CATALOG NO. 035-274GENERAL, GUIDELINES TO STUDENTS ‘This training unit consists of a video tape presentation with an accompanying workbook. The video program is divided into sections. After each video tape section, you will be directed to the workbook where you couplete an exercise (answer questions and do readings). This training program takes approximately two hours to complete. ‘The recomended sequence is as follows: a Q) (3) (4) After the adninistrator gives the introductory remarks, the student reads the objectives. The student briefly discusses the objectives with the administrator and other class members. The videotape is tumed on and the student views the material. Upon completion of tape Section I, the tape is tumed off. ‘The student opens the workbook, reads the questions and writes the answers directly in the workbook, When the group has completed the workbook questions, the administrator will review and discuss the material just completed. When there is no further discussion, the aduinistrator will start the videotape for Section 2, When this is completed, the tape will be tumed off and again the Students retum to the workbook.(5) (6) qa) Work through ali sections in this manner, A quiz covering the material in the entire unit will be administered by the instructor after the unit has been completed, In the event that the program is to be self- adninistered, the student will refer to the administra~ tor's guide.; OBJECTIVES At the conclusion of this program, the student will be able to perform a Stop Major (ST3 FML) on a Trane CVHE Series Hermetic Centrifugal Machine as defined by the Task Handbook. iiiPreparation for Servicing Compressor and Compressor CONTENTS (HIGHLIGHTS) TTRANE CVHE 3 STAGE COMPRESSOR Disassembly A. B, Fen FR Safety Tools needed Removing ofl and refrigerant Compressor disassenbly Removing oil Lines Removing, suction cover Removing impellers Removing volute Motor and Bearing AL B c Bearing disassenbly Bearing reassenbly Checking thrust and rumout Compressor Reassenbly A, B, c D, Compressor reassembly Spacing the impellers Labyrinth seal clearance Post job follow-up procedures iv© Table 1 — Clearances IMPELLER SEAL RING CLEARANCE Compr Size ist Sta. 2nd Sig. 3rd Sig. 013 thru 614 (0296/.0195 -024/.0165 247.0165 015 thru 020 (0285/.0195 022 (0295/.0195 (023 thru 032 039/.022 | 035 039/.022 t (036 thru 045 .0365/,0245 i (049 thru 050 -033/.022, i 055 0365/.0245 (056 thru O74 -049/.0285 079 thru 080 0365/.0245 (089 thru 112 “467.031 -049/.0285 125 “0497-0285 Shaft to Seal Clearances st Stage — 0.018/0.024 in. 2nd Stage — 0.018/0.024 in. st Table 2 — Thrust Bearing, Journal Bearing and Shaft Dimensions (inches) MOTOR | THRUSTBEARING | cuarro.p, | JOURNAL BEARING FRAME BEARING ID. MIN/MAX. BEARING LD. SHAFT 0.D. size MINIMAX. : MIN./MAX. 1500, 1700 2.164872.1654 2.1650/2.1655 5.605075 6065 '5,5096/6.6000 ‘SOME 1700° ALL 1900 AND 9.5425/3.5493 9.5420/9.5494 6.4050/6.4065 6.3995/6.4000 “Applies only to journal bearing/shaft dimension.SECTION ONE‘PRE-DISASSEMBLY PROCEDURE In this program, you will learn how to disassenble the compressor for the Trane Centravac 3 stage model CVHE, ‘The reason we're taking this machine apart, is because of low ofl pressure, But whether the repair is a result of compressor failure or routine maintenance, the procedure is the same. Included in this program will be: - Safety considerations - Tools needed - Pre-Disassenbly procedures - Disassenbly procedures Inspecting the internal parts ~ Recording clearances and Reassenbly Before starting, make sure you have all the necessary safety gear, including proper safety glasses and gloves. Be sure that all your tools and equipment are sturdy and in good working order. And for safety's sake, always lock and tag all discon- nects. Tf you have questions about safety procedures, read the Carrier Safety Guide before working on a centrifugal machine.Additional materials needed for this job include: - insulation and glue - clean lint free rags > refrigerant 11 approved centrifugal compressor ofl - soldering material - replacement spare parts, ‘O" rings, filters, etc. We will store all the bolts and parts in plastic storage buckets and identify the contents of each. We will store all the parts in a dry, clean area, and keep them orderly so that the parts will not be lost and reassembly may be completed more rapidly and accurately. Figure 1We will use our parts order list and confirm that we have all the necessary replacement parts and "0" rings on hand and ready for the job. Let's start this program by covering pre-disassenbly procedures. First, isolate the chilled and condenser water circuits by closing the valves. Be sure the main disconnect is Locked open and tagged to the compressor motor, oil heater, purge, and the control panel. Pressurize the unit with dry nitrogen to 10 PSI and leak test the entire unit. Look for unusual leaks that can be repaired while the compressor is being overhauled. After tagging all leaks, proceed to remove the refrigerant and store it in clean drums. Because this is a specialized job, the first step in preparation is assenbling a gantry and the necessary tools. You'll need a " frame capable of supporting up to 4,000 pounds. gantry or Also you will need a couple of special tools for rigging, one for the guide vanes and one for the compressor suction covers. You may have to buy or field fabricate these. Figures 2 & 3 With the refrigerant removed, drain the compressor oil. We will check this oil for metal chips or other contamination,It's important to leave 1 to 2 PSI positive pressure. Then break the refrigerant and tubing connections. And renenber, while the unit is open, keep the refrigerant side as clean and dry as possible. Do this by taping all openings closed with plastic material to prevent foreign materials from entering the machine. Also, oil down all compressor parts to prevent rusting. Let's cover the things which mist be done before you disconnect the compressor volute assembly. First disconnect the items which attach the volute assembly to the rest of the machine. Discommect all control wiring that would prevent moving the compressor. Identify and tag all wires. Next, remove the economizer. The economizer has three conmec- tions: one to the cooler, one to the condenser and one used for motor cooling. ‘The cooler and condenser lines have flanges; remove these bolts, ‘The motor cooling line will have to be cut. Use a floor jack to support the economizer. The economizer mst be umbolted from the compressor at the second and third stage. Figure 4 Remove the economizer to allow for compressor volute clearance. Notice the refrigerant metering device.1 Next, remove the compressor suction elbow, Remove the bolts on the suction cover and evaporator connections. Disconnect and remove the control panel support bracket. Attach a sling with overhead chain hoist to the suction elbow to support its weight. Rig the suction elbow up and move it away from the compressor. Notice the suction cover "0" rings it looks as though its been leaking. Figure 5 Cover the evaporator suction pipe to prevent entry of dirt and debris into the evaporator. Coat all bare metal surfaces with a Light coat of compressor oil to prevent rust formation. Next, remove the inlet vane actuator linkages. Disconnect the universal joints at the first and third stage inlet vane operator levers. Remve four bolts securing the vane drive support assemblies to the compressor castings. Lift the linkage and ‘vemove it. Remove the cotter pin securing the vane operator stud. Slide the vane motor off the stud and remove the vane motor from the chiller. Next, remove the vane tang operator. Loosen and remove the bolts and lockwashers securing the tang operator to the suction cover. ‘Then remove the tang operator assenbly. Before disassenbling the compressor, scribe lines on the exteriorof all compressor castings in two locations, 90 degrees apart. ‘This must be done so that all components are precisely realigned during reassembly. Failure to complete this step my result in misalignment of the suction elbow and possible distortion of the compressor. This can result in seal-to-impeller interference and possibly impeller failure, Also take note that we dovel pinned each of the stages together. The dowel pins will allow for precise reassembly of the compressor components in their original position, Now, rempve the inlet vane assembly. This requires the special rigging tool or a field fabricated one. Match mark the vane assembly to the suction cover. With the tool in place and tension on the rigging, remove the counter sunk allen head suction cover screws, Hold the vane assembly in place since it will slide out when the setscrews are removed, The housing should then be lifted slightly and removed from the suction cover. Figure 6 Next the first stage impeller nose seal, First use a fecler gage to measure and record the seal clearance for indication of excessive wear. Table 1 provides proper clearance specifica- tions. Identify the seal for top and first stage. Bend the tab washers back allowing the hex head bolts which secure the seal to be removed. With the bolts out remve the seal. Inspect the seal for wear and damage. Figure 7 10Next remove the suction cover and "0" ring. Match mark the suction cover so reassembly will be easier. Remove the alignment dowels from the suction cover and store the dowels. Attach the special rigging tool to the suction cover for lifting. Remove all the bolts except one near the top and two bolts near ow Figure 8 the bottom. Adjust the rigging to find the center of gravity. Lift and take the weight off the remaining bolts. Remove the 2remaining bolts and then carefully remove the suction cover. Pull it straight out and be careful to not damage the impeller. Figure 8 Also remove the suction cover "O" ring. Lightly coat all bare metal surfaces with compressor oil. Move the suction cover away from the work area, Now, remove the first stage impeller, Bend the lock tab securing the impelier locknut. Remove the impeller locknut and lockwasher using a spanner wrench. This has right-hand threads. Remove the Jocknut, Remove the lockwasher. Remove the springwasher. Renove the impeller. It may be necessary to use a puller. Mark the inpeller FIRST STAGE. Remove the impeller key and shims from behind the impeller, Remove the spacer, Now remove the first stage shaft seal. Check the seal clearance for wear and record measurement. Proper clearances are given in Table 1. Mark the seal for TOP and FIRST STAGE. Remove the shaft spacer. Removal may require the use of a puller. Lightly coat the spacer with compressor ofl. Straighten the tabs, loosen and remove the 3/8" bolts which secure the seal to the vane plate, Remove the seal and check for wear. To remove the first stage diffuser plate, mark the diffuser plate for TOP and FIRST STAGE, Remove all but two top socket screws, 13Place protection on the compressor shaft. Remove the remaining Socket head screws. Pull the diffuser plate, straight out and remove it. Depending on the coupressor size, it may or my rot ' have to be rigged. Renove it from the work area. Figure 9 Figure 9 Next, remove the second stage shroud assembly. Mark the TOP of the shroud assembly. Remove the 1/4"'-20 flathead screws securing the shroud asseubly. Remove the shroud, guiding it clear, Tightly coat the shroud with compressor oil. Remove it from the i Next, remove the second stage impeller nose seal. First measure 4 iand record the seal clearance for indication of wear. Table 1 Provides proper clearances. Mark the seal. for TOP and SECOND STAGE. Straighten the tabs and remove the 3/8" seal bolts. Renove the seal and check it for wear or damage, Now we will remove the second stage suction cover and "0" ring. First seribe two marks, 90 degrees apart, on the outer surface of the casting and mating casting, if you haven't already. This will allow precise alignment of the components when reassenbling the compressor. Remove the second stage suction cover bolts. Attach the lifting rig to the suction cover and adjust the rigging to find the center point, Remove the remining bolts securing the suction cover and then rewve the suction cover. Goat all bare metal surfaces with compressor oil to prevent corrosion. Next, remove the second stage impeller and shim in front of impeller. Mark the impeller SEOOND STAGE, A puller may be necessary to remove the impeller. Remove the impeller and inspect it for damage and cracks. Remove the key and shims from behind the impeller. These mist also be marked SECOND STAGE. Lightly coat the components with compressor oil. Now we will remove the second stage shaft seal. First, measure the seal clearance and record for wear indication. Proper clearances are given in Table 1. Mark the seal for TOP. Straighten the tabs and remove the 3/8" bolts which secure theseal to the vane plate. Remove the seal and inspect it for wear. Remove the shaft spacer. It may be necessary to use a puller. Next, remove the second stage diffuser plate. Mark the plate for TOP. Remove the socket head screws. Cover the shaft to protect it, Pull the diffuser plate straight and remove from the work area. Remove the third stage shroud and vane assecbly, Mark the assembly for TOP, Remove the 1/4"-20 flathead screws securing, the shroud, Pull straight out and remove the shroud and vane assenbly. Lightly coat the components with compressor oil. Figure 10| © Now remove the third stage impeller nose seal. Measure and record seal clearance for wear indication, Table 1 provides proper clearances, Measure the clearance all the way around the seal, Mark the seal for TOP and THIRD STAGE, Straighten out the tabs and remove the bolts, Remove the seal. Check for wear and damage. Lightly coat the seal with compressor oil. Remove the third stage impeller shim. Scribe two marks, 90 degrees apart, in the third stage suction cover casting and mating casting. Also we dowel pinned the third stage suction cover to third stage volute. ‘this will allow precise alignment of the components during reassenbly of the compressor. Attach lifting rig to the suction cover. Remove the remaining bolts securing the suction cover and remve it. Lightly coat all bare metal surfaces with compressor oil for protection from corrosion. Now, remove the third stage impeller. Mark the impeller for THIRD STAGE, A puller may be required for removal. Mark and remove the key and shims, after removing the impeller. Lightly coat all components with compressor oil to prevent corrosion. Identify and store these shims for reassenbly. Now, remove the bearing oil seal and gasket. Measure and record the seal clearance for wear indication. Measure the seal clear- ance all the way around. Proper clearances are 0.0005 inches minimm and 0.003 maximm, Mark the seal for TOP. This is impor- 7tant since the seal has a small ofl drain hole in the back which mst be correctly aligned during reassembly. Straighten the locle- ‘ing tabs and remove the hex head screws securing the seal and Basket. Notice the small drain hole located at the bottom of the bearing oil seal. Remove the bearing ofl seal momting plate and gasket, Mark the Plate for TOP, Remove most of the socket head screws. Remove the remaining screws, plate, and gasket. Lightly coat the plate with compressor oil. ‘nis ends the coupressor disassenbly procedure. Inspect all. com- Ponents for damage or excessive wear. Do not reassenble the compressor using faulty components. Clean each component and apply a Light coat of compressor oil to protect the components from moisture and corrosion (especially “o" ring and gasket surfaces), 18SECTION ONE Give Three symptoms that would require you to do an over- haul, What is the first thing you should do prior to working on a centrifugal machine? True or False: Moisture and dirt are the enemies of any centrifugal refrigeration machine, so while the machine is open, keep the refrigerant side as clean and dry as possible. Do this by taping all openings closed with plastic material to prevent foreign materials from entering the machine, ‘True or False: Before disassenbling the centrifugal machine, leak test the entire unit and tag all leaks. Caution: You must remove the before pulling the suction cover to avoid damage to the impeller nose. 19SECTION TWO @SECTION TWO COMPRESSOR MOTOR DISASSEMBLY The next section will describe the procedure for removal and replacement: of the CVHE motor and bearings. Jn this section DRIVE END refers to the shaft extension or compressor end of the motor. OPPOSITE DRIVE END refers to electrical terminal end of the motor. Figure ll & 12 ‘The motor bearings and rotor can be changed (after compressor disassenbly) without removing the entire motor from the chiller. We will start with the motor drive end bearing. This procedure also provides for inner bearing seal replacement. Go to the DRIVE END (shaft extension end) of the motor, Use rigging to support the motor shaft when removing components from the motor. There mst be shaft support at all times to prevent damage to the rotor. Remove the drive end bearing retaining bolts. The bearing should slide out rather easily using the jack bolt holes. If the bearing drags, inspect the shaft-to-bearing clearance. If the 23 |Joyerodeng dossaidwiog ug ang Bung ‘eysoddg xog feujuuey TOI pug eau Jossaiduozsyanasey “8 pics Sueten a at 9 A nauosavo I porn i ; $B. aan (Gy Dw \ mowanof” Soy 7 \ OFSH EH sos, e 7 OY) SS LAG 2 s j 1 Wate 2 | “omsvae 7 wmisaisa, / Ps Od. ono sul | sieve L Z ie ae Mat 19 ae BHSWM lea steve SE oui SS sm ner ones vero / sno OP Nob crmaran hoicnsae uw BASSBE96 (oA J) tee Suara oe, | | Le nro uvoa waives mauosavo _ ff toma Lr" ‘Ovan xan 2] NEVES wansvil ¢ “ascvn vanevninooy MSeOBavO p®@clearance is inadequate, move the shaft up or dom slightly until adequate clearance is obtained. Failure to provide adequate bearing clearance can result in damage to the shaft or bearing, After the bearing is removed from its housing, rest the bearing on the shaft. Protect the bearing and shaft from damage. Disconnect the 1/4" copper bearing oil supply line. ‘The line can be cut or unsweat, If cut, a coupling will be required for reassembly. It may be necessary to heat the area around the fittings to loosen the sealing compound and aid in removal of the fittings. Next, remove the seal bolts. Once the seal bolts have been removed, remove the drive end bearing bracket. Use guide pins to Support the weight of the bracket. The bearing can be moved out on the shaft and removed. Now remove the guide bolts and renove the bearing bracket, Remove the immer bearing cap seal. Inspect the seal and bearing for wear or damage. Place gasket material between the rotor and stator to prevent damage. The rigging can now be renoved, Cover the rotor shaft with cloth and tape to protect it, Now, go to the OPPOSITE DRIVE END of the motor. Renove the drain Line at this end of the motor. The paint should be removed from 26the lines prior to cutting the lines. Use sandpaper to remove the paint, and use a tubing cutter to cut the line. These joints will be recomected by brazing. All openings mist be sealed while work is in progress to prevent debris from contaminating the lubrication system. Remove the opposite end bearing inspection plate bolts, and the OPPOSITE DRIVE END bearing inspection plate. Remove the old "0" ring next, and clean the sealing surfaces of the plate, Remove the four 9/16" capscrews from the bearing retaining ring. Remove the bearing retaining ring. Now remove the bearing oil supply ine. Loosen the flare nuts on each end, then remove the line, Remove the eight 3/8" allen head screws which secure the bearing seal. ‘To insure proper component alignment when the motor and compress- or is reassenbled, drill two 1/4" holes in the motor end bell vhich will allow for installation of two dovell pins during reassenbly. ‘These holes mst be drilled before loosening the motor end bell retaining bolts. Make certain the dowel pins are installed before proceeding. Loosen the bearing bracket (motor end bell) retaining bolts. 27Remove two of the bolts and replace them with guide pins which are used to support the bracket and motor shaft weight. Remove the bolts retaining the bearing bracket. ‘There are two short bolts used in the electric terminal box area, These should be identified properly so that they are reinstalled correctly. Using the jack-bolt holes, remove the bearing bracket. The bearing bracket mist be separated from the outer ball bearing race. Separate the bearing bracket from the bearing race using a gentle back and forth rocking action. As the bracket is removed, it will drop slightly as the sealing surface is cleared (when the bracket has been moved out approximately 1/2"). Once the sealing surface 1s cleared, the bearing bracket can be lowered until the Totor rests on the stator, Extreme care mist be exercised to Prevent the bracket from jamming on the bearing, and to prevent movenent of the rotor assenbly, which could in tum damage the stator assembly. Remove the bearing bracket completely. At this point you would want to talk to the customer. Explain to him what you found wrong with the machine, and recomend the needed repairs. ‘The customer needs to know if additional parts or time is needed for the repairs. Your supervisor should be at this meeting, because the customer will have to approve any additional charges against the job. This commmication is very important to maintain good customer relations. 28DISCHARGE VOLUTE Our next operation will be replacing the discharge volute "0" rings. To do this we will remove the volute with the rotor and stator in place. Start by cutting the ofl drain line from the drive end bearing, Use sandpaper to remove the paint, then use a tubing cutter to cut the line, Use rigging to support the discharge volute. Set up rigging to support the motor. Put tension on rigging. Match mark the volute base to make reassenbly easier. Now remove the bolts that secure the volute to condenser. Remove the bolts that secure the mtor stator to the discharge volute. Pull the discharge volute straight out and away from the motor stator, Be careful to clear, and not hit, the rotor shaft. Lower the volute to the work area and remove the "0" rings. MOTOR ASSEMBLY Now, we'll cover motor reassembly. First, all parts mist be thoroughly cleaned and inspected for wear, Matching faces mist be perfectly clean and new "0" rings should be used. 29Clean all "0" ring grooves and mating surfaces and carefully look for irregularities in the surfaces. Then, clean everything with a solvent. We will start with the discharge volute replacing both the discharge and motor "O" rings. Apply a recommended sealer to the "0" ring grooves. ‘Then put the "O" rings in place. Start at the top and work your way to the bottom, Install a new coupling on the drive end oil drain line. Now rig the volute into place being careful not to damage the rotor shaft. With the volute in place and the match marks lined up start the bolts. With a few base bolts in place, start the mtor to volute bolts. With the motor to volute bolts started, go to the flange bolts, Start all the flange bolts, In this next section we want to check and record the motor bearing clearances. Use micrometers or dial calipers to measure the outside diameter of the drive end rotor shaft. Then use a telescope gauge to measure the inside dianeter of the journal bearing. Make several measurements 90 degrees apart, and get an average. To find the clearance, subtract the rotor shaft measurement from the journal, Compare this reading with Clearance Table 2. ‘The drive end bearing was found to be worn past the maximm and mist be replaced. Check for the correct clearance on the new 30replacement bearing. Now move to the opposite end and check the alignment of the opposite end bearing. Measure the Total Indi- cated Runout (TIR) at the five locations as shown in your work- book. Compare the runout for each race. The difference between the mmout for each side of the race should be minimal (0.0002 inches maximm difference). If the bearing rmout is not within specifications, the bearing will have to be aligned or replaced, Figure 13 Now, put a new gasket on the opposite end bearing ofl seal and make sure the oil drain hole is at the bottom. Next, install a new opposite drive end bearing bracket "0" ring, using a sealer. Lift the bearing bracket. The bearing bracket should be positioned on guide rods to support the weight. Install threaded rods into the opposite drive end bearing seal. When positioning the bracket, the threaded rod connecting to the inner seal must pass through the bolt holes in the bearing bracket so that the oil drain hole is on the bottom. Work the bearing bracket into position and secure it with several bolts. ‘The bracket should slide over the bearings with minimal force. If necessary, the bearings can be cooled with refrigerant to ease assenbly. Install the two dowel pins that were drilled prior to disassenbly. ‘These pins are necessary for proper location of the bracket so that the original compressor seal clearances are re- established. Tighten all bearing bracket bolts to the proper torque. 31#1 TIR #2 TIR #3 TIR #4 TIR #5 (FACE) TIR - ‘Measurement Locations for Determining Overall Total Indicated Runout of Thrust Bearing Assembly Figure 13 32@ Now, move to the drive end and install the drive end inner bear- ing seal and gasket. Make sure all components are clean and have been inspected for damage and wear. Remove the rotor protection. Use a new "0" ring and lift the drive end bearing bracket into place. Install guide bolts to support the drive end bearing bracket. Install two sections of 3/8" threaded rod to hold the immer bearing seal and gasket in place. MAKE CERTAIN THE BEARING SEAL OIL DRAIN HOLE IS AT THE BOTTOM. Once the guide pins and threaded rod from the bearing seal are aligned, slide the drive end bearing bracket into place. Figure 14 Figure 14Start the bearing bracket bolts and remove the alignment bolts. ‘Tighten the bearing bracket bolts to the proper torque. Now, the drive end bearing. Slide the bearing onto the rotor stopping just before contacting the bearing surface of the shaft. Oil the bearing and rotor shaft. Support the rotor shaft with rigging, lifting slightly until the bearing is aligned and will slide into place easily, The bearing should not drag during assenbly. Any difficulty in reassenbly is probably due to misalignment, Do not try to force the bearing into place, since this may result in damage to the bearing. Reposition the shaft as necessary. Use the special ramp washers, and start the bearing bolts, tightening to the proper torque. Then use feeler gauges to align the inner seal. Start the seal bolts. When the seal is aligned, tighten the seal bolts. Now move to the opposite end, Set the opposite drive end inner bearing seal in place and install two ‘socket-head screws to hold the seal firmly in place, The seal is adjusted by moving the threaded rod up or dom. The seal mist be centered. Once the seal is located, the seal retaining bolts should be tightened to 24 ft-lbs. torque. ‘The inner bearing seal must be aligned and installed before the retaining ring because the retaining ring covers the bearing seal bolts. The outer race of the bearing should extend approximately 1/16" beyond the bearing bracket. If not, the bearing seal is 34not seated properly and the bearing will be able to float causing extensive compressor damage. Replace the bearing retaining ring and tighten the bolts. ‘This retaining ring provides a clamping force on the bearing outer race to prevent it from rotating, Torque the retaining ring bolts to the proper torque. Next, the opposite to the drive end inspection cover. Slide a coupling over the ofl drain line, Use a new "O" ring, install the cover and replace the bolts. Tighten the bolts to the proper torque. Now move to the drive end, Set up a dial indicator and measure the rotor shaft rmout. ‘The maximm allowable total indicated runout is 0.0012 of an inch at the end of the shaft. There should be no end play. Next, set up a dial indicator to check the thrust. Total end float is 0.004 of an inch maximm and 0,002 of an inch minimm, ‘The motor assembly is now complete and ready for compressor reassenbly. 35SECTION TWO 1, In this section, refers to the shaft extension or compressor end of the motor. fu refers to electrical terminal end of the motor. 2. ‘True or False: Volutes must be removed when servicing or HEH replacing the rotor and motor. 3. True or False: The CVHE bearings and rotor can be changed (after compressor disassenbly) without xemoving the entire motor from the chiller. 4. ‘True or False: ‘To insure proper component alignment when the motor and compressor is reassenbled, drill two 1/4" holes in the motor end bell which will allow for installation of two dowel pins during veassenbly. 5, ‘True or False: Both rotor shaft runout and thrust must be checked to complete the motor reassenbly. 36SECTION THREESECTION THREE (COMPRESSOR REASSIMBLY In this module, we'll cover compressor reassenbly, including spacing the impellers. First, all parts mist be thoroughly cleaned and inspected for wear. Matching faces mst be perfectly clean and new "0" rings should be used. Next, clean all "0" ring grooves and mating surfaces and careful~ ly look for irregularities in the surfaces. Then, clean every- thing with a solvent. Next, inspect all parts. Clean the impellers and compressor shaft. Inspect the impeller for wear, cracks, warpage and scratches on the seal surface, If there are scratches deeper than 1/16", replace the impeller. Inspect the impeller keyway using dye penetrant. Discard the impeller if cracks are found. Clean the seal and all mating surfaces using solvent and a lint-free rag. Examine the labyrinth grooves for excessive wear. If the seal is found to be outside of the specifications given in Table 1, replace the seal. Figure 15 With all the parts inspected we will reassemble the compressor. First, use a torch to reconnect the bearing oil seal supply Line, 39= Ss i = | vane: | oeeetion o> | SeScuocy 77 beTAIL A I One nee caswer | i COVER eSNG | tA | | & IA sce DETAL Leven ( IMPORTANT i i wana aseveeh ASTOR - ‘ASSEMBLY iA) 4 O-RING J os Xx ‘SPRING NS WASHER ZZ - ld Aree 7 eH: Sige __vevs__MPRLLER fe Locanut vy G Yj a ‘Lockwasien st SN (sheer PAST STAGE ‘soncen FyOse Sea “ NS SECOND St ene J sa FEONO Stace fpserserew Ol. SEAL iA ky rg a We iN wk AN Z| 3 O earn NZ On SEAL seconn eas soucmnet Sate Pate OmFrUSen PLATE SEAL eran NMEELER | j Figure 15 \ 40Next use guide bolts to install the bearing oil seal mounting plate. Replace the bolts and tighten the bolts to the proper torque. At this point, we would install the bearing ofl seal, Install the seal with new gasket and tab or ramp washers and bolts. INSTALL THE SEAL WITH THE OIL DRAIN HOLE IN THE BACKSIDE OF THE SEAL FACING DOWN AND TOWARDS THE MOTOR. Tighten the retaining bolts very lightly. Use feeler gauges to set the seal clearance. Set the seal-to-shaft clearance at 0,002" minimm and 0,004" maximm, Tighten the retaining bolts to 24 ft.-Ibs. and then recheck the clearance, Bend the tabwashers to secure the bolts. Figure 16Next, install the third stage impeller. Insert the impeller key and install the impeller with the keyway in the up position. Slide the impeller on the shaft. Add shims as necessary to line up the innermost discharge surface of the impeller with the diffuser plate. The surfaces mst be level with one another or, at most, the impeller surface may be no more than 0.005 inches above the diffuser plate surface, Measure the impeller nose runout. Mount the dial indicator. Rotate the impeller by hand and observe the dial indicator. ‘The maximm allowable nose runout on the impeller is 0.003 inches. If the mmout exceeds this amount the shims should be inspected for the presence of foreign material. Recheck the rmout. Replace the impeller if runout is still excessive. Figure 17 42Next, install the third stage suction cover casting. Clean dirt, debris and oxidation from the suction cover using a solvent which leaves no residue, Clean the "0" ring groove. There should be no nicks or chips in the "O" ring groove which might deform the "Oo" ring, Remove all old sealing compound from the "0" ring groove, and also clean the miting surface. Use a new "0" ring. Install the suction cover. Insert retaining bolts to secure the cover. Align the scribe marks which were made during disassenbly. Install the two alignment pins into the holes that were drilled prior to disassenbly, then tighten the retaining bolts. Figure 18 Figure 18 Next, install the impeller nose seal. Clean the seal to remove all dirt and debris. Inspect the labyrinth grooves for wear or 43damage. Replace the seal if cracked, warped or worn beyond clearance tolerances, If the seal is reused, be sure it is in- stalled with the TOP in the proper position. Install the seal and lightly tighten the bolts with tabwashers in place. Set the seal radial clearance according to Table 1. Use feelers gauges to set the clearance, IE a new seal is used and the clearance is too tight, the seal may be lightly sanded with a fine grade of sandpaper to achieve the proper clearance. ‘Tighten the seal bolts to 24 ft.-Ibs. end recheck the radial clearance, Readjust as necessary. Bend the locking tabs. Next, install the third stage inlet vane assembly. Clean the assembly with solvent and a lint-free rag. Lf any of the inlet vane assembly components are worn excessively, replace the assenbly, Lift the assembly into place. Tighten the 1/4"-20 flathead screws to 6 ft.-Ibs. torque. ‘The head of these screws must not protrude into the diffuser passage. The second stage diffuser plate is installed next. Using solvent and a lint-free rag, clean all dirt, debris, oxidation, ete. from the plate and mating surface. Move the diffuser plate into posi- tion, Make sure the TOP is positioned properly. Install the shim that was between the spacer and the impeller. ‘The steel shim is necessary to prevent aluminum-to-aluminum contact. Next, install the impeller spacer. Thoroughly clean the spacer. Lubricate the adspacer with compressor oil, Install the spacer with the pull-off holes away from the motor and align the reference mark made dur- ing disassenbly, Use the second stage impeller to center the plate. There must be equal distance around the impeller, With the diffuser plate centered around the impeller and shaft, secure the diffuser plate with socket-head capscrews, and tighten to 24 ft.-Ibs. Minimm radial clearance between the impeller and diffuser plate is 0.030 inches, Now, install the second stage shaft seal. Clean the seal and inspect the labyrinth grooves for excessive wear. Install the seal with the TOP in the correct position. Secure the seal loosely with bolts and locking tabs. Set the seal clearance using feeler gauges at 0.018 inches minimm, and 0.024 inches maximum radial clearance. If a new seal is used and the clear- ance is too tight, the seal may be lightly sanded with a fine grade of sandpaper to achieve the required clearance. After the proper clearance is set, tighten the retaining bolts to 24 ft.-Ibs. Recheck the seal clearance and adjust position as necessary. If everything is okay, bend the locking tabs. Now install the second stage impeller. Replace any impeller shims. Insert the key and install the impeller with the keyway up. Add shims behind the impeller, as necessary to line up the imemost discharge surface of the impeller with the diffuser plate surface. ‘he surface mist be level with one another or at 45most the impeller surface may be no more than 0,005 inches above the surface of the diffuser plate. Measure the impeller nose runout by mounting a dial indicator. Rotate the impeller by hand and observe the dial indicator. The nose runout tolerance is 0,003", T£ the runout exceeds 0.003", look for burrs or debris between the impeller shims. Recheck the runout. Replace the impeller if runout is still excessive, Next, install the second stage suction cover, using a new "O"ring. Rig the suction cover and move it into position. Do not bump or damage the impeller or shaft during this process, Install the suction cover retaining bolts tightening them te 150 £t.-Ibs. Figure 19 Figure 19 46Next, install the second stage impeller nose seal with TOP properly positioned. Lightly tighten the 3/8" bolts with locking tabs in place, Set the seal clearance according to Table 1. Tighten the retaining bolts to 2h £t.-lbs. and then recheck the clearance, adjusting if necessary to achieve the proper clear- ace, Bend the locking tabs over. If the clearance is too tight, the seal may be lightly sanded with a fine grade of sand- Paper to achieve the proper clearance. Now, install the second stage vane shroud. Clean the shroud and all mating surfaces using solvent and a lint-free rag. Lift the shroud up and into place, installing it with the TOP correctly positioned. Tighten the 1/4"-20 flathead screws to 6 ft.-Ibs. ‘The heads of these screws must not protrude into the diffuser Passage. Install the shim that was between the spacer and the impeller. The steel shim is necessary to prevent aluminum-to- aluminum contact. Next, install the first stage diffuser plate. Clean the plate and all mating surfaces using solvent and a lint-free rag. Lift the diffuser plate into position with top correctly positioned. Start the diffuser plate bolts. Use the first stage impeller to help position the diffuser plate. he diffuser plate must be centered with respect to the impeller, and the diffuser will have to be raised to center it. Use feeler gauges to obtain equal clearance around the impeller. ‘The minimm clearance is 0.030". With the diffuser plate centered around the impeller, secure the 47diffuser plate with sockethead capscrews and tighten to 2 ft.-Ibs. Next, install the impeller spacer, which should be thoroughly cleaned with solvent and a clean lint-free rag, and lubricated with compressor oil. Install the spacer with the pull-off holes away from the motor and align the reference marks made during disassembly. Install the first stage shaft seal, Clean the seal and all mating surfaces using solvent and a lint-free rag. Examine the labyrinth grooves for excessive wear, Replace the seal if it is found to be outside of the specifications. Install the seal with the TOP correctly positioned. Lightly tighten the retaining tolts with tabs in place. Set the seal clearance at between 0,018" minimum and 0,024" meximm, Tighten the bolts to 24 ft.-Ibs, and recheck the clearance, Readjust the clearance as necessary. Bend the tabs, If the seal is new and the clearance is too tight, the seal may be Lightly sanded with a fine grade of sandpaper to achieve the proper clearance. Install the first stage impeller. Install the shim that was between the spacer and the impeller, Insert the key and then install the impeller with the keyway up. Add shims as necessary to align the immer discharge surface of the impeller with the first stage diffuser plate surface. The surfaces mst be level with one another or at most, the impeller surface may be no more 48than 0.005" above the diffuser plate surface. Also recheck the impeller to diffuser plate radial clearance. The clearance between the impeller and diffuser plate mist be no less than 0.030", Now, install the spring washer. NOTE: The spring washer mst be installed so that it compresses and flattens towards the impel- Jers. ‘Therefore, the tapered portion must be such that it tapers towards the compressor motor. Now, install the impeller lockwasher and locknut, The locknut should require only mmual force until it mikes contact with the spring washer. Tighten the lockmut to achieve solid metal-to- metal contact. This is approximately 115 ft.-Ibs. torque. Care Figure 20 49must be taken to compress but not completely flatten the spring- washer, Also, the locknut must be positioned such that a lock~ \ washer tab aligns with a slot in the locknut. Bend the lockwasher tab over and into the locknut slot. Figure 20 Figure 21 | Measure the first stage impeller nose runout, Mount the dial indicator on @ solid surface. Rotate the impeller by hand and observe the dial indicator. The runout must not exceed 0.003". ( 50If the runout exceeds this tolerance, inspect behind the impeller for burrs or debris between the shims. Recheck the runout, and if the runout is still excessive, replace the impeller. Figure 21 Next, install the first stage suction cover. Thoroughly clean the suction cover and all mating surfaces. Clean the ring Brooves. Use a new "0" ring. Then using the special rigging tool move the suction cover into place. Align the scribe marks on the outside of the cover with the scribe marks on the mating surfaces. Install the two alignment pins into the holes that were drilled prior to disassembly, This will insure proper alignment when the compressor is completely assembled. Replace the suction cover bolts and tighten to 150 £t.-1bs. Now, install the first stage impeller nose seal, Install the seal with the TOP correctly positioned. Lightly tighten the retaining bolts. Set the seal clearance according to Table 1. Tighten the 3/8" bolts to 24 ft.-Ibs. Bend the tabs over. Re- cheek the seal clearance and readjust the clearance as necessary. Turn the impeller by hand to make sure the compressor turns free. Install the first stage inlet vanes, Clean the inlet vane assembly. Inspect the components for excessive wear or damage. Replace as necessary. Insert the assembly into the suction cover. This may be accomplished using the other special rigging 31fool. Be careful becsuse the vane assembly will not stay in Position without holding it there. It is very possible that the assoubly will slide out of position unless it is held there. Fosition the inlet vane assembly so that when inserted into the suction cover the tang operator comects with the proper drive vane. Secure the assenbly with three 5/16" setscrews. Minally, install the suction elbow, Remove the protective covers which were installed during disassembly. Clean the suction elbow and all mating surfaces, Pay particular attention to all gasket surfaces and "0" ring grooves. Use a new "Ol ring, The suction elbow my be Lifted using a sling, Set the suction elbow in Place and start tightening the retaining bolts. Well, that does it. In this program we covered: - Safety considerations - Tools needed - Pre-Disassenbly procedures - Disassenbly procedures - Inspecting the internal parts > Recording clearances ~ and Reassenbly After the compressor is completely reassenbled, the chiller mst be Testarted as if it were a new chiller. This includes replace ‘ing the oil filters, pressure testing the chiller, evacuation, charging and all other procedures included in the initial start- up of a new chiller. 52SECTION THREE ‘True or False: Inspect the impeller for wear, cracks, warpage, and scratches on the seal. surface, If there are scratches deeper than 1/16", replace the impeller. True or False: Inspect the impeller keyway using dye penetrant. Discard the impeller if cracks are found, ‘True or False: Feeler gauges should not be used to check the laby seal. clearance. ‘True or False: A magnetic base and dial indicator should be used to check the impeller nose runout and record the read- ings. True or False: Be cautious and don't mix the first stage and second stage inpeller spacing washers.