screw compressor (aerzen vro 125l)

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Rev. 0 Jan 2018 1 ©

Screw Compressor Pump – INSTRUCTOR MANUAL

SCREW COMPRESSOR

(Aerzen VRO 125L)

Date Revision Prepared by Checked by Approved by 26-01-2018 0 PCM BB


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Table of Content

Table of Content ....................................................................................................................... 2

1. Instructor Note: ............................................................................................................ 4

2. Introduction .................................................................................................................. 4

3. Objectives: ..................................................................................................................... 5

4. Prerequisites .................................................................................................................. 5

5. Materials and tools ....................................................................................................... 5

6. Screw Compressor principle ....................................................................................... 6

7. Construction of the Screw compressor ....................................................................... 7

8. Screw compressor specifications ................................................................................. 8

9. Maintenance on compressor ...................................................................................... 10

10. Safeguarding Pump (L.O.T.O.) ................................................................................. 11

11. Storage and transport ................................................................................................ 11

12. Oil supply .................................................................................................................... 11

13. Cooling ......................................................................................................................... 12

14. Detail of sealing variants in general .......................................................................... 12

15. Sealing of the compressor (fig. 4, OZV-874) ............................................................ 15

16. Inspection report ........................................................................................................ 15

17. Gearbox drive shaft and cover removal ................................................................... 15

18. Gearbox disassembly .................................................................................................. 22

19. Removal gearbox main body (OZV-874 – 3) ........................................................... 23

20. Removal of bearings gearbox side main and secondary rotors .............................. 24

21. Removal wheel case (Dwng OZV-874 – 11) ............................................................. 28

22. Removal intake side plate with rotors ...................................................................... 29

23. Removal of Rotary seals from main body ................................................................ 30

24. Drawing 1ZVG-12 ...................................................................................................... 32

25. Drawing OZV-874 ...................................................................................................... 33


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26. Inspect, clean and measure parts .............................................................................. 34

27. Assembly screw compressor ...................................................................................... 34

28. Finally .......................................................................................................................... 36

29. What did you learn? ................................................................................................... 36


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1. Remove the oil from the compressor housing into a collection bin by opening the drain plugs of the compressor housing and the main body of the compressor.

2. There are several drains plugs

Check the oil

Ø Dark oil; tells the temperature has been too high and probably contains metal particles. If a plug has a magnetic end piece, metal particles cam tells there is a worn-out bearing. If not use a magnet on the bottom of the can with removed oil to search for metal.

Ø Misty oil; tells there is water mixed in the oil. Ø Clean oil with water underneath; tells there is water

in the oil.

3. Dispose oil in designated container.


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4. Next remove the rectangle cover on top of the

compressor, this gives a visual on the inside of the gearbox cover part. Leave the cover on with one or two bolts to prevent anything from falling in.

5. Remove the oil pump body end cover, by unscrewing the (8x) Allen key bolts

6. Remove and slide pump body from axle, remove gear

wheel from axle and place in pump, mind key installed,

inspect parts and salvage


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7. Remove stationary seal from drive shaft

a. Remove the two keys from the drive shaft

b. Remove the (4) countersunk screw out of the

copper plate

c. Remove the copper plate. It may be sticky

due to light sealant. There is an opening on

the side to lift this plate. Thickness of plate

appr. 2 mm thickness

d. slide the copper plate from the axle inspect,

and salvage. This copper plate protects from

sparkling in case of a bearing failure.

e. Remove the (4) Allen key bolts, that are now

exposed and salvage.


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g. Remove the cover from the body, inspect the

components and seal for damage

h. Note the centering pin on the bearing bush and

housing

i. Overview from on the body of the gearbox


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e. Remove the torsion shaft, inspect and

salvage

19. Removal gearbox main body (OZV-874 – 3)

1. Mark the position of main gear box vs the

compressor with a center point

2. Unscrew the (14) circumferential Allen key bolts and

prepare the hoisting strap thru the hoisting eye

Note: the little bolt and the opposite plug. The little bolt

represents a hole where a dowel is placed between

flanges. From the opposite plug hole, it can be removed

via the outside of the gearbox body. At this stage there is

no need to remove this bolt and plug


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3. Thru the rectangle side plates on both sides of the compressor one can inspect the gas (of

cooling water?) chambers

a. To remove this, unscrew the Allen key bolts,

remove cover and salvage

4. Put tension on the hoisting equipment and break the

two flanges using a mallet, this again may be sticky

due to used sealant, inspect and place the gearbox

on a pallet.

5. You are now Looking at the compressor body, main

rotor (RH) and secondary rotor (LH)

20. Removal of bearings gearbox side main and secondary rotors

1. Remove the nuts from both the rotor axles. Use

special tool hook wrench 30-32


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10. Remove Allen key bolts (3x) from main rotor axle radial

bearing. This procedure is the same as described in 8b

11. Remove radial bearing from main rotor axle, inspect and

salvage. Special attention to the ring spacers in between.

These spacers are a distance adjustment and thickness

marked on each ring. Note down the thickness of each

spacer and position and salvage

a. Spacers main rotor axle

3x 1,04 mm / 3x 2,5 mm

Given sizes only for unique s/n compressor

12. Remove Allen key bolts (3x) from secondary rotor axle

radial bearing


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13. Remove radial bearing from secondary rotor axle,

inspect and salvage. Special attention to the ring

spacers in between. These spacers are a distance

adjustment and thickness marked on each ring.

Note down the thickness of each spacer and position

and salvage

a. Spacers secondary rotor axle

3x 2,3 mm / 3x 1,08

Given sizes only for unique s/n compressor

21. Removal wheel case (Dwng OZV-874 – 11)

1. Remove Allen key bolts (11x) from wheel case housing

on inlet side compressor, remove wheel case cover

and salvage


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5. Next carefully pull the intake side plate together with the

rotors out of the main compressor body, inspect and

salvage to a pallet

6. Inspect and clean the cylinders in the main body of the

compressor

Note: View from gearbox side with rotors removed

23. Removal of Rotary seals from main body

1. Remove the rotary seal from the main axle by taking out

the circlip with hook wrench (see tool list). This

procedure is the same use done in chapter 17.8.b


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possibly chipping of the seal faces. It can also cause the faces to separate if significant axial vibration occurs.

3. Check face squareness and concentricity With bigger pumps it is essential, and possible, to check the squareness and concentricity. with the size at hand it is almost impossible to mount a dial indicator within the bracket. However, it is beneficial to be familiar with the principle.

28. Finally

After completion of the exercises do the following:

Ø Put test equipment and tools in their cases and storage facilities.

Ø Keep your collected papers for future reference.

Ø Report to instructor.

29. What did you learn?

After completion of these exercises you have learned:

Ø Working principle of a screw compressor

Ø Disassemble and assemble a single stage screw compressor pump

Ø Explanation on axial and radial bearings

screw compressor (aerzen vro 125l)

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