Heavy Duty Balanced Opposed Compressors

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FOR MODELS: JG AND JGA SECTION 5 - MAINTENANCE screw until snug using a criss-cross pattern. Next tighten each cap screw to 25% of full torque, moving from cap screw to cap screw in a criss-cross pattern. Repeat this step for 50%, 75% and 100% of full torque. See Table 1-15 on page 1-15 for tightening torque value. Reconnect VVCP packing vent. When installing a new VVCP, check total piston end clearance and re-set crank end/head end feeler clearances with VVCP completely closed. See Table 1-2 on page 1-8 for clearances. Adjustment VVCP clearance volume may be changed with the compressor running or stopped. Consult the Packager’s instructions regarding where to set the VVCP. Also reference the VVCP data sheet in the Ariel Technical Manual Parts Book. The VVCP piston ring is designed not to be gas tight, to allow a nearly balanced gas pressure for ease of VVCP adjustment with the cylinder pressurized. Gas pressure behind the VVCP piston normally vents when cylinder is vented. Process debris or rust around the piston ring can make a seal that takes some time to vent. If gas is trapped behind the piston, the VVCP can be adjusted when the cylinder is pressurized, but difficult to turn when the cylinder is vented. This problem is corrected by disassembling the VVCP and cleaning. To adjust the volume, loosen the stem locking handle, so that stem is free to turn. Turn the stem by use of the hand wheel on the outboard end of the shaft. Turn hand wheel clockwise to load; counterclockwise to unload. Re-tighten the stem locking handle to 150 lbs-ft (203 Nm) torque. Compressor Cylinder Compressor Piston & Rod Assembly VVCP Piston Ring (not gas tight seal) VVCP Assembly VVCP Packing Trapped Gas Pressure FIGURE 5-20: CYLINDER WITH VVCP - TYPICAL VVCP Packing Vent O-Ring Grease Fitting Stem & Piston Hand Wheel Thread Protector Bellows Locking Handle PAGE 5 - 36 11/01
FOR MODELS: JG AND JGA SECTION 5 - MAINTENANCE Water-Cooled Compressor Rod Packing When any disassembly of water-cooled rod packing cases is required, proper re-assembly and testing is required. This is to ensure that the cases do not leak. Re-assembly Cases are lapped, and care must be taken to prevent scratching of the mating surfaces of the cups. Scratches can cause significant leakage problems. The cups are numbered on the outside diameter and are to be assembled in consecutive order, starting with the end cup. The studs are offset so the cups will only fit one way. Make sure the tie studs are completely screwed into the end cup. Put the proper ring in the groove and facing the proper direction. Be careful when sliding parts onto the tie studs to ensure that no scratching occurs to the lapped faces. Install second cup next, put the rings into place, and make sure the two (2) small O-rings are in place around the coolant holes. Continue assembling the remaining parts in the proper configuration to the packing case drawing. In consecutive order, by repeating the above step. Install tie stud-nuts and tighten to the values given in Table 1-15 on page 1-15. Using fingers, make sure that all rings move freely, radially, in their grooves. Side loaded AL rings will be snug, but should still move using fingers. Testing 100% verification of function is required for all internal passages. The passages are to be checked by blowing compressed air thru the connection taps on the flange and verifying that air is exiting at the proper holes. When air is applied to the connection tap stamped “Coolant In”, air should be exiting the connection tap stamped “Coolant Out”, or if air is applied to the tap stamped “Lube”, air should be exiting at the appropriate cup on the inside diameter of the case. Pressure leak test packing cases as follows: 1 Plug the “Coolant Out” connection> 2 Apply 60 to 100 psi (400 to 700 kPa) dry, compressed air pressure to the “Coolant In” connection. For water cooled rod packing cases in non-lube service, compressed air is to be oil free. Air should exit at connection tap “Coolant Out”. Air applied to the tap stamped “Lube” should exit at the appropriate cup on the inside diameter of the case. 3 Plug the “Coolant Out” connection and apply 60 to 100 psi (400 to 700 kPa) dry, compressed air pressure to the “Coolant In” connection through a ball valve with a calibrated pressure gauge located between the ball valve and packing case. Close the ball valve and disconnect the air supply. There should be no pressure drop for 5 minutes minimum. 4 If water cooled packing cases are used in lubricated applications, leak testing may be done by submersing the packing case in oil with 10 to 100 psig (400 to 700 kPa) test air pressure. After the air trapped in the ring grooves has been 11/01 PAGE 5 - 37
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