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Overhaul Instructions

Si50-203

10

Semi-Hermetic Single Screw Compressor Version III

4.

Overhaul Instructions

The driving and friction parts in the compressor wear for prolonged over time. To prevent
accidents caused by worn parts, it is necessary to inspect those parts regularly and overhaul the
compressor as needed.

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Summary of Contents for (A)5LLF

Page 1: ...m The specifications designs and information in this manual are subject to change without notice Printed in Japan 02 2003 AK Semi Hermetic Single Screw Compressor Version For Overhaul and Inspection Applied Models ZH C 3LSF ZH3LMF ZH C 3LTG ZH C 5MLF ZH5SLF ZH C 3WLG ZH C A 5LLF ZH5LMF ZH C A 5LMG ZH C A 7SLF ZHA7MLF ZH C A 5WLG ZH C 7LLF ZHA7MSG ZH C 7LSG ZH C A 9SLF ZH C A 7WSG ZH C A 9LLF ZH C ...

Page 2: ... Inspection Instructions 5 4 Overhaul Instructions 10 4 1 Disassembly and Inspection 11 4 2 Replacing The Bearing 20 4 3 Final Assembly 24 5 Airtightness Test 29 6 Charging Oil 30 7 Caution in Test Operation 31 8 Required Tools 32 Applicable Models ZH3LSF ZH3LMF ZHC3LSF ZH3LTG ZHC3LTG ZH5MLF ZH5SLF ZHC5MLF ZH3WLG ZHC3WLG ZH5LLF ZH5LMF ZHC5LLF ZHA5LLF ZH5LMG ZHC5LMG ZHA5LMG ZH7SLF ZHC7SLF ZHA7SLF Z...

Page 3: ...mi hermetic single screw compressor for use in Model F type ZH_F G type ZH_G Replacement intervals specified in the booklet are empirically worked out based on the design service life expected of the compressors operated under the design conditions and are intended to provide a general guide by which to formulate a maintenance plan ...

Page 4: ... problems as decreasing insulation resistance of the motor oil deterioration and worn and fatigued bearings during long periods of operation Most of such changes with time are invisible from the outside in many cases and it is only after an accident that they are noticed For this reason in the case of equipment required to be highly reliable it is most important to grasp their wear condition preci...

Page 5: ...odic Inspection Items and Intervals Table 3 1 shows periodic inspection items and intervals Conduct inspections at the earliest indicated inspection intervals Table 3 1 Periodic inspection items and intervals No Item Inspection 1 Measurement of motor insulation resistance 1 year 2 Inspection of refrigeration oil 7 500 hr or 4 years 3 Inspection of gate rotor 20 000 hr or 4 years 4 Inspection of su...

Page 6: ...ime because absorption current flows through the insulated object at an early stage lowering the resistance value correspondingly 2 Prohibit anyone from measuring insulation resistance in a vacuum It must be measured at atmospheric pressure or after the filling of refrigerant The reason is that in a vacuum the insulation ability of gas lowers and thus electric discharge is apt to occur Measuring P...

Page 7: ...ith check valve of the compressor see Fig 3 2 Remove the partition lid then tighten the flare nut to discharge refrigerant from the compressor To loosen and tighten the flare nut use two wrenches to turn the flare nut and keep the other nut stationary Fig 3 2 Service port and oil charge port locations 3 After confirming that refrigerant is completely discharged drain oil from the two drain ports l...

Page 8: ...be visible on the level gauge during equipment operation Take care not to let in air or dust and other foreign particles remaining on the bottom of the oil container When charging oil from a previously opened container conduct vacuuming of the compressor to remove moisture and air 3 Inspecting The Gate Rotor This inspection is done to check that no abnormal condition is present due to dust and oth...

Page 9: ... and it affects the compressor performance and reliability to a great extent Therefore the slit clearance must be set properly 60 to 90 µm While pressing the periphery of the gate rotor shaft with fingers insert a thickness gauge into the slit clearance to measure the gaps on both suction and discharge sides Be careful not to insert the thickness gauge too deep If the thickness gauge is inserted t...

Page 10: ... lid then tighten the flare nut to discharge refrigerant from the compressor Same as Section 3 2 2 3 Disconnect the suction pipe and remove the suction filter 4 Remove dust and foreign particles from the inside of the filter by using compressed air and cleaning solution Check the filter thoroughly for tears and damage Replace the filter if there is a tear Dry the filter thoroughly before installat...

Page 11: ...crew Compressor Version III 4 Overhaul Instructions The driving and friction parts in the compressor wear for prolonged over time To prevent accidents caused by worn parts it is necessary to inspect those parts regularly and overhaul the compressor as needed ...

Page 12: ...ide and The Discharge End Cover in case of ZH9F oil collector Receive remaining oil with a drain pan Be sure to mount guide bolts when removing the discharge end cover Be careful not to damage the oil filter with the discharge end cover Locate the first demister between the discharge end cover and cylinder cover and remove it Except ZH9F Fig 4 1 Removing side cap Fig 4 2 Removing discharge end cov...

Page 13: ...ue exceed the standard value replace the gate rotor Standard value 0 15 mm or less for all teeth ZH3 5 and 0 20mm or less for all teeth ZH7 9 Fig 4 4 Measurement of gate rotor backlash 4 Disassembling The Gate Rotor and Surrounding Parts 1 Positioning the screw rotor Position the screw rotor so that the gate rotor can be removed without damage 2 Removing the gate rotor partition lid In the ZH3F th...

Page 14: ...d units In the guide bolt hole thread the bolt that was used for the lower bearing holder mounting and lift the lower bearing holder from the casing Remove the shims inserted between the lower bearing holder and casing Do not lose the shims The lower bearing holder and casing are sealed by an O ring Therefore it may be difficult to remove the lower bearing from the casing To separate them insert t...

Page 15: ... replace it with a new one 4 Install the gate rotor on the shaft and mount the C type retaining ring The gate rotor has front and back sides Position the gate rotor so that the manufacturing number is visible 6 Removing The Suction End Cover 1 Remove all the mounting bolts 2 Mount guide bolts in two bolt holes on the upper section Be sure to mount guide bolts since the suction end cover is heavy 3...

Page 16: ...crewdriver 2 Loosen the lock nut Use the special tool or jig 1 3 As shown in Fig 4 11 grip rotor fins with pliers and remove the rotor Securely support the rotor so as not to drop the rotor At removal be careful not to damage the stator coil end 4 Remove the motor rotor key from the screw shaft Fig 4 10 Removing rotor locking plate Fig 4 11 Removing motor rotor ...

Page 17: ...r Fig 4 12 Cross sectional diagram of controller 1 Remove the slide valve arm Loosen the two locking nuts of the slide valve shaft and the bolt at the center of the arm A thread lock compound was used for the hexagon head bolt at the center Use an impact wrench to loosen this bolt Fig 4 13 Removing slide valve arm ...

Page 18: ...lts and remove the cylinder cover 4 Pull out the piston 5 Remove the mounting bolts and remove the main bearing holder fixing plate Use guide bolts when removing the fixing plate since it is heavy Do not lose screw adjusting shims 1 located inside 6 Remove the oil filter from the fixing plate and clean except for ZH3F After cleaning dry thoroughly If the filter is damaged or torn replace 7 Remove ...

Page 19: ...er 2 Removing the screw shaft Push the screw shaft from the suction side until the bearing holder completely extends from the discharge side Then pull out the shaft from the discharge side Insert one hand through the side cap hole and support the shaft to prevent the screw shaft from damaging the casing when the screw rotor section comes out of the casing Use leather gloves during removal to preve...

Page 20: ...rsion III 19 Fig 4 18 Removing screw shaft 2 3 Disassembling the screw assembly Remove the bolts and remove the screw bearing retainer plate Remove the main bearing holder from the screw shaft Do not lose screw rotor adjusting shims 2 Fig 4 19 Disassembling screw assembly ...

Page 21: ...ial jig 2 to remove the outer ring 2 Screw shaft inner ring of cylindrical roller bearing Remove the C type retaining ring Remove the inner ring of the bearing by using a chisel Be careful not to scratch the screw shaft If the screw shaft is accidentally scratched remove burrs by grinding the irregular surface Fig 4 20 Removing inner ring of screw shaft bearing 3 Main bearing holder angular contac...

Page 22: ...by placing a bronze rod and hammering it Since the outer ring is not pressed in deeply it can be removed easily Fig 4 22 Removing main bearing holder bearing 2 Gate Rotor Bearings Angular Contact Bearing Deep Groove Ball Bearing Remove the angular contact ball bearing and deep groove ball bearing from the lower bearing holder by using a bronze rod and hammer Fig 4 23 Removing lower bearing holder ...

Page 23: ...n the housing mount the C type retainer ring to secure the bearing 2 Screw shaft inner ring of cylindrical roller bearing Heat the inner ring of the bearing 120 C max and insert the tip of the screw shaft After the shaft is inserted place a plate and hammer the shaft all the way Then mount the C type retainer ring 3 Main bearing holder angular contact ball bearing deep groove ball bearing Insert t...

Page 24: ... in the lower bearing holders mounted with the bearings and check the preload of the bearings Insert the gate rotor shaft into the bearings Install gate rotor shims 2 and the gate rotor bearing retainer plate and tighten the bolts to the specified torque Turn the gate rotor with full force by hand The gate rotor must rotate smoothly and should not produce rolling sound a When rolling sound is prod...

Page 25: ...e Screw Shaft and Main Bearing Holder Install screw adjusting shims 2 and the main bearing holder on the screw shaft and install the screw bearing retainer plate Tighten the two bearing retainer plate mounting bolts evenly Adjust clearance δ between 0 03 and 0 05 mm except ZH9 0 04 0 06mm ZH9 only as shown below Minimum clearance on periphery Fig 4 27 Adjusting clearance between screw rotor and ma...

Page 26: ...ves The screw shaft is heavy and the main bearing holder rotates making it difficult to hold it Be careful not to drop the screw shaft during installation Fig 4 28 Inserting screw shaft 3 Installing The Motor Rotor Insert the motor rotor key into the screw shaft from the suction side and insert the motor rotor Insert the motor rotor in the direction shown below Fig 4 29 Motor rotor inserting direc...

Page 27: ...he holding section of the cylindrical roller bearing is made of plastic It can break easily if applied with impact Lift the screw shaft slightly higher than the side cap and gently insert the screw shaft from the discharge side Fig 4 30 Installing suction end cover 4 Rotate the screw rotor to make sure it moves smoothly 5 Positioning The Screw Rotor Mount jig 3 to the main bearing holder and casin...

Page 28: ...ting bolts may damage the threads since they are too short for this process Before the casing and the flange of the lower bearing holder contact insert shims and tighten securely 4 Install the gate rotor bearing retainer plate To prevent the gate rotor from rotating hold the gate rotor by hand while tightening 5 Measure the slit clearance gap between the gate rotor and casing with a clearance gaug...

Page 29: ...tighten the four bolts around the cylinder After tightening bolts make sure the piston moves smoothly Fig 4 32 Adjusting piston and installing cylinder cover 6 Tighten the other mounting bolts of the cylinder cover In case of ZH_G 5 6 place the cylinder cover Extend the piston until it contacts the cylinder cover then tighten the bolts After tightening the bolts make sure the piston moves smoothly...

Page 30: ...r or soap water to check for leaks Apply soap water on the side caps and other cover mounting sections to make sure no air bubbles are formed If air bubbles are formed release the pressure then re tighten the bolts If the leak does not stop check the packing seating surfaces and replace the packing refrigerant type R22 2 8MPa 28bar R134a 2 0MPa 20bar R407c 2 98MPa 29 8bar ...

Page 31: ... Part of oil may remain in the refrigerating system Therefore charge the same amount of oil removed from the compressor during disassembly When a new gate rotor is installed pour about a half of the total oil capacity to the suction side to prevent excessive heating during initial operation ...

Page 32: ...make sure all bolts are tightened 2 Check the wiring for proper connection 3 Conduct inching Check the rotating direction using high and low pressure gauges If the rotating direction is correct the low pressure gauge indicates decreasing and the high pressure gauge shows rising pressure Check that no abnormal noise is generated ...

Page 33: ...6 Fixing plate and cover installation 5 Other general tools Adjustable end wrench spanners pliers screwdrivers hammer plastic hammer T shape wrenches chisel Measuring instruments 6 Megger taster 500 V megger 7 Depth gauge Dial type minimum scale division 0 01 mm Screw shims 1 8 Thickness gauges 0 03 to 0 10 mm Clearance between main bearing holder and screw and slit clearance 9 Dial gauge Minimum ...

Page 34: ...ing Jig Applicable model ZH3_ ZH5F ZH7F ZH9F ZH5G ZH7G ZH9G 150 200 250 150 200 7 0 7 6 8 1 7 0 8 1 5 6 7 6 7 76 3 89 1 101 6 76 3 101 6 66 75 92 70 86 10 10 12 10 11 Material STPG370E 65A sch80 STPG370E 80A sch80 STPG370E 90A sch80 STPG370E 65A sch80 STPG370E 90A sch80 Z0115 through hole 4 locations ...

Page 35: ...plate 1 SS400 or SM400A See next page Batten 1 2 SS400 or SM400A See next page Batten 2 1 SS400 or SM400A See next page Removing bolt 1 S45C JIS B1180 fully threaded hexagon head bolt A M10x70 10 9 chamfered end Hexagon bolt 2 S45C JIS B1180 hexagon head bolt with nominal diameter body A M8x25 5 6 Z0116 Suction end cover housing section Bearing outer ring ...

Page 36: ...Si50 203 Required Tools Semi Hermetic Single Screw Compressor Version III 35 Jig 2 1 Bearing Removing Jig Parts ...

Page 37: ...ntity Material Remarks Guide plate 1 SS400 or SM400A See next page Batten 1 SS400 or SM400A See next page Removing bolt 1 S45C See next page Hexagon bolt 2 S45C JIS B1180 hexagon head bolt with nominal diameter body A M6x30 5 6 Z0118 Holding device Cylindrical roller bearing Bearing outer ring Suction end cover holding section ...

Page 38: ... 12 8 12 9 13 9 13 54 62 46 67 30 40 30 50 Removing bolt JIS B 1180 fully threaded hexagon head bolt A M8x70 10 9 chamfered end JIS B 1180 fully threaded hexagon head bolt A M12x70 10 9 chamfered end JIS B 1180 fully threaded hexagon head bolt A M8x70 10 9 chamfered end JIS B 1180 fully threaded hexagon head bolt A M12x70 10 9 chamfered end 2 M6 through hole M through hole ...

Page 39: ...Required Tools Si50 203 38 Semi Hermetic Single Screw Compressor Version III Jig 3 Temporary Bearing Holder Mounting Plate jig For ZH3_ Material SS400 ...

Page 40: ...Si50 203 Required Tools Semi Hermetic Single Screw Compressor Version III 39 Jig 3 Temporary Bearing Holder Mounting Plate jig For ZH5_ Material SS400 ...

Page 41: ...Required Tools Si50 203 40 Semi Hermetic Single Screw Compressor Version III Jig 3 Temporary Bearing Holder Mounting Plate jig For ZH7_ Material SS400 ...

Page 42: ...Si50 203 Required Tools Semi Hermetic Single Screw Compressor Version III 41 Jig 3 Temporary Bearing Holder Mounting Plate jig For ZH9_ Material SS400 ...

Page 43: ...Handle Jig Set Parts No Name Handle Stay 1 Stay 2 Disc Straight pin Material STPG370E SS400 or SM400A SS400 or SM400A SS400 or SM400A S45C Remarks 20A sch40 t2 9 JIS B1354 Class A or equivalent ZH3_F 300 160 6 20 6 22 ZH5_F 325 185 8 24 8 28 0 012 0 0 012 0 004 0 015 0 0 015 0 006 Z0124 ...

Page 44: ... Z0125 Parts No Name Handle Stay 1 Stay 2 Disc Straight pin Material STPG370E SS400 or SM400A SS400 or SM400A SS400 or SM400A S45C Remarks 20A sch40 t2 9 Refer next page JIS B1354 Class A or equivalent Refer next page Applicable model ZH3_F ZH3_G ZH5_ ZH7_ ZH9_ 307 287 333 321 371 160 140 185 170 220 ...

Page 45: ... Jig 4 2 Handle Jig Parts Z0126 Applicable model ZH3_F ZH3_G ZH5_ ZH7_ ZH9_ 6 6 8 8 8 6 6 8 8 8 20 20 24 24 24 22 26 28 32 36 50 5 50 5 60 5 75 5 80 5 7 7 8 11 11 60 60 70 85 90 0 012 0 0 012 0 0 015 0 0 015 0 0 015 0 0 012 0 004 0 012 0 004 0 015 0 006 0 015 0 006 0 015 0 006 ...

Page 46: ...mi Hermetic Single Screw Compressor Version III 45 Jig 5 Oil Filter Removing Jig For ZH3_F Parts No Name Handle Stay 1 Stay 2 Spanner Material STPG370E SS400 or SM400A SS400 or SM400A SS400 or SM400A Remarks 20A sch40 t2 9 Z0127 ...

Page 47: ...Holder Fixing Plate Assembling The Controller and Installing The Oil Filter 28 Installing The Motor Rotor 25 Installing The Suction End Cover 26 Insulation Resistance of The Motor 5 Insulation Resistance Testing Measurement Standard 5 Measuring Procedure 5 O Overhaul 3 Overhaul Instructions 10 P Periodic Inspection 4 Periodic Inspection Instructions 5 Periodic Inspection Items and Intervals 4 Posi...

Page 48: ...Si50 203 ii Index ...

Page 49: ...nting Plate jig For ZH7_ Material SS400 40 Jig 3 Temporary Bearing Holder Mounting Plate jig For ZH9_ Material SS400 41 Jig 4 1 Handle Jig Set 42 Jig 4 2 Handle Jig Parts 44 Jig 4 2 Handle Jig Set 43 Jig 5 Oil Filter Removing Jig For ZH3_F 45 M Measurement of gate rotor backlash 12 Measuring slit clearance on suction side 8 Motor insulation resistance measuring method 5 Motor rotor inserting direc...

Page 50: ...Si50 203 iv Drawings Flow Charts ...

Page 51: ...m The specifications designs and information in this manual are subject to change without notice Printed in Japan 02 2003 AK Semi Hermetic Single Screw Compressor Version For Overhaul and Inspection Applied Models ZH C 3LSF ZH3LMF ZH C 3LTG ZH C 5MLF ZH5SLF ZH C 3WLG ZH C A 5LLF ZH5LMF ZH C A 5LMG ZH C A 7SLF ZHA7MLF ZH C A 5WLG ZH C 7LLF ZHA7MSG ZH C 7LSG ZH C A 9SLF ZH C A 7WSG ZH C A 9LLF ZH C ...

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