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Single screw compressor presentation

Working principle & inspection guidelines


Internal Use Only

Daikin Single G-type Screw


Compressor

G - Type Single Screw R134a


Up to 90 KW120 Hp

R407C
Up to 135KW/180 Hp

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Internal Use Only

Stepless Single Screw Compressor


History
step control step control

F-type G-type G-type stepless


time
2000 2003 2005
Robustness, reliability = Robustness, reliability
Performance = Performance
1988 Dimensions = Dimensions
ZH13L & ZH15L Limited control (stepped) ≠Extended control (stepless)

The stepless compressor is a DAIKIN development !

Designed, tested and manufactured in Daikin’s own laboratories.

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Internal Use Only

G type compressor
• Nomenclature

3-5-7-9 sizes

G, G4 = step
GU,G5, G6 =Stepless

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Internal Use Only

G type compressor with step control


G-type step range from 30KW to 135 KW

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Internal Use Only

G type compressor with stepless control


G-type stepless range from 30KW to 135 KW

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Internal Use Only

The single, mono or globoïd screw

Satelite driven by 2-pole motor


Or Gate Rotor =
Special composite
Open end
material

Closed end
12 x 2900 = 34,800 compressions per minute = continuous flow !
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Internal Use Only

Gate rotor and gate rotorshaft

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Internal Use Only

The G-type screw compressor

Oil separator Compression Motor &


& capacitycontrol section suction section

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Internal Use Only

The Heart of the single screw compressor

Oil separator Compression Motor &


& capacitycontrol section suction section
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Internal Use Only

The flow inside compressor

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Internal Use Only

Compression
Principle

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Internal Use Only

G-type screwcompressor
• Compression principle

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Internal Use Only

Capacity adjustment design

Loading & Unloading


Mechanism

G types until 2005 G types from 2005


step control stepless control
3 to 4 fixed capacity steps Continuous control
F types between 30 and 100%

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Internal Use Only

Capacity adjustment design step

Step control
Principle
Is based on internal
pressure differences

Selection of capacity
step with solenoid
valves
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Internal Use Only

step control/essential parts


• Capacity solenoid valves

12%
40%
12

70%
12

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Internal Use Only

step control/essential parts


• Sliding vanes with bridge and springs

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Internal Use Only

step control/essential parts


• Slide vane bridge with capacity cylinder/piston

12%
40%
70%
Springs

40 12
70 %
% %

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Internal Use Only

Capacity adjustment design

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Internal Use Only
Step control system

Dynamic Force by
springs
pressure Spacer
point Hi press
Screw rotor

Dynamic
Pressure
Pressure
dHp
Point Hp
SV1=12%
Energized = open !
SV2=40%
dHP= Hp + 2 kg/cm²
Low pressure side Time SV3=70%
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Internal Use Only

Hi press

Compressor start
Compressor loads-up to 40%
12%
SV1 closes = de-energized
Low press. side
capacity
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Internal Use Only

Hi press

Compressor loads-up to 70%


40%
SV1 and 2 close = de-energized
Low press. side
capacity
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Internal Use Only

12%
40%
70%

Compressor loads-up to 100% 70%


SV1,2 and 3 close = de-energized
Low press. side
capacity
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Full travel approx. 4cm Internal Use Only

Hi press

Full Load =
All solenoid valves are de-energized !

Low press. side

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Internal Use Only

Capacity adjustment design stepLESS

Stepless control
Principle
Is based on internal
pressure differences

Regulation of stepless
capacity step with motor

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Internal Use Only

Stepless Single Screw Compressor

STEPLESS capacity regulation

The compressor has built-in capacity control by 30 – 100%


by stepless slide valve mechanism, and adjustable volumetric ratio
Chiller Load Chiller Load

100% 100%

30%
Starting position 15% Starting position
12% 12% Demand
Demand

Single Circuit Double Circuit

Designed, tested and manufactured in Daikin’s own laboratories. 26


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Internal Use Only

G type compressor with stepless control


12 % solenoid

Step / motor module

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Internal Use Only

stepless control/essential parts


Slide vanes Slide vanes with bridge

Pilot valve/ special piston stepmotor

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Internal Use Only

Stepless Single Screw Compressor


STEPLESS capacity regulation
How does it work ?

Pilot Valve + cylinder

Loading and unloading via Pilot Valve:

-Pilot valve is driven by rod mechanism

-The rod mechanism is driven by


shaded-pole motor

Loading
Unloading
High pressure side
Rod mechanism

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Internal Use Only

Stepless control
STEPLESS capacity regulation
How does it work ?

Pilot Valve

Balancing hole
Bleedhole for pilot valve

High pressure side


Rod mechanism
 Loading
 Unloading
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Internal Use Only

Stepless regulation/pressure difference


Sliding Vane Spring

HP (High Pressure) Load/unload


mechanism

HP = High pressure =
HP Pressure of refrigerant at
HP dHP discharge port
dHp = dynamic high
pressure =
Pressure of refrigerant at
Piston just before discharge port =
HP dHP dHp slightly > HP

Main screw

Dynamic HP HP (High Pressure)

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Internal Use Only

Stepless Single Screw Compressor


Sliding Vane Spring
@ 100%
Gate rotor HP (High Pressure)
Position of
PILOT VALVE
is not changed!
Load/unload
HP mechanism
Low Pressure HP dHP Small bleed
Towards LP-
side
(Indicated by the green circle)

Pilot Valve (ΔP = 2kg/cm²)


Low Pressure
HP dHP HP+ spring = dHP

Main screw
SLIDING VANE
Dynamic HP HP (High Pressure) stays @
Rod mechanism driven position 100%
Bearing of the rotor by shaded-pole motor
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Internal Use Only

Unloading
Stepless Single Screw Compressor from 100% to 90%
Position of
pilot vane @ 100%
moves to right
side
(towards 90%) Position of
PILOT VALVE
moves right

HP
Low Pressure HP dHP Bigger bleed
Towards LP-
side

HP+spring > dHP


Low Pressure
HP dHP

SLIDING VANE
moves to right
decrease CC

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Internal Use Only

Stepless Single Screw Compressor


@ 95%
Position of
PILOT VALVE
moves right

HP
Low Pressure HP dHP Bigger bleed
Towards LP-
side

HP+spring > dHP


Low Pressure
dHP
HP

SLIDING VANE
moves to right
decrease CC

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Internal Use Only

Stepless Single Screw Compressor


@ 90%
Position of
PILOT VALVE
is not changed!

HP
Low Pressure HP dHP Small bleed
Towards LP-
side
(Indicated by the green circle)

(ΔP = 2kg/cm²)
Low Pressure
dHP
HP HP+spring =
dHP

SLIDING VANE
stays @
position 90%

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Internal Use Only

Stepless Single Screw Compressor


Bypass Dyna
Press to Lp
@ start
Position of
PILOT VALVE
Y11S – 12% Completely to
the right!
HP
dHP bleed DP
Low Pressure HP 0% pos Towards LP-
side
Via 12% valve
No further
Low Pressure HP dHP cap% build up
possible

SLIDING VANE
stays @
position 12%

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Internal Use Only

Stepless Single Screw Compressor


• Start up sequence
capacity
100%

30%

Upload
possible

12 %

0% 20 s 40 s 120 s

180 S

Time
Compress
Start
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Internal Use Only

Stepless Single Screw Compressor


SLIDING VANE does not move
Small bleed no CC change
• HPz dHP
Towards LP-
Chiller Load

Position of 100%
LP PILOT VALVE side
Does not move t0 = t1
15%
HP+spring = dHP Demand

SLIDING VANE moves to right


Bigger bleed decreased CC
Chiller Load
HP dHP Position of Towards LP- 100%
LP PILOT VALVE side t0
moves RIGHT
t1
15%
HP+spring > dHP Demand

SLIDING VANE moves to left


NO bleed increased CC
Chiller Load
HP dHP Position of Towards LP-
100%
LP PILOT VALVE side t1
moves LEFT t0
HP+spring < dHP 15%
22-Apr-18 Demand
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Internal Use Only

Stepless Single Screw Compressor


• Step motor feedback principle Feedback from potentiometer
Vcc
Vcc = 21V Single circuit
(double circuit)
V+ input GND Vcc = 12V double circuit
V pot
Vpot= Vcc * Rpot
Red (6) or black (4)

Rpot + R 470
5
white

R 470

R Pot

Potentiometer Output

@ 100% R=+/- 125 Ohm

@ 30% R=+/- 35 Ohm

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Internal Use Only

Stepless Single Screw Compressor


• Stepmotor steering for Analog out 5V
J4-VG A1P A0

• ZH(A)(C)3,5
J4 Y1 J4-Y2

V Comm Optocouplers

TCO1
Loadup Loaddown
TCO1 TCO2
A1 A1

TCO2

A2 A2

GND

Resistance value
towards analog input
ctrl

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Internal Use Only

Stepless Single Screw Compressor


• Stepmotor steering for Analog out 5V
J4-VG A1P A0

• ZH(A)(C)7,9
J4 Y1 J4-Y2

V Comm Optocouplers

TCO1
Loadup Loaddown
TCO1 TCO2
A1 A1

TCO2

A2 A2

GND

Resistance value
towards analog input
ctrl

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Internal Use Only

Stepless Single Screw Compressor


• Stepmotorconnections
ZH.. 3& 5 types ZH.. 7&9 types

VM30APTE VM30APZTE

Motor connection
On terminals 2-3
To be switched

GND
GND

230V from SSR’s 230V from SSR’s

Towards anaog Towards analog


input controller input controller

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Internal Use Only

Single screw compressor


Oil and Liquid injection design

Simplified
Reduces
Lubricates
Cools
Sealsoil sound
management

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Internal Use Only

Single screw compressor


• Liquid injection point (fixed oriffice) Cool Main screw

• Never shut off,


during operation
compressor

• For pumpdown use


integrated pump
down function of
controller
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Single screw compressor


• Liquid injection piping
(example for EWAD MBY)

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Internal Use Only

Single screw compressor

Periodic Inspection

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Internal Use Only

Single screw compressor - Inspection

Periodic Inspection - Check points

 Insulation Resistance of the Motor.

 Inspection/Changement of the Refrigerant Oil.

 Inspection the Gate Rotor.

 Cleaning the Suction filter.

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Internal Use Only

Single screw compressor - Inspection


Check points

 Insulation Resistance of the Motor.

After 1year of operation.


Use a 500-V megger.
Loose all the wires.
Measure between the phases
Measure between the CTP and phases
Measure between earth, CTP and phases
Value >= 3MΩ

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Internal Use Only

Single screw compressor - Inspection


Check points

 Inspection/Changement of the Refrigerant Oil.


Take a oil sample on one of the two oil drain ports.
Check oil (color, acid test, moisture, …)
Reduce the pressure (pump down).
Recover the internal rest pressure.
Take a oil sample on one of the two oil drain ports.
Check oil (color, acid test, moisture, …)
After 7500 hr or 4 years operation. Adviced to change oil

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Internal Use Only

Single screw compressor - Inspection


• Oil drain ports

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Single screw compressor - Inspection


• Oil charging port & service port (vacuum pump)

Service port

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Single screw compressor - Inspection


Surface
Check points yellowing

 Inspection the Gate Rotor

scar
After 20000 hr or 4 years operation.
Reduce the pressure (pump down).
Recover the internal rest pressure.
Remove the side covers.
Inspection of the gate rotor.
Item Standard Remedy
Cracking No cracking
Chipping No chipping 3 mm or
more in long side Replace
Scar No scar 1 mm or deeper
Surface scratching
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Single screw compressor - Inspection

Check points

 Inspection the Gate Rotor

Measuring the slit clearance (60 to 90 μm).

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Single screw compressor - Inspection

Check points

 Cleaning the Suction Filter

After 20000 hr or 4 years operation.


Reduce the pressure (pump down).
Recover the internal rest pressure.
Disconnect the suction pipe.
Clean the suction filter with compressed air.

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Internal Use Only

Single screw compressor

Overhaul

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Internal Use Only

Low Maintenance Costs


Only three rotating parts ...

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Internal Use Only

Low Maintenance Costs … and two sliding parts


NO O-rings
NO gaskets

Sealing via
oilpressure

NO Oilpump

Oilcirculation
due to differntial
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pressure 57
Internal Use Only

Single Screw Compressor - Overhaul

Overhaul (see service manual Si50-402A)

• Overhaul interval:40.000 hrs or 7 years, wichever comes first


• Change of oil
• Change of gate rotors if needed + O-rings
• Change of all gaskets and O-rings
• Change of all bearings (mainscrew and gaterotor bearings
 Complete dismanteling of compressor needed

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Internal Use Only

Single Screw Compressor - Overhaul


Overhaul Instructions Chart (See Service Manual SiE50-402A)

1. Disassembly and Inspection


 Drain The Oil
 Remove Side Covers
 Inspection of The Gate Rotors and Surrounding Parts
 Dissamble The Gate Rotor and Surrounding Parts
 Remove and Install The Gate Rotor
 Remove The Suction End Cover
 Remove The Motor Rotor
 Disassemble The Loading/Unloading Mechanism
 Remove and Disassemble The Screw Assembly Pulley

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Internal Use Only

Single Screw Compressor - Overhaul

Overhaul Instructions Chart(See Service Manual SiE50-402A)

2. Replacing The Bearing


 Remove The Bearings
Suction end cover bearing (Outer ring)
Screw shaft bearing (Inner ring)
Main bearing (matched pair)
Gate rotor bearings ( 4 )

 Install The Bearings

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Internal Use Only

Single Screw Compressor - Overhaul

Overhaul Instructions Chart (See Service Manual SiE50-402A)

3. Final Assembly
 Assemble The Screw Shaft and Main Bearing Holder
 Insert The Screw Shaft
 Install The Motor Rotor
 Install The Suction End Cover
 Verify The Position of The Screw Rotor
 Install The Gate Rotor and Adjust The Slit Clearance
 Install The Main Bearing Holder Fixing Plate, Assemble The Loading/Unloading
Mechanism and Instal The Oil Filter
 Install The Discharge End Cover

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Single Screw Compressor - Overhaul

Overhaul Instructions Chart (See Service Manual SiE50-402a)

4. Airtightness Test

 Using dry air mixed with refrigerant, or Nitrogen, pressurize to A

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Single Screw Compressor - Overhaul

Overhaul Instructions Chart (See Service Manual SiE50-402a)

5. Charging Oil

 Charge the same quantity of oil removed during disassembly


 Devide the quantity over the suction and discharge side

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Internal Use Only

Single Screw Compressor - Overhaul

Overhaul Instructions Chart (See Service Manual SiE50-402a)

6. Caution in Test Operation

 Check the tightness of all bolts


 Check wiring connection
 Check pressures
 Check noise and vibrations

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Single Screw Compressor – Overhaul pics

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Internal Use Only

Stepless Single Screw Compressor


• 12 % solenoid valve

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