caution - exercise care as head passes over hub seal ring to avoid breakage. Temporarily install plain flat washers on bottom two studs and tighten these nuts. The bearing rollers should now turn freely in the outer race. Position bearing so that the bottom two rollers straddle the vertical centerline.

Jack, or lift with hoist, each head vertically till all clearance is removed between bottom two rollers and bearing races. See Fig. 24. Centralize remaining rollers by shifting head radially from side to side, so that clearances between corresponding rollers on either side of vertical centerline are equal. See Fig. 25. Check roller clearance with 'feelers' as shown in Fig. 24. Tighten all cylinder head stud nuts firmly.

Cover exposed bearings with cloths and drill (2) (6mm) diameter holes (180) apart 5/8" (15mm) to (19mm) deep into cylinder using 'lead' holes in cylinder head. Re-drill these holes to 1/64 (.37mm) less than dowel pin diameter and hand ream to size. Blow out cuttings and remove covers.

Drive a dowel pin into each hole with a solid 'drift' until pin bottoms in cylinder. Pins are inserted beveled end first.

Remove cylinder heads, rotor jacks and feeler strip so that rotor is free in cylinder. Break edges of newly drilled dowel holes on cylinder side of heads with a counter-sink. Dowels must be tight in cylinder and protrude approximately (9.5mm) to (12mm) beyond cylinder ends.

Reassemble heads to cylinder and bearing retainers to heads and make a final check of bottom clearance as described previously. Be sure cylinder head backing-off pins are in place before assembly.

Complete final assembly as described on page 24. Special tools, as follows, can be procured from F L Smidth for the (13mm) dowels: 19/64 (8mm) high speed drill, 9" (230mm) flute, 12" (300mm) overall 31/64 (12.3mm) high speed, straight shank extension drill, 9" (230mm) flute, 12' (300mm) overall .500 (13mm) spiral flute reamer with extended shank, 12 (300mm) overall Note: English & metric dowel systems are distinctly different sizes.

Figure 24. Lift or jack cylinder head to remove clearance between bottom two bearing rollers and inner race.

Figure 25. Equalize clearance between corresponding rollers on either side of inner race by positioning cylinder heads on studs. Use feeler gauge.


F.L.Smidth

27

DOWELING AND BOTTOM CLEARANCE CIRCULAR BORE CYLINDERS (See Page 22 and clearance plate on Compressor) Bolt cylinder feet to firm support. Insert rotor (with bearing inner races assembled) into cylinder and place on shim stock or feeler located approximately 1-1/2" (38mm) from each end. Rotor is assumed to have been indicated and runs true within .001" (.025mm), body to bearing journals, and .003" (.075 mm) for shaft at coupling. Select shims or feelers that are .001" (.025 mm) to .002" (.05mm) thicker than bottom clearance specified on name plate and equivalent in length to about half of rotor diameter. Place fixed end of rotor flush with cylinder face. Vertical surfaces have been precision machined on both sides and at each end of the cylinder. Each surface is equidistant from the centerline of the cylinder bore. To center the rotor, use depth micrometer to obtain equal measurements from each machined surface to a bearing or shaft diameter and to be within .002" of each other. (See Fig. 26.)

Insert rotor 'jacks' with loose clamping force (between top of rotor and cylinder bore) directly above feelers and wedge tightly to cylinder bore. Install round bars (drill rod or equal) between sides of rotor and cylinder (See Fig. 26). Apply light force to these bars to prevent any horizontal movement of the rotor during the head doweling procedure. NOTE-If an assembled unit and bolt is used as a 'jack', be sure to protect rotor and cylinder surfaces with brass or aluminum sheet stock. Brass or hardwood wedges can also be used. Recheck dimensions after 'jacks' have been tightened. Verify bottom clearance at center and both ends of cylinder with long feeler gauges inserted thru inlet and/or discharge ports. Be sure feelers are inserted far enough to carry down over cylinder and underneath rotor body. (See Fig. 23.) Tolerances on bottom clearances are plus .001" (.025mm) - minus .000 (0.0mm) for rotors to 10" (255mm) in diameter and plus or minus .001" (.025mm)

for larger rotors. Install cylinder head gaskets as determined by section on rotor end clearances. Use a minimum of two regular gaskets at fixed end. Paper gaskets may only be used

between regular gaskets. Do not trim center to suit bore at this point. Assemble the heads to cylinder (with bearing outer races in place) and centralize on studs. Caution - exercise care as head passes over hub seal ring to avoid breakage. Temporarily install plain flat washer on bottom two studs and tighten these nuts. The bearing rollers should now turn freely in the outer race. Position bearing so that the bottom two rollers straddle the vertical centerline.

Figure 26 Wedge rotor against shim stock laid across bottom of cylinder bore at each end to establish bottom clearance. Circular bore cylinders.


F.L.Smidth

28

Jack, or lift with hoist each head vertically till all clearance is removed between bottom two rollers and bearing races. See Fig. 24. Centralize remaining rollers by shifting head radially from side to side, so that clearance between corresponding rollers on either side of vertical centerline are equal. See Fig. 25. Check roller clearance with 'feelers' as shown in Fig. 27. Tighten all cylinder head stud nuts firmly. Cover exposed bearings with cloths and drill (2) (6mm) diameter holes (180) apart 5/8" (15mm) to (19mm) deep into cylinder using 'lead' holes in cylinder head. Redrill these holes to 1/64" (.37mm) less than dowel pin diameter and hand ream to size. Blow out cuttings and remove covers. Drive a dowel pin into each hole with a solid 'drift' until pin bottoms in cylinder. Pins are inserted beveled end first. Remove cylinder heads, rotor jacks, round bars and feeler strip so that rotor is free in cylinder. Break edges of newly drilled dowel holes on cylinder side of heads with a counter-sink. Dowels must be tight in cylinder and protrude approximately .3/8 (9.5mm) to (12mm) beyond cylinder ends. Reassemble heads to cylinder and bearing retainers to heads and make a final check of bottom clearance as described previously. Be sure cylinder head backing-off pins are in place before assembly. Special tools, as follows, can be procured from FL Smidth for the 7/16" (10mm) dowels:

NOTE: English & metric dowel systems are distinctly different sizes.

Fig 27 Equalize clearance between corresponding rollers on either side of inner race by positioning cylinder heads on studs.

1/4" (6mm) high speed drill, 8 (200mm) flute, 12" (300mm) overall 27/64 (9.6mm) high speed, straight shank extension drill, 8 (200mm) flute, 12 (300mm) overall 7/16 (10mm) spiral flute reamer with extended shank, 12 (300mm) overall


F.L.Smidth

29

RENEWAL PARTS Blades, bearings, head gaskets, coupling pins, hub seal rings, packing or mechanical seal, shaft seal or "O" ring,

lubricator belt (for multiple lubricator), lube pump motor, pumping unit and rupture disc are parts suggested for stock to meet an emergency.

Spare blades are supplied in a sealed can to provide protection during storage. Do not open the can until blades

are actually required. Replacement bearings should be procured from FL Smidth. While they are of a standard design, they are built

with special internal clearances to suit the design of the compressor. In addition, interchange of inner races and outer races cannot be made.

Coupling pins are supplied in plastic bags with moisture absorbing compound to maintain dimensional stability.

Keep bags tightly sealed. When placing repair orders, refer to the item and item number shown on parts list, together with the compressor

size and serial number as stamped on nameplate. FL Smidth sales offices are located in principal cities and as listed on back cover. Also Available

Two Stage Compressors For producing pressures to 125 pounds (8.8 bar) gauge, these two-stage compressors equipped with overhead intercoolers are especially functional where a space problem exists. They produce from 150 (255) to 4000 cfm (6797mhr) pressures to 125 Ibs. (8.8 bar) gauge.

Vacuum Pumps Well suited to most all wet and dry vacuum work, F.L.Smidth rotary vacuum pumps are especially effective at higher vacuums to 29.97 Inches (761mm) of mercury.


F.L.Smidth

30

SPECIAL NOTICE PARTS

For your protection in today's changing industrial scene, FL Smidth, maintains a policy of "multiple sources" for many, important purchased compressor components. This permits mutual pricing benefits and insurance that the parts are available from our stock when your needs are urgent. FL Smidth's years of experience and knowledge of the applications are used to achieve interchangeability both dimensionally and in service life. Such parts are never under severe service or heavy load so that sizing is conservative. This procedure is efficiently handled by a modern computer system since each part can be identified by a single number - regardless of its manufacturer. Current stock, at any one time, may thereby reflect the continuous changes in purchasing quantities and deliveries from any one specific supplier. This makes it difficult and at certain times, impossible to supply a part of a "specified manufacturer." Should your storeroom or expeditor encounter this situation, we request your cooperation to update your records and accept the part supplied with full confidence of FL Smidth's concern and experience to provide reliability. Some compressor parts in this category are:

Parts List Numbers C67-A114 Two Stage

Item

C66-A446 Single Stage

Low Pressure High Pressure

Blades 3 103 1003 Front bearing 6 106 1006 Rear bearing 7 107 1007 Bearing locknut 8 108 1008 Bearing lockwasher 9 109 1009 Shaft packing 14 114 1014 Hub seal rings 17 117 1017 Cylinder head gaskets 21 121 1021 Coupling pins 42 142 1042 Pressure gages 54 -- 1054 Mechanical shaft seals 62 -- 1062 Safety valves --- -- --


F.L.Smidth

31


F.L.Smidth

32

I M P O R T A N T !

For major factory repairs or reconditioning: Send Purchase Order to: Ship Compressor to:

F.L.Smidth F.L.Smidth 2040 Avenue C 236 South Cherry Street PO Box 2040 Manheim, PA 17545 Bethlehem, PA 18017

Or call toll-free: 1-800-523-9482

Note: Before shipping please call F.L.Smidth and request a Return Material Permit.


F.L.Smidth

33


F.L.Smidth

34


F.L.Smidth

35

APPENDIX A

Cog (Synchronous) Belt Tension Adjustment for Integral Drives Measure the force required to deflect belt 1/64" for every inch of span length. For example for a 32" span between sprockets, the deflection would be 32/64 or 1/2" deflection. The belt tension should be then adjusted to equal the force in the table below based on motor hp and smaller sprocket diameter. Force perpendicular to belt at mid span between drive and driven sprocket. Note: Force is based on 1800 rpm motor. For other speeds multiply force by: 1800/Actual RPM

Drive Motor Horsepower at 100 RPM 200 250 300 350 400 450

Smaller Sprocket Diameter in / mm Force # / Newtons

8 in 203 mm

56 # 247 N

69 # 309 N

83 # 371 N

97 # 433 N

111 # 494 N

125 # 556 N

10 in 203 mm

44 # 198 N

56 # 247 N

67 # 297 N

78 # 346 N

89 # 396 N

100 # 445 N

12 in 305 mm

37 # 165 N

46 # 206 N

56 # 247 N

65 # 288 N

74 # 330 N

83 # 371 N

14 in 356 mm

32 # 141 N

40 # 177 N

48 # 212 N

56 # 247 N

63 # 283 N

71 # 318 N


F.L.Smidth

36

APPENDIX B

Compressor Lubrication Feed Rate Tabulation

Drops per Minute Rate of Feed

Size

(60hz) Rpm

Each Head

Cyl. Int.

Flange

Cyl. No.

Feeder

Wall Drops Each

Total Drops

Total No.

Feeds

Pints (Liters) Per Day

15 1780 4 4 -- -- 12 3 1.23 (6)

30-40-50 1180 4 4 -- -- 12 3 1.23 (.6)

60-70 880 4 4 -- -- 12 3 1.23 (.6)

75-80-100 880 5 5 2 5 25 5 2.57 (1.22)

110-120 705 5 5 2 5 25 5 2.57 (1.22)

135-150 705 6 -- 3 6 30 5 3.09 (1.5)

175-200 590 7 -- 3 7 35 5 3.60 (1.7)

225 590 8 -- 3 8 40 5 4.11 (1.95)

250-300 590 7 -- 5 7 49 7 5.04 (2.4)

350 590 9 -- 5 9 63 7 6.48 (3.1)

375-400-450 500 11 -- 5 11 77 7 7.92 (3.7)

508-608 500 11 -- 7 11 99 9 10.18 (4.8)

1. All mechanical shaft seals; three (3) drops per minute each.

2. Basis of drop rate - approximately .491 grains/drop, 28,000 drops/quart (29,600 drops/liter).

3. Some compressors with mechanical seals also have oil buffered bearing seals. These compressors have

two (2) additional lube points.

4. For other compressor speeds, readjust feed rate in direct proportion to speed change.

5. Lube rates can be reduced depending on compressor applications. Consult F.L.Smidth Compressor Engineering.


F.L.Smidth

37

APPENDIX C PROCEDURE FOR REMACHINING CYLINDER MAIN BORE, UNDERCUT BORE &

BROACH BORE ON HORIZONTAL BORING MILL

As shown by these drawings, the undercut is a key to the high volumetric efficiency of the F.L.Smidth rotary compressor. After boring the cylinder to size, the boring bar is dropped to the point of rotor eccentricity and a second cut is taken at bottom only and at same radius as the rotor. After the bore intersections are blended, this undercut section of the cylinder is parallel to the rotor surface for approximately 30 and, with close running clearance, acts as an effective seal between discharge and suction pressures. At assembly, the rotor is placed on clearance shims in the undercut and the heads are dowelled to the cylinder to maintain the bottom running clearance. REMACHINE MAIN BORE ONLY - (A) 1. Indicate diagonally from 2 positions from end to end, to establish and position the original main cylinder bore

centerline. 2. Measure the main bore horizontally. 3. The boring bar should be set to cut a diameter equal to this horizontal bore plus the small amount required to

remove major corrugations. 4. The intersection of this new cut with the untouched part of the cylinder must be stoned for a smooth surface. REMACHINE UNDERCUT BORE ONLY - (B) 11. Repeat operation (1) for main bore remachining. 12. Lower boring bar, from original cylinder bore centerline, an amount equal to the eccentricity for the cylinder.

This amount, stamped on the face of the cylinder inlet flange and referred to as "ECC" or "be", ranges from .420" (10.7mm) to 1.142" (29mm).

13. Measure the major rotor body diameter. 14. The boring bar should be set to cut-a diameter equal to this rotor body diameter plus the small amount required

to remove major corrugations. 15. The intersection of this new cut with untouched part of the cylinder must be stoned for a smooth surface. REMACHINE BOTH MAIN BORE AND UNDERCUT BORE - (A) AND (B) 21. Repeat operations 1 to 3 for main bore remachining and operations 12 to 14 for undercut bore remachining. 22. The intersection made by above two cuts must be removed by either stoning or machining followed by stoning.

In order to do this by machining, the boring bar, following remachining of undercut bore, is raised 2/3 of the eccentricity and the cutting tool is extended to start its cut in the undercut section at a predetermined horizontal distance from the vertical centerline and as tabulated below:

Size (See nameplate) Horizontal Distance 30, 40, 50 1-3/16 (30.2mm) 60, 70, 75, 80, 100 1-3/4" (44.5mm) 110, 120, 135, 150 2-3/32" (53.2mm) 175, 200, 225, 250, 300, 350 2-5/8 (66.7mm) 375, 400, 450, 508, 608 2-3/8" (60.3mm)

This third cut, called the "broach bore, will remove the large ridges at the intersection of the main bore and undercut bore leaving four small ridges and which can readily be removed by stoning. The circular bore design re quires remachine of main bore only. (A) See bore charts on page 45 and 46 for both undercut and circular bore design.


F.L.Smidth

38

GENERAL NOTES: I. Finish of cylinder to be equivalent to G. E. Co. "F" roughness specimen (125 average micro inches roughness

by profileometer) or smoother. II. For hand stoning of the bore intersections, suggest using an abrasive dressing stone having an approximately

120 grit size. A typical stone is a #C120P-Vuf as manufactured by Carborundum Company, use light oil in dressing.

III. After boring operation is completed, the cylinder ends must be checked square (90 within .002" (.05mm) with surface of undercut. If necessary, face one end from the boring mill set-up and machine opposite end parallel. (See VIII).

IV. After remachining undercut bore, it is always necessary to redowel in order to restore the bottom clearance as stamp D. on cylinder nameplate. If more than .030" (.75mm) metal has been removed from the undercut, the cylinder head stud holes may need enlargement by 1/8 (3.2mm) maximum to obtain some latitude in obtaining the proper bottom clearance.

V. Minor surface imperfections are of no importance. The creation of a smooth, continuous surface for even blade peripheral rubbing contact thru each revolution is important.

VI. Should the cylinder bore show cracks or holes, it must be hydrostatically tested to 125# (8.8 bar) ga. for tightness. Use the cylinder heads with gaskets to close the cylinder ends and pressurize the jacketing. Examine interior thru bearing cavity in each head.

VII. As a general guide, an average reboring involves the removal of from .020" (.5mm) to .060 (1.5mm) metal with a corresponding slight increase in displacement and horsepower. On this basis, a cylinder can be reworked from two to three times.

VIII. FES - F.L.Smidth Ammonia Boosters, designed by prefix "A" on nameplate, have CYL, ends skewed from square on horizontal centerline.

After operation of note III, adjust cylinder on boring table to check and reface ends, by shortening length of discharge side with respect to intake side, by the amount given, per end, and measured on the O.D.

A135, A150 - .005" (.125mm) A2S0, A300 - .010" (.25mm) A508, A608 - .0I5" (.381mm) A175, A200 -.005" (.125mm) A350, -.012" (,30mm) Tolerance .002" (.O5mm) Tolerance .003'(.076mm) Tolerance .003" (.076mm)


F.L.Smidth

39

APPENDIX D ROTOR SLOT CRITERIA

NOTES A. Slots must be straight & true with parallel sides. See slot dimension tabulation. B. Bell mouthing, at finish sanding or filing; must not exceed, .004" (.10mm) over maximum width tolerance. (New or reconditioning work) C. Major - finish area approx. (6.4mm) deep x full length. Desired finish E(63M.I.) Max. finish F (125 to 150 M.I.). For short sections not exceeding 2 (50mm), minor uni-directional saw tear marks, not exceeding 1/32 (.8mm) width x .005 (.125mm) depth, are approved provided spacing creates good blade support area. File break corner knife top edges of slot to an equivalent 1/32" (.8mm) radius. D. Minor - finish area - length x standout - finish F (125 to 150 M.I.) maximum. E. Since rotor may be rotated in either direction, finish of "C" and "D" applies to both walls or slot. F. Finish designations to G. E. surface finish gages or by sight and feel to Manheim slot gage blocks.

G. See other notes on rotor drawings. H. For repairs to worn slots: Reslotting, for a thicker blade, is required if .040" (1.0mm) feelers (maximum) can be

inserted, alongside of a new blade, for 3/8 (9.5mm) depth or more - extending 1/4 or more of blade length. Two reslottings - limit.

Standard Slot Blades

Blades T Slots A

Min. in (mm) Max. in. (mm) Min. in (mm) Max. in. (mm) .231 (5.86) .241 (6.12) .252 (6.4) .256 (6.5) .292 (7.42) .302 (7.67) .315 (8.0) .319 (8.1) .350 (8.89) .360 (9.14) .375 (9.5) .379 (9.6) .411 (10.43) .421 (10.69) .438 (11.1) .442 (11.2 ) .480 (12.19) .490 (12.44) .499 (12.9) .503 (12.8)


F.L.Smidth

40

APPENDIX E

INDICATOR METHOD OF SETTING ROTOR END CLEARANCE FOR F.L.SMIDTH SLIDING VANE COMPRESSOR

STEP #1: Place rotor in cylinder. Install two 1/64" (.4mm) gaskets on each end of the cylinder per instruction

book. STEP #2: Assemble fixed end cylinder head, with outer race of fixed bearing, on rotor. Place race with bearing

manufacturer's name at the top and facing outside. Install .010", (.25mm) bearing shims behind outer race. Do not install locknut or bearing retainer.

STEP #3: Assemble expansion end cylinder head on rotor with exp. bearing. Position outer bearing race with manufacturer's name at top, facing outside. Do not assemble bearing retainer, but use retainer gasket behind outer race in head. Lock washer tine in locknut slot after tightening locknut.

STEP #4: Tighten heads firmly using all the stud nuts except one on exp. head. STEP #5: Mount dial indicator on exp. end cyl. head stud firmly and set to indicate end of rotor shaft or face of

locknut. Alternate firm mountings acceptable. STEP #6: Force rotor forward against the fixed head using a bar or jack. With rotor in contact with fixed head set

dial indicator to zero making sure the indicator point is in contact. STEP #7: Using bar or jack, force rotor against the exp. head. With rotor against head, read and record dial

indicator reading as "A". This reading is the total possible float of the rotor between the heads. Repeat procedure several times for an accurate reading. It should match the total rotor float clearance given on the clearance plate, plus .001" (.025mm) for each head gasket used. If reading differs from this sum, readjust gasket thickness at exp. end. (The .001" (.025mm) allowance per gasket, compensates for compression set or shrinkage during initial heat of operation).

STEP #8: The rotor should now be forced against the fixed head. Install bearing thrust collar, bearing inner race spacer (on older machine), lockwasher and locknut. Tighten locknut but do not bend washer tine. Set the dial indicator to zero.

STEP #9: Mount fixed end bearing retainer, with bearing retainer flat gasket or "0" ring seal removed, and bolt tightly. Do not attempt to draw retainer flange against head because the skirt comes into contact with the bearing outer race before the flange contacts the head. This step moves the rotor away from the fixed end head in the amount of the minimum fixed end clearance. Read dial indicator and record. Repeat procedure several times for accuracy. Adjust bearing shims to obtain correct minimum fixed end clearance "B"-add shims to decrease, remove shims to increase.

STEP #10: Again set the dial indicator to zero with rotor positioned toward fixed end but with bearing retainer (from #9 bolted in place). Optionally, leave indicator reading from #9 as is, and measure difference to new reading for this operation as "C". The rotor should now be forced towards the exp, head using a bar or jack. This movement represents the axial clearance or play in the fixed end bearing. Read and record as "C". This dimension should not exceed the maximum play "C" shown on the clearance plate and tabulation. Repeat procedure.

STEP #11: After clearances are final, remember to install bearing retainer flat gaskets or "0" ring seals and bend down lockwasher tine in locknut at fixed end. Install exp. end bearing retainer with its gaskets. Complete assembly per instruction book.

STEP #12: This indicator method creates directly the min. fixed end running clearance "B" as opposed to the old procedure described in the main section of the instruction book (using feeler stock) which is obtained indirectly by setting a max. fixed end clearance, and reliance on bearing manufacturers' axial end-play limits. The lesser figures in these columns correspond approximately to the old clearance plate stamping of-Max. Fixed End Clearance". The figures listed are the sum of "B" plus "C".

STEP #13 The procedure applies to all machines having a #103-10-12932-01 clearance plate which lists: A" Total. Rotor Float; B" Minimum Fixed End Clearance; C" Maximum Fixed End Bearing Axial Play; Rotor Bottom "D". The plate also shows, for correlation to the old feeler-lead wire procedure, the Maximum Fixed End clearance and Minimum Expansion End clearance used for assembly and stamped on A12932 clearance plates. This Minimum Exp. End clearance is approximately figured as the sum of "B" and "C" subtracted from A".


F.L.Smidth

41

STEP #14:

MINIMUM FIXED END CLEARANCE B

MAX.PLAY F.BRG.C

MAX. FIXED END CLEARANCE RANGE BASIC

MACHINE SIZE

TOLER. ROTOR TOTAL FLOAT

A

C/V F.L.Smidth

in.(mm)

A/F FES in.(mm)

Toler. Both

in.(mm)

In.(mm)

C/V F.L.Smidth

in.(mm)

A/F FES In.(mm)

15, 16 (.076) .003

(.203) .008

.008(.203)

.010(.254)

30, 40, 50 (.076) .003

(.076) .003

(.225) .009

.009(.229)

.013(.330) .009(.229) .013(.330)

60, 70, 80, 100

(.1) .004

(.1) .004

(.25) .010

.011(.279)

.015(.381) .011(.279) .015(.381)

110, 120

+.003 (+.076mm) -.000

(.127) .005

(.1) .004

+.001 (+.025) -.000:

(.25) .010

.012(.305)

.016(.406) .011(.279) .015(.381)

135, 150

(.15) .006

(.25) .010

(.31) .012

.014(.35)

.020(.508) .018(.457) .024(.610)

175, 200, 225

(.15) .006

(.25) .010

+.002 (.05) -.000 (.330)

.013 .015(.381) .021(.533)

.019(.483)

.025(.635) 250, 300

(.178) .007

(.25) .010

(.381) .015)

.017(.432)

.025(.635) .020(.508) .028(.711)

350

(.178) .007

(.30) .012

(.381) .015

.017(.432)

.025(.635) .022(.559) .030(.762)

375, 400, 450

+.005 (+.127mm) -.000

(.25) .010

(.381) .015

.017(.432)

.025(.635) 508, 608

+.007 (+.178mm) -.000

(.25) .010

+.003 (.076) -.000

(.381) .015

.023(.584) .031(.788)

NOTE: For FES-A refrigeration machines using synthetic fiber gaskets only, a tolerance of -.005 (.127mm) is permitted for total rotor float A. STEP #15: Remove (1) stud nut on exp. end head on horizontal centerline. (Cylinder head must be in place.) With 5/16" (8mm) dia. rod upright screwed to clamp, attach clamp securely to exposed threads of stud. With indicator screwed to (6.4mm) dia. rod, connect to upright with sliding swivel clamp. Adjust so that indicator spindle contacts firmly any vertical surface of the exposed rotor such as the bearing locknut face or end of rotor shaft. Suggested: Brown & Sharpe Cat. #599-7740 Universal Dial Indicator Set. SHOWING INDICATOR SETUP (on small machine.)


F.L.Smidth

42

APPENDIX F RECONDITIONING LIMITS - GUIDELINES

The units returned will be disassembled, cleaned and given a thorough inspection. Cylinders and/or heads will be hydrostatically tested where necessary. A complete report will be submitted to Parts and Engineering Departments. In addition to the normal obvious examination criteria, the following is a list of allowable limits for repair-ability. CYLINDERS: See Table 1 for rebore limitations (pages 45 & 46) Minor repairs of the outer jacket by "Devcon" procedure are permissible. (103-79-1-2003) Small gouge or pit marks in the bore and minor cracks above the discharge port are permissible. Cylinders with corroded water connections can be re-tapped to the next size. Cylinder and/or heads, repaired by welding, brazing, or metalocking, by customer, are acceptable for temporary

repair but not suitable for the exchange program. Cylinders having corroded water ports on ends, for less than 1/4" (6.35 mm) gasket seal width, are to be scrapped

for the exchange program. Max. undersize in length 0.030" (.762 mm). When remachining cylinder bore and/or undercut, remove only enough metal to restore to a smooth surface. ROTORS: Repair of shafting is permissible by steel bonding or metallizing under packing, seal or bearing journal areas. Repair of shaft in coupling area is to be done by welding. Reslotting criteria per manual (Y) page 38; (B) page 49 LP/SS allowed (2) 1/16 (25.4 mm) reslots over standard. HP allowed (1) 1/16" (25.4 mm) reslot over standard. Maximum allowable undersize for body diameter from standard after rework - C30 to 50 .005" (.127 mm) - C60 to 350 .010" (.254 mm) Undersize body diameter over these limits indicates scrapping rotor. Maximum allowable undersize for body length from standard after rework - C30 to 120 .010" (.254 mm) - 30H to 120H .005"(.127 mm) - C135 to 225 .015" (.381 mm) - 135H to 350H .010" (.254 mm) - C250 to 350 .020" (.508 mm) Undersize body length over these limits can be built up by spraying ends of body with aluminum-bronze material. Machine rotor body to proper length and reslot or sand slots accordingly. Increase keyway length for all standard coupling type LP and HP in sizes 110 and larger per Table 2. Maximum allowable for rework of a bent rotor shaft is .030" in coupling area.


F.L.Smidth

43

CYLINDER HEADS: Maximum allowable refacing .015" (.381 mm) to 100 size and .025" (.635 mm) above (103-78-1-2003) Bushing hub bore acceptable per manual (Y) P. 37; (B) P.46) Heads with graphitic corrosion of the water ports and/or lubrication boss exceeding 1/8" (3.2 mm) shall be scrapped. Old bearing retainers may be reused with longer bolts for new heads. Minor cracks in the hub bore, which do not reach the internal jacketing diameter nor leak, and not exceeding (3) in

number, are permitted. Standard displacements, dimensions, and blade size per 103-70-4-2001-1- shall be followed. All unused dowel pin holes on outside of head are to be plugged using drive lock pins. When one head is replaced, install new head on fixed end with proper bearing retainer. When an NRV or coupling half is returned with the assembly, it will be repaired as a separate item and returned to

the customer with separate billing. Miscellaneous general repair standards apply. After reboring cylinder, reface ends to be 90 exact true to undercut bore to assure bearing alignment. Cylinder

reboring instructions are given by C66-B244. Hydrostatic test required after reboring as required on note VI p. 33. When refacing heads, be sure resulting wall thickness to bearing cavity is true within .0005 (.0127 mm) for 360 at

bore I.D. When refacing, minor indentations or raised hard spots to 0.5 sq in (322 sq.mm) max are permissible to 0.001

(.025mm) to C100; and 0.002 max variation from flat. Rotor is always indicated for alignment of body to bearing journals and shaft to journals. When reworking, re-

center ends to zero run-out on journals and work body or shaft to this base. Always reface rotor body ends with light cut for 90 trueness to O.D. Body must be true to journals within .001" (.0254 mm). Shaft at coupling: .001 (.0254 mm) for shafts to 2-3/4" (69.85 mm) diameter and .0025 (.0635 mm) above.

Page 38 describes slotting standards. (Manual) Where reboring undercut lowers rotor by more than .030" (.762 mm), it may be necessary to re-drill cylinder head stud holes 1/16 (1.38 mm) larger to permit dowelling, for proper bottom clearance. For general reconditioning other than the exchange program, these limits and guidelines are followed. However, exceptions and relaxations of limits, for specific cases of practical and economical reasons, are permissible but do not allow the use of standard parts as being interchangeable. Rebore limitations, per Table 2, apply except for size change, Heads can be refaced to a greater extent than given and up to 3/32" (23.8 mm) maximum, however, a special shim, matching bearing retainer gasket I.D. and O.D. and of thickness equal to amount removed from head face, must be inserted in cylinder head behind bearing to realign bearing outer race assembly to its inner race on rotor. Aluminum, steel, or brass materials are OK. (103-78-1-2003)


F.L.Smidth

44

Compressor instruction book gives detailed information on overall assembly procedures including gaskets for rotor end clearances and dowelling procedures for bottom clearance. Cylinder and head jackets must be cleaned, for all reconditioning, to achieve a minimum of +40F above adiabatic discharge air temperature, during test, at clearance pressure. Cleaning procedures must suit type of jacket fouling; i.e. - chemical for hard scale type and mechanical-flushing type for soft, mud/sludge deposits.

Reference Instruction List 103-72-2-3401 Cylinder Assembly Part Nos. and Construction 103-75-2-2003 Single Stage Shop Card (Clearances, Porting, etc.) 103-75-2-2016 Two Stage Shop Card (Clearances, Porting, etc.) C67 -A458 (7 Pages) Servicing Instructions C66-B244 Cylinder Rebore Instructions C64-A402 Rotor Slot Criteria 103-70-4-2001 (2 pages) Basic Engineering Data 103-71-3-3701 Cross Section & Change Old to #69 Construction 103-69-1-2008 Method of determining Fixed End Bearing Alignment Using Dial Indicator 103-71-1-2016 Indicator Method for Setting End Clearances C66-A446 Single Stage Instruction Book (Y) C67-A114 Two Stage Instruction Book (B) 103-87-1-3405 Dowelling Instructions


F.L.Smidth

45

COMPRESSOR SERVICE Certain emergency field procedures must be, and are justified, and the customer should realize the remote possibility of failures-balanced against the urgency of the repair. Included in these procedures are: Cold straightening of rotor shafts Cold straightening of rotor slot segments Welding of rotor shafts particularly at shaft section changes Cold welding (Devcon) interior or exterior cylinder cracks Metalock of cylinder bore cracks Rotor shaft metalizing on v-belt drives Coupling fits made with shim stock Any other emergency repair where the original strength or design is weakened Welding of internal cylinder cracks


F.L.Smidth

46

TABLE 1: CYLINDER RE-BORE LIMITATIONS, SINGLE STAGE (SS) UNDERCUT BORE DESIGN (C) Size

R.P.M. Cylinder Drawing No.: 103-

New Cylinder Bore

New Rotor Body Diameter

New Cylinder Undercut

Max. Cylinder Re-bore

7.024 (178.4 mm) 7.182 (182.4 mm)

30 40 50

1180 86-4-3106 7.340 (186.4 mm)

6.287 (159.7 mm) .075 (1.91 mm) 7.438 (188.9 mm)

10.039 (245 mm) 60 70 880 86-4-3107 10.236 (260 mm) 8.937 (227 mm) .079 (2.0 mm) 10.370 (263.3 mm)

10.040 (255 mm) 80 100 880 85-4-3101 10.236 (260 mm) 8.937 (227 mm) .079 (2.0 mm) 10.370 (263.3 mm)

12.024 (305.4 mm) 110 120 705 85-4-3108 12.208 (310.1 mm) 10.630 (270 mm) .118 (3.0 mm) 12.413 (315.3 mm)

12.038 (305.8 mm) 135 150 705 86-4-3109 12.206 (310 mm) 13.307 (338 mm) .118 (3.0 mm) 12.413 (315.3 mm)

175 15.064 (382.6 mm) 200 590 86-4-3110 15.355 (390 mm) 225 590 86-4-3111 15.189 (385.8 mm)

13.307 (338 mm) .118 (3.0 mm) 15.439 (392.2 mm)

250 15.109 (383.8 mm) 300 590 86-4-3112 15.355 (390 mm) 13.307 (338 mm) .118 (3.0 mm) 15.433 (392 mm)

350 5590 82-5-3101 15.355 (390 mm) 13.307 (338 mm) .118 (3.0 mm) 15.439 (392.3

CC150

Documents

Transcript of CC150