Spare parts manual. HPC100Mk4LL Reciprocating compressor unit

Transcription

1 Spare parts manual en HPC100Mk4LL Reciprocating compressor unit

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3 Manual for HPC 100 Mk 4 LL Manual for HPC 100 Mk 4 LL 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 Fixed speed Variable speed (VSD) Ex-execution (ATEX) T3 T4 Other Equipment for parallel operation Oil separator SABROE OVUR SABROE OHUR en /40

4 Contents Manual for HPC 100 Mk 4 LL Spare parts HPC How to use the parts list Amendments Parts list Tools for compressor Supplementary tool set for SMC 100 Mk 4, HPC Mk 4 and HPX Mk Tool set for change of main bearings Drawings HPC Coupling AMR Coupling CFA 30 & Solenoid valve controlled oil return Oil separator, OHUR / 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 LL, 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 Amendments New document (named Upgrade 2015 ) based on Spare parts manual en but with bearing shells as introduced in Technical information 2015/09. Upgrade kits based on former versions of SMC Mk 4 have been omitted Updated with new working valves, as introduced in Technical Information 2016/02. Update of spare parts kits for stop valves. Renamed to HPC 100 Mk 4 LL (Long Life) Updated with liquid drain system Technical information 2016/05, new spring retainer, Technical information 2017/03 and new unloading cylinders, Technical information 2017/ en /40

6 1.3 Parts list Pos. no. Part no. Description Qty. per kit Quantity per compressor HPC Compressor frame 1A Frame HPC A Frame HPC A Frame HPC B Oil level glass C O-ring x D Hexagon head M6 x Top cover air cooled 2A Top cover, HPC100 Mk A Top cover with flange, HPC100 Mk C Gasket for top and side cover E Cylinder screw M14 x F Cylinder screw M14 x Top cover water cooled 2A 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 C Gasket for top and side cover D O-ring x D O-ring x E Cylinder screw M14 x F Cylinder screw M14 x G Nut M H Staybolt M14 x 138, SMC/HPC 100 MK J Nut m Kit assembly staybolts for top cover G-1/ 2J Nut M14 8 2H Staybolt M14 x 138, SMC/HPC 100Mk4 4 Side cover - air cooled 3A Side cover, air cooled C Gasket for top and side cover E Cylinder screw M14 x Side cover - water cooled 3A Side cover with cooling fins, HPC100 Mk B Water cover right, SMC100 Mk B Water cover left, SMC100 Mk C Gasket for top and side cover D O-ring x F Cylinder screw M14 x G Nut M H Stayblot M14 x 85, SMC/HPC 100 MK J Nut M Side cover water cooled kit Kit assembly staybolts for side cover G-1/ 3J Nut M14 8 3H Staybolt M14 x 85, SMC/HPC 100Mk Gasket kit top/side cover HPC 104Mk4 1 2C-1/ 3C Gasket for top and side cover 4 25AG Gasket for valve/compr. 1 6/ en

7 Pos. no. Part no. Description Qty. per kit Quantity per compressor HPC AG O-ring x Gasket kit top/side cover HPC 106 Mk4 1 2C-1/ 3C Gasket for top and side cover 5 25AG Gasket for valve/compr. 1 25AG O-ring x Gasket kit top/side cover HPC 108 Mk4 1 2C-1/ 3C Gasket for top and side cover 6 25AG Gasket for valve/compr. 1 25AG O-ring x Gasket kit top/side water covers SMC/HPC 104 Mk4 1 2D O-ring x D-2/ 3D O-ring x Gasket kit top/side water covers SMC/HPC 106Mk4 1 2D O-ring x D-2/ 3D O-ring x Gasket kit top/side water covers SMC/HPC 108Mk4 1 2D O-ring x D-2/ 3D O-ring x Oil pump Complete RT pump Q O-ring x 2,62 1 4F Male stud coupling 1 4F 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 4D Needle valve 3 4L 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 4K End cover 1 4S 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 A RT Pump housing Kit assembly complete RT pump Complete RT pump 1 4C Cylinder screw M12 x C Cylinder screw M12 x Rivet, self drilling 2.9 x Mounting parts for RT pump C Cylinder screw M12 x en /40

8 Pos. no. Part no. Description Qty. per kit Quantity per compressor HPC C Cylinder screw M12 x C Cylinder screw M12 x B Washer 2 7A Coupling 1 4B Gasket Kit assembly valves oil pump housing D Needle valve 1 4E-1, 4K Needle valve 2 4L Check valve 16 bar Kit assembly differential pressure control eletronic H Intermediate bracket 1 4J Cylinder screw M5 x N Differential pressure indicator, electronic 1 4R Spring washer 4 4G Gasket Kit assembly differential pressure control mechanical H Intermediate bracket 1 4J Cylinder screw M5 x N Differential pressure indicator, mechanical 1 4R Spring washer 4 4G Gasket Gasket kit RT pump SMC 100 Mk B Gasket for RT pump housing 1 4G Gasket for differential pressure control 1 4Q O-ring 72,69 x 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 coupling for RT pump A Coupling for RT pump SMC 100 Mk4 1 7B Washer 2 7C Cylinder screw M12 x 60 2 Bracket for instrument console Kit assembly bracket for instrument console Bracket for safety cut-out Hexagon head screw M6 x Washer 12.5/6.4 x Endcover at pump end 5A Bearing cover B Hexagon head screw M14 x Endcover at shaft seal end 6A Bearing cover B Cylinder screw M14 x E Washer M / en

9 Pos. no. Part no. Description Qty. per kit Quantity per compressor HPC Endcover at shaft seal end kit Gasket kit end/bearing cover T/SMC Mk D Gasket 0.3 mm 1 5D Gasket 0.5 mm 1 5D Gasket 0.75 mm 1 5D Gasket 1.0 mm 1 6D Gasket end cover 1 11D Gasket shaft seal cover 1 38E O-ring x 5, Service kit main bearings HPC Mk C Main bearing 1 6C Main bering anti clock wise rotating HPC Gasket kit end/bearing cover T/SMC Mk Kit assembly shaft seal cover HPC A Shaft seal cover 1 8B Gasket for cover 1 8C 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 8H Grooved pin dia. 4 x A Retaining flange 1 10B Spring 10 10H 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 10G O-ring x J Cylinder screw M5 x B Gasket for cover 1 Oil filter 9A Oil filter B Nipple Oil filter kit Gasket kit oil change only for HPX C O-ring x C Gasket for top and side cover 1 3D O-ring x A Oil filter 1 Unloading cylinder Unloading cylinder complete L=75 S=21.5, qvad A Unloading cylinder, qvad 1 12 B Piston for qvadring 1 12 C Piston rod 75 mm 1 12 D Threaded plug 1 12 E Gasket 1 12 F Seeger ring en /40

10 Pos. no. Part no. Description Qty. per kit Quantity per compressor HPC 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 12T Qvad-ring x Unloading cylinder complete L=100 S=46.5, qvad A Unloading cylinder, qvad 1 12 B Piston for qvad-ring 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 1 12T Qvad-ring x Unloading cylinder complete L=125 S=71.5, qvad A Unloading cylinder, qvad 1 12 B Piston for qvad-ring 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 1 12T Qvad-ring x Unloading cylinder complete L=150 S= A Unloading cylinder, qvad 1 12 B Piston for qvad-ring 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 12T Qvad-ring x Unloading cylinder kit Gasket kit unloading cylinder qvad for SMC E Gasket 25/17 x N Gasket for cover (TSMC HP Only) 1 12 R O-ring x 2.62 (TSMC HP only) 1 12 S Gasket 100 x 100 x T Qvad-ring x / en

11 Pos. no. Part no. Description Qty. per kit Quantity per compressor HPC L Cylinger screw M Frame for unloading Frame complete A Suspension rod 1 13B Suspension rod 1 13-C Cross piece 1 13-D Cross piece 1 13 E Countersunk screw Service kit unloading frame SMC/HPC 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 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 A Rocker 4 15 B Spacing ring 4 Crankshaft - all without certificate 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 w/o certificate T/SMC Conrod bare 1 17 A H Half-section bearing, metal- polymer 2 17 B Bushing for piston pin 1 17 C Bolt for connecting rod 2 17 D Lock nut 2 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 H Half-section bearing, metal -polymer 4 17 D Lock nut en /40

12 Pos. no. Part no. Description Qty. per kit Quantity per compressor HPC 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 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 LL Ring plate 1 19 G Helical spring 6 19 H Suction valve retaining plate Model 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 2, 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 LL Ring plate 1 19 G Helical spring 6 19 H Suction valve retaining plate Model 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 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 LL Ring plate 1 19 G Helical spring H Suction valve retaining plate Model J Guide ring for discharge valve 1 19 P Lock washer 6 19 N Cylinder screw M6 x T Gasket dia. 163/141 x 0.2mm Cylinder liner with suction valve, Model A Cylinder liner S and L 1 19 B Unloading ring with pins S and L 1 12/ en

13 Pos. no. Part no. Description Qty. per kit Quantity per compressor HPC C Washer dia 8/4.3 x D Spring for unloading ring 6 19 E Tension spring 1 19 F LL Ring plate 1 19 G Helical spring 6 19 H Suction valve retaining plate Model J Guide ring for discharge valve 1 19 P Lock washer 6 19 N Cylinder screw M6 x T Gasket 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 A Discharge valve seat 1 20 B Retaining plate, Model C LL Ring plate 1 20 E Hexagon head screw M14 x E Lock washer 1 20 G Helical spring Discharge valve, Model A Discharge valve seat 1 20 B Retaining plate, Model C LL Ring plate 1 20 E Hexagon head screw M14 x E Lock washer 1 20 G Helical spring Discharge valve, Model A Discharge valve seat 1 20 B Retaining plate, Model C LL Ring plate 1 20 E Hexagon head screw M14 x E Lock washer 1 20 G Helical spring Discharge valve, Model A Discharge valve seat 1 20 B Retaining plate, Model C LL Ring plate 1 20 E Hexagon head screw M14 x E Lock washer 1 20 G Helical spring Discharge valve, Model A Discharge valve seat 1 20 B Retaining plate, Model C LL Ring plate 1 20 E Hexagon head screw M14 x E Lock washer 1 20 G Helical spring en /40

14 SELECTION OF SUCTION VALVE TYPE HPC 100 Refrigerant Conditions Valve type Complete Cylinder liner part no. Suction valve retaining plate part no. R717 TE < 0ºC Model 1 HPC100S TE 0ºC Model 4 HPC100S R410A TE < -45ºC Model 2 HPC100S TE -45ºC Model 3 HPC100S R744 TE = All Model 3 HPC100S One small groove indicates Model 1 Two small grooves indicate Model 2 Three small grooves indicate Model 3 Four small grooves indicate Model 4 14/ en

15 SELECTION OF DISCHARGE VALVE TYPE HPC 100 Complete Discharge valve Refrigerant Conditions Valve type discharge valve retaining plate part no. part no. TC < 40ºC Model R717 TC 40ºC Model R410A R744 TC < -5ºC Model º < TC < 15ºC Model TC 15ºC Model TC < -20ºC Model TC -20ºC Model One small groove indicates Model 1 Two small grooves indicate Model 2 Three small grooves indicate Model 6 One large groove and one small groove indicate Model 3 One large groove and two small grooves indicate Model 4 One large groove and three small grooves indicate Model 5 Pos. no. Part no. Description Qty. per kit Quantity per compressor HPC Discharge valve kit 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 LL Service kit ring plates F LL Ring plate 2 19 G Helical spring (Qty. for Model 3) C LL Ring plate 2 20 G Helical spring (Qty. for Model 5) en /40

16 Pos. no. Part no. Description Qty. per kit Quantity per compressor HPC E Lockwasher 2 12 E Gasket Service kit pair of cylinder liners SMC 100 S/L Kit assembly valve springs 19 G-1/ 20 G Helical spring 20 21A 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 D Socket cap screw M8 x E Spring washer 15/8 x Stop valves Complete stop valve DN Complete stop valve DN AG O-ring x 3.53 for valve DN AG O-ring x 3.53 for valvedn Hand wheel 25 S Hand wheel DN65 (Incl. Screw+washer) S Hand wheel DN100 (Incl. Screw + washer) Connecting parts 25 V Spring washer dia V Spring washer dia Z Screw valve/comp. M14 x 45 for DN65 valve Z Screw valve/comp. M16 x 45 for DN100 valve Spare Parts kit stop valve Inspection kit SVA DN Repair kit SVA DN Overhaul kit SVA DN / en

17 Pos. no. Part no. Description Qty. per kit Quantity per compressor HPC Spare Parts kit stop valve Inspection kit SVA DN Repair kit SVA DN Overhaul kit SVA DN 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 HPX A Suction filter w. drain, 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 J Sight glass dia K Bonded seal disc size 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 1 Discharge pipe oil system kit 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 Couplings Coupling AMR Size 312 Compressor hub for coupling AMR F Compressor hub for coupling AMR J Locking assembly TLK x en /40

18 Pos. no. Part no. Description Qty. per kit Quantity per compressor HPC 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 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 Spare part set AMR Size 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 B Coupling bolt AMR C Washer steel 8 48 D Lock nut E Washer 16 Coupling CFA Size G Intermediate part CFA 30 L = 104 mm G Intermediate part CFA 30 L = 128 mm M Pin bolt for CFA Compressor hub for coupling CFA F Compressor hub for coupling CFA J Locking assembly TLK x K Flywheel CFA 30 1 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 Spare part set CFA Size A Elastic element CFA L Radial bolt M16x55 mm with securing paste Copper grease 1 Coupling CFA Size G Intermediate part CFA 90 L = 128 mm 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/ Compressor hub for coupling CFA F Compressor hub for coupling CFA 90/ J Locking assembly TLK x / en

19 Pos. no. Part no. Description en /40 Qty. per kit Quantity per compressor HPC K Flywheel CFA 90/140 (only HPC 104 and 108) 1 1 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 Spare part set CFA Size A Elastic element CFA L Radial bolt M20x70 mm with securing paste Copper grease 1 Coupling CFA Size 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 Compressor hub for coupling CFA F Compressor hub for coupling CFA 90/ J Locking assembly TLK x K Flywheel CFA 90/140 1 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 Spare part set CFA Size A Elastic element CFA L Radial bolt M20x70 mm with securing paste Copper grease 1 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 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. 1C 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 1 1 1

20 Pos. no. Part no. Description Qty. per kit Quantity per compressor HPC C TLT valve J Coil 10 W 220/230V-50/60Hz J Coil 10 W 110V-50/60Hz J Coil 10 W 240V -50Hz 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 EVRB/NC X Membrane 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) Pulley Cone Clamping unit Pulley DP 400, 4 Grooves, SPB Pulley DP 400, 6 Grooves, SPB Pulley DP 400, 8 Grooves, SPB UNISAB Support for SMC 104/106/108 UNISAB III / en

21 Pos. no. Part no. Description Qty. per kit Quantity per compressor HPC 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 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 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 Pipe works HPC 104 HPC 106 HPC 108 Unloading Thermo pump Standard Extended and Total VSD Fixed speed VSD No motor tunnel With motor tunnel No motor tunnel With motor tunnel No motor tunnel With motor tunnel en /40

22 1.4 Tools for compressor The SMC Mk 4, HPC Mk 4 and HPX Mk 4 compressor tool set comprises the tool set for Mk 3 and a supplementary set for Mk 4. The tool set for Mk T _0/1,2 22/ en

23 SMC Mk 3 & TSMC Mk 3 - Types S-L-E HPC Mk 4 HPX Mk 4 Line no. A600 = Normal set, tool set no Line no. A601 = Extended set, tool set no Line no. A602A = Tools for coupling (SMC ), tool set no Line no. A602B = Tools for coupling (SMC ), tool 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 2 Tools for shaft seal Tommy screw for cylinder liner Theaded plug for unloading 3/8 BSP cylinder 5 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/ Socket wrench NV 3/ Ratchet handle NV 11/ Speed handle 1 16 Universal joint for socket wrench Extension rod for socket wrench en /40

24 Line No. Pos. no. Designation Dimension Part no. A600 A601 A602 A603 A B 17-2 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 24/ en

25 1.5 Supplementary tool set for SMC 100 Mk 4, HPC Mk 4 and HPX Mk Line no. A605 = Supplementary tool set for Mk 4 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 /40

26 1.6 Tool set for change of main bearings 1 Pos. no. Designation Part no. Line no. A606 1 Tool set for change of SMC/HPC/HPX main bearings / en

27 Drawings 2. Drawings 2.1 HPC Fig. 1: HPC en /40

28 Drawings Piston, cylinder liner and connecting rod 19 G 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 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 28/ en

29 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 /40

30 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 Water 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 30/ en

31 Drawings Crankshaft, bearings and coupling 48I 48J 48H 48A 48B 48D/E 48C 6C-1 48G 48F 16A-1 5C-1 Fig en /40

32 Drawings Oil system Fig. 6 32/ en

33 Drawings Unloading frame/cylinder 12E-1 12D-1 SMCand TSMCLP 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 Unloading cylinder 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 /40

34 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 34/ en

35 Drawings Safety equipment Fig en /40

36 Drawings Stop valves P os. 18 : Gas k e t f o r c ap P os. 8 : P a c k i ng g l and i n c l. g a sk e t s P os. 5 : Cone c o m p l e t e, i n c l. s t ee l ba ll s and Allen screw P os. 13 : O-r i ng f or ho u s i ng an d bonne t P os. 19 : B a c k s ea l i ng (for s i z es only) Fig. 10 The pos. numbers are included in the spare parts kits for SVA stop valve. Inspection kit: Gaskets, O-rings and aluminium rings. Repair kit: Complete packing gland (pos. 8), gaskets, O-rings and aluminium rings. Overhaul kit: Cone with steel balls (pos. 5), complete packing gland (pos. 8), gaskets, O- rings and aluminium rings. 36/ en

37 Drawings 2.2 Coupling AMR 312 Fig. 11: AMR 312 Exploded en /40

38 Drawings 2.3 Coupling CFA 30 & 90 Fig. 12: CFA 30 & 90 Exploded 38/ en

39 Drawings Fig. 13: CFA 30 & 90 with flywheel en /40

40 Drawings 2.4 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 Fig. 15 B C Drainage A Oil return to compressor 40/ en

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42 Version 1 Johnson Controls Denmark ApS SABROE Factory Christian X's Vej Højbjerg Denmark Phone Fax