York Turbomaster M 255 Installation, Operation And Maintenance Manual Download Page 1

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INSTALLATION, OPERATION AND

MAINTENANCE

SERIES M TURBOMASTER

COMPRESSORS

Supersedes: 220.11-NM1 (

366

) Form 220.11-NM2 (602)

SERIES M TURBOMASTER COMPRESSORS

00617VIP

Summary of Contents for Turbomaster M 255

Page 1: ...INSTALLATION OPERATION AND MAINTENANCE SERIES M TURBOMASTER COMPRESSORS Supersedes 220 11 NM1 366 Form 220 11 NM2 602 SERIES M TURBOMASTER COMPRESSORS 00617VIP...

Page 2: ...nced materi als This individual shall also be familiar with and com ply with all applicable governmental standards and regu lations pertaining to the task in question SAFETY SYMBOLS The following symb...

Page 3: ...these documents to the equip ment in question If there is any question in the mind of operating service personnel as to the applicability of these documents then prior to working on the equip ment the...

Page 4: ...YORK INTERNATIONAL 4 FORM 220 11 NM2 602 TABLE OF CONTENTS SECTION 1 Description of System and Fundamentals of Operation 7 SECTION 2 Installation 11 SECTION 3 Operation 14 SECTION 4 Service 32...

Page 5: ...s 19 5 AOP Differential Coltrol Settings 29 6 COP Low Oil Differential Safety Settings 29 7 Oil Pressure Switch Tubing Sizing 30 8 Maintenance Requirements for YORK Multistage Centrifugal Compressors...

Page 6: ...mbling Shaft Seal Collar 40 16 Seal RingAssembly 40 17 Removing Drive End Journal BearingAssembly 42 18 Removing Drive End Oil Seal Assembly 42 19 Exploded View PRV and Oil Seal Assembly 43 20 Oil Res...

Page 7: ...ough a speed increaser reducer Ro tation must always be driven counter clockwise facing the shaft end FUNDAMENTALS OF OPERATION AND MACHINE COMPOSITION This family of compressors has great flexibility...

Page 8: ...luid to be directed to an atmo spheric drain trap cast into the leg of the main casing Bolt Patterns Due to the varied application of this compressor fam ily there can be differences in the bolting an...

Page 9: ...FORM 220 11 NM2 602 9 YORK INTERNATIONAL FIG 2 TYPICAL COMPRESSOR CROSS SECTIONAL VIEW LD07317 1...

Page 10: ...er cise caution when preparing to service or remove parts from the system Be sure to wear eye protection to avoid any possible splash hazards The compressor contains many close clearance areas and hea...

Page 11: ...conditions can result in very low temperatures which can be damaging to equipment personnel 1 Conduct the pressure test in accordance with de sign parameters outlined in the application data sheet The...

Page 12: ...ng temperatures carefully Compressors that utilize refrigerant cooled oil coolers may not be oper ated if there is no source of coolant available C Check that the oil cooler s is functioning prop erly...

Page 13: ...6 EA ADD L 500 100 27 22 2 STAGE 10 500 2 750 230 190 38 EA ADD L 1 300 350 90 75 2 STAGE 25 000 5 000 630 500 55 EA ADD L 3 000 1 000 250 200 TABLE 3 APPROXIMATE COMPONENT WEIGHTS FOR SERIES M COMPRE...

Page 14: ...Figure 4 Since suction gas enters the first stage impeller 1 at suction pressure and leaves the high stage impeller 2 at discharge pressure the pressure differential becomes progressively greater bet...

Page 15: ...FORM 220 11 NM2 602 15 YORK INTERNATIONAL FIG 3 TYPICAL PRIMARY COMPRESSOR GAS FLOW LD07318 3...

Page 16: ...YORK INTERNATIONAL 16 FORM 220 11 NM2 602 FIG 4A MAJOR COMPONENTS LD07319 Operation...

Page 17: ...FORM 220 11 NM2 602 FORM 220 11 NM2 602 YORK INTERNATIONAL YORK INTERNATIONAL 17 17A FIG 4B CUT A WAY VIEW MODEL 255 COMPRESSOR LD07817 3...

Page 18: ...application For this reason it is very difficult to tabulate all clearance values for all applications Form 160 71 M can be used for two stage water chilling application The infor mation in that docum...

Page 19: ...8 SPRING SHAFT SEAL 109 WASHER SPRING RETAINING 110 SEAL O RING 111 RING SHAFT SEAL 112 SCREW MACHINE FLAT HD 113 RING RETAINING SEAL 115 DOWEL PIN 116 NUT HEX 150 ROTOR ASSEMBLY 151 DIFFUSER DISK VAN...

Page 20: ...nor mal and does not indicate a problem Leakage rates are dependent upon coupling size shaft rotational speed and oil reservoir sump pressure Larger diameter and FIG 6 EXPLODED VIEW OF ATMOSPHERIC SH...

Page 21: ...e oil reservoir hous ing 5 and flows to the space around the shaft between the thrust bearing 6 and the discharge end main bear ing 8 From this space part of the oil passes through the main bearing 8...

Page 22: ...YORK INTERNATIONAL 22 FORM 220 11 NM2 602 FIG 7 OIL PIPING SCHEMATIC FOR SERIES LUBRICATION SYSTEM PRIOR TO 1970 LD07320 Operation...

Page 23: ...FORM 220 11 NM2 602 23 YORK INTERNATIONAL FIG 8 OIL PIPING SCHEMATIC FOR PARALLEL LUBRICATION SYSTEM AFTER 1970 3 LD07321...

Page 24: ...sor D Start all system auxiliaries E If the compressor is motor driven be sure the pre rotation vanes are closed to unload the mo tor during starting Some systems are equipped with a safety switch whi...

Page 25: ...jet nozzle body is controlled by cooling the oil 7 Opening the pre rotation vanes and cooling of the oil by the oil cooler will both reduce oil foaming and oil pressure fluctuations 8 Be sure the wat...

Page 26: ...to Replacing Oil Filter Element Compressors on which the oil reser voir pressure can fall below atmo spheric should be equipped with a shaft seal oil pressure gauge and regu lating valve 4 Adjust the...

Page 27: ...p valve 24 ahead of the oil filter 3 should never be closed except while servicing the auxiliary oil pump or charging oil 2 During normal operation the auxiliary oil pump suc tion 21 and discharge val...

Page 28: ...pump discharge connection to the oil charging valve located at the end of the compres sor oil sump Be sure the connections are rated for the design pressure of the system Do not com pletely tighten t...

Page 29: ...l pump differential control switch is ac tuated by the pressure differential between the oil res ervoir and the main oil pump discharge sensing the out put of the main oil pump only independently of t...

Page 30: ...or stops due to a power failure the auxiliary pump can not start This should not damage the com pressor because the main oil pump will supply oil while the compressor slows down and residual oil will...

Page 31: ...FORM 220 11 NM2 602 31 YORK INTERNATIONAL Operation 3 This page intentionally left blank...

Page 32: ...ructions From Inspect as Compressor is Disassembled Once compressor parts have been disassembled and cleaned valuable indications of the compressor condi tion are lost For example Materials found in o...

Page 33: ...e performed more frequently if refrigerant losses exceed 10 of system charge 4 TABLE 8 MAINTENANCE REQUIREMENTS FOR YORK MULTISTAGE CENTRIFUGAL COMPRESSORS PROCEDURE DAILY WEEKLY MONTHLY QUARTERLY SEM...

Page 34: ...he responsibility of the service technician and his her organization to be aware of current regulations and to comply with them Be careful that the system is not sub jected to a freeze condition durin...

Page 35: ...actors such as oil dilution sump pressure and exter nal seal gas pressure A 4 seal are found to be correct Scoring or wearing of the suction end inboard A 1 oil seal can result in oil loss into the co...

Page 36: ...iven compressor disk fall to the floor 7 Remove the driven compressor disk and spacers Removing the Drive Coupling Disk 1 Be sure the clamp ring is in the driven disk 2 Install the wrenches Table 9 It...

Page 37: ...FIG 10 COUPLING GUARD LD07322 LD07323 00622VIP 4 TABLE 9 COMPRESSOR TOOLS ITEM DESCRIPTION QTY TOOL KIT 1 1 WRENCHES 1 2 WRENCH SUPPORT 1 3 GUIDE PIN 4 4 SNAP RING PLIERS 1 5 SNAP RING PLIERS 1 6 MAIN...

Page 38: ...YORK INTERNATIONAL 38 FORM 220 11 NM2 602 FIG 13 LOOSENING DRIVE SHAFT WITH WRENCHES FIG 12 LOOSENING THE DRIVE SHAFT WITH SPECIAL WRENCHES LD07324 LD07325 LD07326 Service...

Page 39: ...COVER SHAFT SEAL 2 SPRING HELICAL 3 WASHER SPRING RETAINING 4 O RING 5 RING SHAFT SEAL 6 PIN INSERT 7 COLLAR SHAFT SEAL 8 RING RETAINING SEAL 9 SCREW MACH FLAT HD 10 GASKET 1 64 THK 11 GASKET 1 32 THK...

Page 40: ...proceed as follows Removing the Shaft Seal If sump is vented to atmosphere the shaft seal can be changed with oil in the main compressor sump The shaft seal reservoir will have to be drained Follow s...

Page 41: ...shoulder on the inboard end of the drive shaft so that the two slots marked by a pencil slide over the insert pins the inside surface of the collar is against the rotor shaft and the rotor is on its a...

Page 42: ...heck that an oil filter is in the housing Plastic flow indicates the bearing has experi enced extremely high temperature usually due to poor lubrication It may also show break down of bearing with par...

Page 43: ...d area Do not force the bearing into position It must slip in easily The bearing and housing should be at the same tem perature when assembling 3 Slip the bearing over the drive shaft and screw the be...

Page 44: ...sleeve housing and rotor shoulder for evidence of rubbing D Examine the seal ring flange and PRV housing mating surface for evidence of wear or scoring use bluing if necessary The inboard surface of...

Page 45: ...ess during reassembly 10 Install the shaft bearing and shaft seal as previ ously described REMOVING OIL PUMP ASSEMBLY THRUST BEAR ING AND DISCHARGE END JOURNAL BEARING The oil pump thrust bearings for...

Page 46: ...r materials MAXIMUM OIL PUMP COMPRESSOR THRUST BEARING RUNOUT T I R OIL SEAL DIAMETRAL CLEARANCE SIZE AXIAL CLEARANCE FACE RIM DRIVE END RESERVOIR END 25 008 012 0005 0005 002 005 001 004 26 008 012 0...

Page 47: ...using and is held in place with a roll pin to prevent rotation within the housing The discharge end journal bearings come in two styles taper bore and taper land See Removing Suction End Journal Beari...

Page 48: ...se plugs remove the external oil piping and flush the oil galleries After cleaning replace the plugs using an oil or paste sealant Do not use teflon tape Some external oil lines are screwed di rectly...

Page 49: ...Set up a dial indicator capable of reading to 0 0005 on the rim of the large O D to check oil pump run out Use a magnetic base or screw an oil pump housing bolt into the sump Turn the pump and rotor...

Page 50: ...TABLE 14 If it becomes necessary to replace the discharge end seal ring or the balance piston seal ring the oil reser voir housing must be removed Proceed as follows 1 Refer to Removing Oil Pump Thrus...

Page 51: ...ugh the end of the compressor casing The seal ring 159 and spring washer 160 can now be pulled off the balance piston Fig 25 shows an ex ploded view of the balance piston seal assembly Observe the pin...

Page 52: ...pull the sump evenly into compressor until the cap screws can be started Keep the sump as square as possible Do not force or damage to the piston ring may result 5 Relax the lifting rigging After the...

Page 53: ...sor The individual vanes seldom require service If foreign material has damaged the vanes or system dirt and corrosion have locked the vanes vane disassembly may be required Vanes are actuated by a ro...

Page 54: ...and the lever arm is bolted on Although some spares are still available for service it is recommended that the new style shaft and cover be installed whenever the compressor is being overhauled Some o...

Page 55: ...s two fulcrum points upper andlower Dependingonhowtheactuatorismounted on the PRV housing either style may be supplied Some units are still supplied with the optional hand wheel and linkage for manual...

Page 56: ...116 4 Screw the four guide studs shipped with the tools into four of the holes from which the casing cap LD07345 screws were removed one stud near each cor ner The purpose of guide studs is to insure...

Page 57: ...essor models vary in construction details but each one essentially con REMOVING LABYRINTH SEALS AND COMPRESSOR ROTOR 1 Remove the oil reservoir and balance piston ring See Removing the Discharge End S...

Page 58: ...ng disk 74 from the lower half Use a pry bar or studs screwed into the tapped holes in the rim of the lower half of the diffuser to rotate it up on the impeller until you can screw an eye bolt into it...

Page 59: ...be necessary to remove the first stage diffuser disk If it becomes necessary to remove this plate the pre rotation vane assembly must first be removed as outlined under Removing the Pre rotation Vane...

Page 60: ...learances 3 Inspect all new parts Be sure they are the correct items Physically try all bearings on the rotor and in the bearing housings before starting assembly Check clearances Fit labyrinth seals...

Page 61: ...reference point during assem bly Position the rotor full toward the suction and set the indicator to zero Refer to the diffuser dia gram Fig 31 Note the exit plate splitline relative to the insert pi...

Page 62: ...mp gas kets Arotor that is not in center with diffusers may impact performance 6 Remove the oil pump Loosen the bolts holding the PRV housing and sump Slide each of them out ap proximately 1 4 Tie the...

Page 63: ...on and discharge flange connections are tightened Maxi mum allowable deflection is 002 total com bined Be sure to install correct flange gaskets Operation without a guard is not rec ommended Cordon of...

Page 64: ...w york com P O Box 1592 York Pennsylvania USA 17405 1592 Subject to change without notice Printed in USA Copyright by York International Corporation 2002 ALL RIGHTS RESERVED Form 220 11 NM2 602 Supers...

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