Spare parts manual. HPC 100 Mk4 Reciprocating compressor unit

Transcription

1 Spare parts manual en HPC 100 Mk4 Reciprocating compressor unit

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3 Spare parts manual for HPC Mk4 The reciprocating compressor and the unit may be fitted with different equipment, depending on their functions and requirements. Part of this equipment is described in this manual although it may not be fitted on your particular unit. Compressor type HPC Compressor no. Refrigerant R717 R410A R744 Other Control Unisab III None Other Water-cooled top and side covers Compressor cooling Air-cooled top and side covers Air-cooled top covers and water-cooled side covers Air-cooled top and side covers + oil cooling (refrigerant-cooled) Drive type Direct drive Explosion-proof electrical design Equipment for parallel operation Sabroe OVUR oil separator en /44

4 Contents 1. Spare parts HPC How to use the parts list HPC Mk Tools for compressor Supplementary tool set for SMC 100 Mk4 and HPC Mk Tool set for change of main bearings Drawings HPC Coupling AMR Coupling CFA Solenoid valve controlled oil return Oil separator, OHUR 44 4/ en

5 1. Spare parts HPC How to use the parts list The key to identify a spare part is the pos. no. of the spare part. By means of the pos. no., the position of the spare part can be found on the spare parts drawings. Usually the spare part no. is stated next to the pos. no. If no spare part no. is stated, it may be because the part is not considered a spare part or because the part is not sold as a spare part. Parts which are not sold individually are contained in spare parts kits. The spare parts list contains single parts and components, complete main parts, e.g. cylinder liner with suction valve, kit assemblies which is a collection of spare parts, service kits and gasket kits. Spare parts which are not available as single parts will be contained in complete main parts as sub parts, kit assemblies, service kits and gasket kits. Example: Component: Pos 19-1, part number , designation: Cylinder liner with suction valve S&L. Kit assembly: Part number , designation: Kit assembly oil pump housing. Service kit: Part number , designation: Service kit ring plates. Gasket kit: Part number , designation: Gasket kit unloading cylinder. The parts list is divided into sections with the main components of the compressor as headlines. For each main part, e.g. cylinder liner complete, the part no. of the main part is stated first and then the pos. nos. of all single parts contained in the main part. Then all kits related to the main part - including the pos. nos. of all sub parts contained in these kits - are indicated. In some cases a kit will be related to several main parts which is why the kit is not indicated until after the relevant main parts. Example A ring plate kit contains a discharge valve ring plate pos. 20C, a suction valve ring plate pos. 19F and valve springs. Therefore, the ring plate kit will be indicated after the discharge valve ring plate pos en /44

6 1.1.2 HPC Mk4 Pos. no. Part no. Description Qty. per kit Quantity per compressor HPC Compressor frame 1 A Frame HPC A Frame HPC A Frame HPC B Oil level glass C O-ring, Included in gasket kit and D Hexagon head M6 x Top cover air cooled 2 A Top cover, HPC100 Mk A Top cover with flange, HPC100 Mk E Cylinder screw M14 x F Cylinder screw M14 x Top cover water cooled 2 A Top cover, HPC100 Mk A Top cover with flange, HPC100 Mk B Water cover for top cover with flange, SMC100 Mk B Water cover left, SMC100 Mk B Water cover right, SMC100 Mk E Cylinder screw M14 x F Cylinder screw M14 x Kit assembly staybolts for top cover G-1/ 2 J Nut M H Staybolt M14 x 138, SMC/HPC 100Mk4 4 Side cover - air cooled 3 A Side cover, air cooled E Cylinder screw M14 x Side cover - water cooled 3 A Side cover with cooling fins, HPC100 Mk B Water cover right, SMC100 Mk B Water cover left, SMC100 Mk F Cylinder screw M14 x Side cover water cooled kit Kit assembly staybolts for side cover G-1/ 3 J Nut M H Staybolt M14 x 85, SMC/HPC 100Mk Gasket kit top/side cover HPC 104Mk4 1 2 C-1/ 3 C Gasket for top and side cover 4 25 AG Gasket for valve/compr AG O-ring x / en

7 Pos. no. Part no. Description Qty. per kit Quantity per compressor HPC Gasket kit top/side cover HPC 106 Mk4 1 2 C-1/ 3 C Gasket for top and side cover 5 25 AG Gasket for valve/compr AG O-ring x C-1/ 3 C Gasket kit top/side cover HPC 108 Mk Gasket for top and side cover 6 25 AG Gasket for valve/compr AG O-ring x AB O-ring x Gasket kit top/side water covers SMC/HPC 104 Mk4 2 D O-ring x D-2/ 3 D O-ring x Gasket kit top/side water covers SMC/HPC 106Mk4 2 D O-ring x D-2/ 3 D O-ring x Gasket kit top/side water covers SMC/HPC 108Mk4 2 D O-ring x D-2/ 3 D O-ring x Oil pump Complete RT pump Q O-ring x 2, F Male stud coupling 1 4 F Plug with nut Threaded plug with gasket 1/ Threaded plug with gasket 1/ Threaded plug with gasket 3/ Threaded plug with gasket 1/2 1 4 D Needle valve 3 4 L Check valve 16 bar Nozzle with 1 mm bleedhole M6 x E Tight fitting M8-10 x Cylinder screw M8 x V Pin Ø8 m6 x B Nipple 1 4 K End cover 1 4 S Gear for oil pump. T/SMC R Gear with shaft for oil pump T/SMC T Journal bearing 20/23 x P Journal bearing 20/23 x en /

8 Pos. no. Part no. Description Qty. per kit Quantity per compressor HPC A RT Pump housing Kit assembly complete RT pump Complete RT pump Cylinder screw M12 x C Cylinder screw M12 x Rivet, self drilling 2.9 x Mounting parts for RT pump Cylinder screw M12 x C Cylinder screw M12 x C Cylinder screw M12 x B Washer 2 7 A Coupling 1 4 B Gasket 4 A House for oil pump (Before pre RT) Kit assembly oil pump housing (Before pre RT) Cylinder screw M5 x C Cylinder screw M12 x F Male stud coupling 1 4 F Plug with nut 1 4 J Cylinder screw M5 x Kit assembly valves oil pump housing D Needle valve 1 4 E-1, 4 K Needle valve 2 4 L Check valve 16 bar Kit assembly differential pressure control eletronic (After Nov. 2006) H Intermediate bracket 1 4 J Cylinder screw M5 x N Differential pressure indicator, electronic 1 4 R Spring washer 4 4 G Gasket Kit assembly differential pressure control mechanical (After Nov. 2006) H Intermediate bracket 1 4 J Cylinder screw M5 x N Differential pressure indicator, mechanical 1 4 R Spring washer 4 4 G Gasket Kit assembly oil pump counter clockwise rotation ( ) A Oil pump ccw 1 11 C Cylinder screw M8 x Gasket kit oil pump (New2006) Upgrade kit oil pump counter clockwise rotation Kit assembly oil pump counter clockwise rotation 1 8/ en

9 Pos. no. Part no. Description Qty. per kit Quantity per compressor HPC Kit assembly hub for oil pump Kit assembly bracket for instrument console Kit assembly plugs oil pump housing Plug with gasket 1/ Plug with gasket 1/ Plug with gasket 3/ Plug with gasket 1/ Seal-ring dia Sealing ring 1/ Kit assembly hub for oil pump ( ) A Driving hub for oil pump T/SMC 100 Mk4 1 7 B Spring washer 2 7 C Cylinder screw M12 x Kit assembly coupling for RT pump ( ) A Coupling RT-pump SMC 100 Mk4 1 7 B Washer 2 7 C Cylinder screw M12 x 60 2 Bracket for instrument console Kit assembly bracket for instrument console (After Nov. 2005) Bracket for safety cut-out Hexagon head screw M6 x Washer 12.5/6.4 x Gasket kit oil pump SMC 100 Mk4 (Before Nov. 2006) Gasket 9.5/5.5 x B Gasket for oil pump housing 1 4 G Gasket differential pressure control 1 4 M Gasket 27/21 x Q O-ring x B Gasket for oil pump Gasket kit oil pump SMC 100 Mk4 ( Nov ) B Gasket for oil pump housing 1 4 G Gasket for differential pressure control 1 4 Q O-ring x B Gasket for oil pump Gasket kit RT pump SMC 100 Mk B Gasket for RT pump housing 1 4 G Gasket for differential pressure control 1 4 Q O-ring 72,69 x Endcover at pump end 5 A Bearing cover B Hexagon head screw M14 x en /44

10 Pos. no. Part no. Description Qty. per kit Quantity per compressor HPC Endcover at shaft seal end 6 A Bearing cover B Cylinder screw M14 x B Washer M Endcover at shaft seal end kit Gasket kit end/bearing cover T/SMC Mk D Gasket 0.3 mm 1 5 D Gasket 0.5 mm 1 5 D Gasket 0.75 mm 1 5 D Gasket 1.0 mm 1 6 D Gasket 1 11 D Gasket 1 38 E O-ring x Service kit main bearings HPC Mk C Main bearing 1 6 C Bushing counter clock wise rotation HPC Gasket kit end/bearing cover T/SMC Mk Kit assembly shaft seal cover HPC A Shaft seal cover 1 8 B Gasket for cover 1 8 C Cylinder screw M10 x Kit assembly hose connection D Hose connection 1 8 E Hose Kit assembly shaft seal F Spirolox ring dia G Lock spring 1 8 H Grooved pin dia. 4 x A Retaining flange 1 10 B Spring H Locking ring Kit assembly gaskets for shaft seal SMC D O-ring x G O-ring x J Cylinder screw M5 x B Gasket for cover Service kit shaft seal SMC D O-ring x E Slide ring, cast iron 1 10 F Slide ring, carbon 1 10 G O-ring x J Cylinder screw M5 x B Gasket for cover 1 Oil filter 9 B Nipple / en

11 Pos. no. Part no. Description Qty. per kit Quantity per compressor HPC Oil filter kit Gasket kit oil change only for HPC 100 Mk C O-ring x C Gasket for top and side cover 1 3 D O-ring x A Oil filter 1 Unloading cylinder Unloading cylinder complete L=75 S= A Unloading cylinder 1 12 B Piston 1 12 C Piston rod 75 mm 1 12 D Threaded plug 1 12 E Gasket 1 12 F Seeger ring 1 12 G Spring guide 1 12 H Spring retainer 1 12 J Spring outer 1 12 J Spring inner 1 12 K Benzing ring dia. 9 mm 1 12 K Benzing ring dia. 7 mm Unloading cylinder complete L=100 S= A Unloading cylinder 1 12 B Piston 1 12 C Piston rod 100 mm 1 12 D Threaded plug 1 12 E Gasket 1 12 F Seeger ring 1 12 G Spring guide 1 12 H Spring retainer 1 12 J Spring outer 1 12 J Spring inner 1 12 K Benzing ring dia. 9 mm 1 12 K Benzing ring dia. 7 mm Unloading cylinder complete L=125 S= A Unloading cylinder 1 12 B Piston 1 12 C Piston rod 125 mm 1 12 D Threaded plug 1 12 E Gasket 1 12 F Seeger ring 1 12 G Spring guide 1 12 H Spring retainer 1 12 J Spring outer 1 12 J Spring inner 1 12 K Benzing ring dia. 9 mm 1 12 K Benzing ring dia. 7 mm en /44

12 Pos. no. Part no. Description Qty. per kit Quantity per compressor HPC Unloading cylinder complete L=150 S= A Unloading cylinder 1 12 B Piston 1 12 C Piston rod 150 mm 1 12 D Threaded plug 1 12 E Gasket 1 12 F Seeger ring 1 12 G Spring guide 1 12 H Spring retainer 1 12 J Spring outer 1 12 J Spring inner 1 12 K Benzing ring dia. 9 mm 1 12 K Benzing ring dia. 7 mm 1 Unloading cylinder kit Gasket kit unloading cylinder for SMC E Gasket 25/17 x N Gasket for cover (TSMC HP Only) 1 12 R O-ring x S Gasket 100 x 100 x 2 1 Frame for unloading Frame complete A Suspension rod 1 13 B Suspension rod 1 13 C Cross piece 1 13 D Cross piece 1 13 E Countersunk screw Service kit unloading frame SMC100 (Before March 2008) K Benzing ring dia. 9mm 1 12 K Benzing ring dia. 7mm 1 12 P Lock nut (TSMC HP only) 1 12 L Hexagon head screw M10 x C Spring retainer 4 15 D Spring 4 15 E Washer for bearing cup Gasket kit unloading cylind. SMC Service kit unloading frame SMC/HPC 100 (After March 2008) K Benzing ring dia. 9mm 1 12 K Benzing ring dia. 7mm 1 12 P Lock nut (TSMC HP only) 1 12 L Cylinder screw M10 x C Spring retainer 4 15 D Spring 4 15 E Washer for bearing cup Gasket kit unloading cylind. SMC / en

13 Pos. no. Part no. Description Qty. per kit Quantity per compressor HPC Bracket for unloading mechanism Kit assembly bracket for unloading mechanism LP A Bracket with pin 2 14 B Spacing ring 4 14 C Hexagon head screw M6 x D Spring washer 4 Rocker for unloading mechanism Kit assembly rocker for unloading mechanism LP (Before March 2008) A Rocker 4 15 B Spacing ring Kit assembly rocker for unloading mechanism LP (After March 2008) A Rocker 4 15 B Spacing ring Upgrade kit Rocker/spring for unloading LP (Before March 2008) A Rocker 4 15 B Spacing ring 4 15 C Spring retainer 4 15 D Spring Upgrade kit Rocker/spring for unloading LP (After March 2008) A Rocker 4 15 B Spacing ring 4 15 C Spring retainer 4 15 D Spring 4 Crankshaft - all without certificate (Before Oct. 2006) Obsolete 16 A Crankshaft HPC 104S MK4 complete 1 16 A Crankshaft HPC 106S MK4 complete 1 16 A Crankshaft HPC 108S MK4 complete 1 16 F Plug M12 S-type F Plug 1/4" L-type Crankshaft - all without certificate (After Oct. 2006) 16 A Crankshaft HPC 104S MK4 complete 1 16 A Crankshaft HPC 106S MK4 complete 1 16 A Crankshaft HPC 108S MK4 complete 1 16 F Plug M12 S-type Connecting rod Connecting rod complete with certificate Conrod with certificate 1 17 A Half-section of bearing 2 17 B Bushing for piston pin 1 17 C Bolt for connecting rod 2 17 D Lock nut en /44

14 Pos. no. Part no. Description Qty. per kit Quantity per compressor HPC Piston Piston with pin and rings A Piston pin 1 18 B Piston ring 2 18 C Oil scraper ring 1 18 D Seeger ring dia Service kit pair of piston rings B Piston ring 4 18 C Oil scraper ring Service kit half section bearings A Half-section of bearing 4 17 D Lock nut Service kit piston pins LP B Bushing for piston ring 4 17 C Bolt for connecting ring 4 18 A Piston pin 2 18 D Seeger ring dia Service kit pair of connecting rod bearings LP Service kit piston pins LP Service kit half section bearings Kit assembly small end bearing D Seeger ring dia C Bolt for connecting rod 4 17 B Bushing for piston pin 2 Cylinder liner Cylinder liner with suction valve, Model II A Cylinder liner S and L 1 19 B Unloading ring with pins S and L 1 19 C Washer dia 8/4.3 x D Spring for unloading ring 6 19 E Tension spring 1 19 F Ring plate 1 19 G Helical spring 6 19 H Suction valve retaining plate Model II 1 19 J Guide ring for discharge valve 1 19 P Lock washer 6 19 N Cylinder screw M6 x T Gasket Cylinder liner with suction valve, Model III 1 19 A Cylinder liner S and L 1 19 B Unloading ring with pins S and L 1 19 C Washer dia 8/4.3 x D Spring for unloading ring 6 19 E Tension spring 1 19 F Ring plate 1 19 G Helical spring H Suction valve retaining plate Model III 1 19 J Guide ring for discharge valve 1 14/ en

15 Pos. no. Part no. Description Qty. per kit Quantity per compressor HPC P Lock washer 6 19 N Cylinder screw M6 x T Gasket dia. 163/141 x 0.2mm 1 Cylinder liner kit Kit assembly springs for unloading ring C Washer dia 8/4.3 x D Spring for unloading ring E Tension spring Service kit pair of unloading ring SMC 100 S/L B Unloading ring with pins S and L Gasket kit pair of cylinder liners SMC Kit assembly springs for unloading ring 1 Discharge Valve Discharge valve, Model II A Discharge valve seat 1 20 B Reataining plate, Model II 1 20 C Ring plate 1 20 E Hexagon head screw M14 x E Lock washer 1 20 G Helical spring Discharge valve, Model III A Discharge valve seat 1 20 B Reataining plate, Model III 1 20 C Ring plate 1 20 E Hexagon head screw M14 x E Lock washer 1 20 G Helical spring Discharge valve, Model IV A Discharge valve seat 1 20 B Reataining plate, Model IVI 1 20 C Ring plate 1 20 E Hexagon head screw M14 x E Lock washer 1 20 G Helical spring Discharge valve, Model V A Discharge valve seat 1 20 B Reataining plate, Model V 1 20 C Ring plate 1 20 E Hexagon head screw M14 x E Lock washer 1 20 G Helical spring Upgrade kit discharge valve seat (Dec. 2007) R Discharge valve seat 1 20 E Hexagon head screw M14 x E Lock washer en /44

16 SELECTION OF SUCTION VALVE TYPE HPC100 Suction valve Complete Cylinder liner part Refrigerant Conditions Valve type retaining plate no. part no. TE < +35ºC Model II HPC100S R717 TE +35ºC Model III HPC100S R410A TE < -45ºC Model II HPC100S TE -45ºC Model III HPC100S R744 TE = All Model III HPC100S One small groove indicate Model I Two small grooves indicate Model II Three small grooves indicate Model III SELECTION OF DISCHARGE VALVE TYPE HPC100 Complete discharge valve part Discharge valve retaining plate part no. Refrigerant Conditions Valve type no. R717 TC 35ºC Model II R410A R744 TC < -5ºC Model III º < TC < 15ºC Model IV TC 15ºC Model V TC < -5ºC Model IV TC -5ºC Model V One small groove indicate Model I Two small grooves indicate Model II One large groove and one small groove indicate Model III One large groove and two small grooves indicate Model IV One large groove and tree small grooves indicate Model V 16/ en

17 Pos. no. Part no. Description Discharge valve kit Qty. per kit Quantity per compressor HPC Service kit pair of cylinder liners SMC K Gasket for cylinder liner 0.5mm 2 19 K Gasket for cylinder liner 0.8mm 2 19 M O-ring x 3.53 (TSMC HP only) 2 19 T Gasket dia. 163/141 x 0.2mm Service kit ring plates F Ring plate 2 19 G Helical spring (Qty. for Model III) C Ring plate 2 20 G Helical spring (Qty. for Model V) Service kit pair of cylinder liners SMC 100 S/L 1 19 G-1/ 20 G Kit assembly valve springs Helical spring A Spring for safety head S and L Oil pressure valve Oil pressure valve kit Kit assembly oil pressure valve A Oil pressure valve 1 22 B Gasket (also included in Gasket kit ) 1 22 C Hexagon head screw M12 x 35 2 Oil charging valve Oil charging valve kit Kit assembly oil charging valve A Needle valve 1 23 B Threaded reduction nipple 1 23 C Socket 1 23 D Gasket 19/14 x E Nut 1 23 F Gasket 18/10 x G Male stud coupling 1 23 H Gasket 34/27 x J Bend Gasket kit oil charging valve D Gasket 19/ F Gasket 18/ H Gasket 34/27 x Packing gland 1 By-pass valve By pass valve dia 28, 39 BAR for R By pass valve dia 28, 34 BAR for HFC By-pass valve kit Gasket kit by pass valve ø B O-ring x C O-ring x Stop valves (Before Feb. 2005) Complete stop valve DN en /44

18 Pos. no. Part no. Description Qty. per kit Quantity per compressor HPC Complete stop valve DN Stop valves (After Feb. 2005) Complete stop valve DN Complete stop valve DN Stop valves (After Apr. 2013) Complete stop valve DN Complete stop valve DN Stop valves kit (Before Feb. 2005) Kit assembly welding nipple 65/65 (Before 2005) AC Counter flange AC Welding nipple dia AK Screw for counter flange M10 x Kit assembly welding nipple 100/80 (Before 2005) AC Counter flange 80/ AD Welding nipple dia AK Screw for counter flange M12 x Kit assembly welding nipple 100/80 (Before 2005) AC Counter flange 80/ AD Welding nipple dia AK Screw for counter flange M12 x AK Threaded plug 3/ Kit assembly stop valve ø50/ø65 (Before 2005) Obsolete Kit assembly stop valve ø100/100 (Before 2005) Obsolete Kit assembly hand wheel 120 (Before 2005) S Hand wheel dia T Screw M5 x U Washer for hand wheel Kit assembly hand wheel 180 (Before 2005) S Hand wheel dia T Screw M8 x U Washer for hand wheel 1 Hand wheel (After 2005) 25 S Hand wheel DN65 (Incl. Screw+washer) S Hand wheel DN100 (Incl. Screw + washer) Z Screw valve/comp. M14 x 45 for DN65 valve Z Screw valve/comp. M16 x 45 for DN100 valve Gasket kit stop valve (Before 2005) F Gasket for screw dia 31/24 x H Sealing ring dia. 62/45 x J Gasket for bonnet dia x M Packing gland 1 25 P O-ring x Q Nylon washer dia. 39.5/28 x Y Gasket for welding nipple 1 18/ en

19 Pos. no. Part no. Description 25 AG Gasket for valve/compr AH Gasket for plug 1 Qty. per kit Quantity per compressor HPC Gasket kit stop valve 100 (Before 2005) F Gasket for screw dia. 36/28 x H Sealing ring dia. 110/91 x J Gasket for bonnet dia x M Packing gland 1 25 P O-ring x Q Nylon washer dia. 34.0/22.0 x Y Gasket for welding nipple 1 25 AG Gasket for valve/compr AH Gasket for plug Spare Parts kit stop valve 65 (After 2005) Spare Parts kit stop valve 65 bonnet/cap Repair kit complete set of gaskets DN Packing gland incl. Gaskets DN Spare Parts kit stop valve 100 (After 2005) Spare Parts kit stop valve 100 bonnet/cap Repair kit complete set of gaskets DN Packing gland incl. Gaskets DN Gasket kit pressure gauges B Nozzle and gasket dia. 14/0.8 x C Gasket dia. 11/4 x B Nozzle and gasket dia. 14/0.8 x Oil suction filter Oil suction filter kit Kit assembly oil suction filter A Oil suction filter 1 33 B Male stud coupling 1 33 C Oil pipe suction 1 33 D Flange connector, el-bow 22 mm pipe (CR-mat) 1 Suction filter Suction filter kit Service kit suction filter A Suction filter open, complete Gasket kit suction filter Gasket kit suction filter D O-ring x F O-ring x B Filter bag C Insert for filter bag E Cover for suction filter G Hexagon head screw M12 x H Spring washer 21.1/12.2 x Discharge pipe oil system 38 A Discharge pipe oil system C Connection for discharge pipe 1 38 C Connection for discharge pipe 1 38 C Connection for discharge pipe en /44

20 Pos. no. Part no. Description Discharge pipe oil system kit Qty. per kit Quantity per compressor HPC Gasket kit discharge pipe oil system M O-ring x D O-ring x E O-ring x F O-ring x G O-ring x Cooling water 40 A Set of hoses for cooling water HPC A Set of hoses for cooling water HPC A Set of hoses for cooling water HPC108 1 Purge valve 42 A Purge valve B Threaded nipple C Male stud coupling E Nut F Connection pipe with collar G Gasket: Included in Gasket kit H Nut Coupling AMR Size Spare part set AMR Size 312 (Before Oct. 2007) (Obsolete) A Coupling disc pack 2 48 B Bolt AMR/SR52 size C Thin washer AMR/SR52 size D Lock nut E Washer Spare part set AMR Size 312 (After Oct. 2007) Disc pack (pair) Hardware kit AMR Size Disc pack (pair + thin washers) A Disc pack size 312 single Ultra thin washer 312 AMR Hardware kit AMR Size 312 (After Oct. 2007) B Coupling bolt AMR C Washer steel 8 48 D Lock nut E Washer 16 Motor hub for coupling AMR H Motor hub AMR 312 L=100 mm bore 48 mm H Motor hub AMR 312 L=100 mm bore 55 mm H Motor hub AMR 312 L=100 mm bore 60 mm H Motor hub AMR 312 L=100 mm bore 65 mm H Motor hub AMR 312 L=185 mm bore 60 mm H Motor hub AMR 312 L=185 mm bore 65 mm H Motor hub AMR 312 L=185 mm bore 70 mm H Motor hub AMR 312 L=185 mm bore 75 mm H Motor hub AMR 312/350 L=120 mm bore 65 mm H Motor hub AMR 312/350 L=120 mm bore 70 mm / en

21 Pos. no. Part no. Description Qty. per kit Quantity per compressor HPC H Motor hub AMR 312/350 L=120 mm bore 75 mm H Motor hub AMR 312/350 L=120 mm bore 80 mm H Motor hub AMR 312/350 L=155 mm bore 65 mm H Motor hub AMR 312/350 L=155 mm bore 70 mm H Motor hub AMR 312/350 L=155 mm bore 75 mm H Motor hub AMR 312/350 L=155 mm bore 80 mm H Motor hub AMR 312/350 L=155 mm bore 85 mm H Motor hub AMR 312/350 L=155 mm bore 90 mm H Motor hub AMR 312/350 L=155 mm bore 95 mm H Motor hub AMR 312/350 L=155 mm bore 100 mm Compressor hub for coupling AMR F Compressor hub for coupling AMR J Locking assembly TLK x Coupling CFA Size 30 Motor hub for coupling CFA H Motor hub CFA 30 Bore 48 mm H Motor hub CFA 30 Bore 55 mm H Motor hub CFA 30 Bore 60 mm H Motor hub CFA 30 Bore 65 mm Compressor hub for coupling CFA F Compressor hub for coupling CFA J Locking assembly TLK x K Flywheel CFA Spare part set CFA Size A Elastic element CFA L Radial bolt M16x55 mm with securing paste Copper grease 1 48 G Intermediate part CFA 30 L = 104 mm G Intermediate part CFA 30 L = 128 mm M Pin bolt for CFA Coupling CFA Size 90 Motor hub for coupling CFA H Motor hub CFA 90 Bore 65 mm H Motor hub CFA 90 Bore 70 mm H Motor hub CFA 90 Bore 75mm H Motor hub CFA 90 Bore 80 mm H Motor hub CFA 90 Bore 85 mm H Motor hub CFA 90 Bore 90 mm H Motor hub CFA 90 Bore 95mm H Motor hub CFA 90 Bore 100 mm Compressor hub for coupling CFA F Compressor hub for coupling CFA 90/ J Locking assembly TLK x K Flywheel CFA 90/140 (only HPC 104 and 108) Spare part set CFA Size A Elastic element CFA L Radial bolt M20x70 mm with securing paste Copper grease 1 48 G Intermediate part CFA 90 L = 128 mm en /44

22 Pos. no. Part no. Description Qty. per kit Quantity per compressor HPC G Intermediate part CFA 90 L = 158 mm G Intermediate part CFA 90 L = 173 mm G Intermediate part CFA 90 L = 203 mm M Pin bolt for CFA 90/140/ Coupling CFA Size 140 Motor hub for coupling CFA H Motor hub CFA 90 Bore 85 mm 1 48 H Motor hub CFA 90 Bore 90 mm 1 48 H Motor hub CFA 90 Bore 95mm 1 48 H Motor hub CFA 90 Bore 100 mm 1 Compressor hub for coupling CFA F Compressor hub for coupling CFA 90/ J Locking assembly TLK x K Flywheel CFA 90/ Spare part set CFA Size A Elastic element CFA L Radial bolt M20x70 mm with securing paste Copper grease 1 48 G Intermediate part CFA 140 L = 128 mm 1 48 G Intermediate part CFA 140 L = 173 mm 1 48 M Pin bolt for CFA 90/140/200 8 Capacity regulation 50 A Valve body with 1 solenoid valve 1 50 A Valve body with 2 solenoid valves 1 50 A Valve body with 3 solenoid valves 1 50 B Coil 10 W 220/230V-50/60Hz B Coil 10 W 110V-50/60Hz B Coil 10 W 240V -50Hz C Service kit for one solenoid valve Crankcase heater 1 1/4 BSP Crankcase heater 1 1/4 BSP kit Kit assembly crankcase heater 460W 115V A Heater 1 57 B Sealing ring Kit assembly crankcase heater 460W 230V A Heater 1 57 B Sealing ring Kit assembly crankcase heater 460W 250V A Heater 1 57 B Sealing ring Gasket kit heater, oil pressure valve etc. 1 C O-ring x B Gasket 1 42 G Gasket 4 45 K Gasket 1 57 B Sealing ring 1 Oil return 80 A Valve block EVRB B mm orifice for mounting in valve block / en

23 Pos. no. Part no. Description Qty. per kit Quantity per compressor HPC C TLT valve J Coil 10 W 220/230V-50/60Hz 80 J Coil 10 W 110V-50/60Hz 80 J Coil 10 W 240V -50Hz 80 J Coil 10 W 24V -50Hz Oil return kit 80 E-/ 80 G Strainer kit EVRB block NO/NC P-H- K-M-L Service kit EVRB block NC G-K- M-LQ Seal kit EVRB block NC L-Q-I Orifice kit 3.3mm Forbens X Menbrame kit Oil Separators Oil Separator OHUR A Coaleser Element B O-ring x C O-ring x D Alu-ring 27/21 x E Alu-ring 36/28 x Oil Separator OHUR A Coaleser Element B O-ring x C O-ring x D Alu-ring 27/21 x E Alu-ring 36/28 x Oil cooling Oil cooler HFC Oil cooler OOKH HFC Oil cooler R Oil cooler OOSI R Oil cooling kit Kit assembly oil cooling A Adaptor for oil cooler 1 92 C Cylinder screw M6 x F Threaded nipple 1 92 H Plug with rim 1/4in RG 1 92 L Plug with rim 3/8in RG Gasket kit oil cooling B O-ring x D Gasket dia. 25/17 x E Gasket dia. 32/27 x G Gasket dia. 27/21 x J Gasket dia. 20/13 x K O-ring x Expansion valve TU-AE. for ( R410A) Nozzle no.04 for TU-A valve for ( R410A) en /44

24 Pos. no. Part no. Description Pulley Cone Clamping unit Qty. per kit Quantity per compressor HPC Pulley DP 400, 4 Grooves, SPB Pulley DP 400, 6 Grooves, SPB Pulley DP 400, 8 Grooves, SPB UNISAB Kit assembly support for UNISAB II (Before Oct. 2007) A Support for UNISAB 1 99 B Distance washers 4 99 C Hexagon head screw M10 x D Hexagon head screw M6 x F Washer 21/10.5 x Support for SMC 104/106/108 UNISAB III (After Oct. 2007) Hexagon head M8 x C Hexagon head M10 x F Washer 21/10.5 x A Console UNISAB III Intermediate plate SMC 1 Pressure transmitters UNISAB II PPT1/ PPT Pressure transmitters AKS /25 BAR PPT Pressure transmitters AKS 32-1/59 BAR PPT1/2/ Male stud coupling PPT V-threaded connection Pressure transmitters UNISAB III PPT1/ PPT Pressure transmitters AKS /25 BAR PPT Pressure transmitters AKS /59 BAR PPT1/2/ Male stud coupling PPT V-threaded connection Temperature sensors (After Sep. 2005) PPT5/ Temperature sensor PT 100, 80mm w. cooling neck PPT Temperature sensor PT 100, 80mm w/o cooling neck PPT5/6/ Reducer PPT5/6/ Gasket / en

25 Pipe works HPC 104 HPC 106 HPC 108 Unloading Standard Extended and Total VSD No motor tunnel With motor tunnel No motor tunnel With motor tunnel No motor tunnel With motor tunnel Thermo pump Fixed speed VSD en /44

26 1.1.3 Tools for compressor The SMC MK4 and HPC Mk4 compressor tool set comprises the tool set for Mk3 and a supplementary set for Mk4. The tool set for Mk T _0/1, 2 26/ en

27 SMC Mk3 & TSMC Mk3 - Types S-L-E HPC Mk4 Line no. A600 = Normal set, tools set no Line no. A601 = Extended set, tools set no Line no. A602A = Tools for coupling (SMC ), tools set no Line no. A602B = Tools for coupling (SMC ), tools set no Line no. A603 = Tools for alignment of coupling Line No. Pos. no. Designation Dimension Part no. A600 A601 A602 A603 A B 1-1 Clamp with screw, compr. type S and L 1-2 Clamp with screw, compr. type E Tools for shaft seal Tommy screw for cylinder liner Theaded plug for unloading cylinder 3/8 BSP Supporting plate for pistons Spanner for heating cartridge NV Trigger for coupling or belt pulley Adjusting jig for coupling Adjusting jig for CFA coupling Wrench for cylinder screw NV Wrench for cylinder screw NV Wrench for cylinder screw NV Wrench for cylinder screw NV Special wrench for shaft seal NV Retaining-ring plier J 21/G Retaining-ring plier A 11/G Open end and ring spanner NV Open end and ring spanner NV Open end and ring spanner NV Open end and ring spanner NV Open end and ring spanner NV Open end and ring spanner NV Socket wrench NV Socket wrench NV Socket wrench NV Socket wrench NV Socket wrench NV Socket wrench NV Socket wrench NV Socket wrench NV Socket wrench NV Socket wrench NV Socket wrench NV 9/ en /44

28 Line No. Pos. no. Designation Dimension Part no. A600 A601 A602 A603 A B Socket wrench NV 3/ Ratchet handle NV 11/ Speed handle 1 16 Universal joint for socket wrench Extension rod for socket wrench Extension rod for socket wrench Torque wrench Nm Torque wrench Nm Coupler for torque wrench 1/ Open spanner for torque wrench NV 11/ Open spanner for torque wrench NV 3/ Feeler gauge 1 28/ en

29 1.1.4 Supplementary tool set for SMC 100 Mk4 and HPC Mk Line no. A605 = Supplementary tool set for Mk4 no Line No. Pos. No. Designation Dimension Part No. A605 1 Allen key for needle valves in pump housing 1/ Box spanner insert for water-cooled covers 22 mm 1/2 square Bit adapter for Mk4 coupling 6 mm Allen key /2 square 4 Open end spanner for torque wrench (temporarily for Mk4 coupling) NV Oil filter wrench for Spin-on oil filter dia en /44

30 1.1.5 Tool set for change of main bearings 1 Pos. Designation Part no. Line no. no. A606 1 Tool set for change of SMC/HPC main bearings / en

31 Drawings 2. Drawings HPC Fig. 1: HPC en /44

32 Drawings Piston, cylinder liner and connecting rod 21 A E B G C A N P J H F T A M TS M C - H P S T A G E 19 K C D B E G A G G B E A D A SM C an d T SM C L P 17 C D B C A D B - 1 Fig. 2 32/ en

33 Drawings Shaft seal 10A-1 10H-1 10E-1 10D-1 10J-1 8G-1 10F-1 10G-1 8B-1 8H-1 10B-1 8D-1 8E-1 10G-1 10B-1 8G-1 10D-1 10J-1 10H-1 8A-1 10A-1 10E-1 8B-1 8A-1 8C-1 8H-1 10F-1 8F-1 8C-1 8F-1 Fig en /44

34 Drawings Covers 6B-1 6A-1 37B-1 37A-1 37C-1 3E-1 3A-1 3F-1 6E-1 22C-1 22A-1 37D-1 37F-1 Air cooled version 3B-1 3G-1 22B-1 2G-1 2B-1 2D-1 6D-1 2E-1 2G-1 37E-1 Wate r cooled version 3C-1 3H-1 3A-2 3G-1 3D-1 2A AG-1 2C-1 2H-1 2H-1 1C-1 1B-1 1D-1 25z -1 2F-1 2G-1 5D-1 2B-1 2D-1 2G-1 2E-1 2A-1 2C-1 5A-1 Fig. 4 34/ en

35 Drawings Crankshaft, bearings and coupling 48I 48J 48H 48A 48B 48D/E 48C 6C-1 48G 48F 16A-1 5C-1 Fig en /44

36 Drawings Oil system Fig. 6 36/ en

37 Drawings Unloading frame/cylinder 12E-1 12D-1 SMC and TSMC LP 12A-1 12S-1 12L-1 12K-1 12B-1 12C-1 12G-1 12J -2 12J -1 12G-1 12F-1 14C-1 14A-1 14B-1 Unload ing cylinde r and frame 13E-1 12K-1 12P -1 14C-1 14D-1 14A-1 14B-1 15D-1 15C-1 15A-1 15B-1 15E-1 13A-1 Fig en /44

38 Drawings By-pass and service valves Oil charge valve 23A-1 23F-1 23D-1 23C-1 23I-1 23G-1 23H-1 23B-1 23E-1 42C-1 42E-1 42H-1 42G-1 42F-1 42G-1 Purge valve 42A-1 24C-1 24B D-1 24E-1 By-pass valve Fig. 8 38/ en

39 Drawings Safety equipment Fig en /44

40 Drawings POS 18: Gas ket for cap POS 8: Packing gland incl. gask ets POS 5: Cone complete incl. stee l ba lls and Allen screw POS 13: O-ring for housing an d bonne t POS 19: Back sea ling (only for size ) Po sitions sho wn ab ove are include d in gasket kit, SVA stopvalve Fig / en

41 Drawings Coupling AMR 312 Fig. 11: AMR 312 Exploded en /44

42 Drawings Coupling CFA Fig. 12: CFA 90 Exploded 42/ en

43 Drawings Fig. 13: CFA 90 with flywheel en /44

44 Drawings Solenoid valve controlled oil return Oil separator Compressor C Valve block A Pos. 80A-1 Solenoid valve Orifice Pos. 80B-1 Stop valve Filter TLT valve Pos. 80C-1 Fig Oil separator, OHUR Discharge gas inlet Ports for pressure difference measurement Discharge gas outlet C A Fig. 15 B Drainage Oil return to compressor 44/ en